1627A-013

REV-00

Pa rt i:
Ope ra t ion a nd
M a int e na nc e M a nua l

Pa rt ii:
Pa rt s M a nua l

Ca t e rpilla r Off-H ighw a y T ruc k

(7 7 7 , 7 8 5 , 7 8 9 & 7 9 3 M ode ls)

Lift ing De vic e

(Body Pivot At t a c hm e nt )

M ode l: 1 6 2 7 A

Ph: +61 7 3865 2660 www.ade.net.au

 1627A-013-001
REV-00

Pa rt i:

Ope ra t ion a nd
M a int e na nc e
M a nua l
Ca t e rpilla r Off-H ighw a y T ruc k
(7 7 7 , 7 8 5 , 7 8 9 & 7 9 3 M ode ls)

Lift ing De vic e

(Body Pivot At t a c hm e nt )

M ode l: 1 6 2 7 A

Ph: +61 7 3865 2660 www.ade.net.au

 7 LITERATURE REFERENCE MATERIALS ......14
1 OVERVIEW.............................................................. 1
7.1 REFERENCE MATERIAL .....................................14
1.1 LITERATURE INFORMATION ............................... 1
1.2 SAFETY .............................................................. 1
1.3 OPERATION ........................................................ 1
1.4 MAINTENANCE................................................... 1

2 SAFETY .................................................................... 2

2.1 IMPORTANT SAFETY INFORMATION ................... 2

2.2 SAFETY SIGNS AND LABELS ............................... 3
2.3 GENERAL HAZARD INFORMATION ..................... 4
2.4 LINES ................................................................. 4

3 PRODUCT INFORMATION SECTION ............... 5

3.1 INTENDED USE & APPLICATION ......................... 5

3.2 RATED CAPACITY .............................................. 5

4 PRODUCT IDENTIFICATION INFORMATION 6

4.1 LIFTING DEVICE ................................................. 6

4.2 LIFTING DEVICE SUPPORT STANDS .................... 6

5 OPERATION & USE ............................................... 7

5.1 COMPONENT IDENTIFICATION ............................ 7

5.2 OPERATION & USE ............................................. 8
5.2.1 Visual Inspection .......................................... 8
5.2.2 Positioning & Setup...................................... 8
5.2.3 Lifting Device Installation .......................... 10
5.2.4 Raising the Rear of the Machine ................ 11
5.2.5 Lifting Device Removal .............................. 12
5.2.6 Storage ....................................................... 12

6 MAINTENANCE SECTION................................. 13

6.1 WHEN REQUIRED ............................................. 13

6.1.1 Disassembly for Cleaning & Greasing....... 13
6.2 BEFORE USE..................................................... 13
6.2.1 Walk-Around Inspection............................. 13
6.3 MONTHLY ........................................................ 13
6.3.1 Grease ........................................................ 13

Operating Instructions
Off-Highway Truck Lifting Device

1 Ove rvie w
1 .1 Lit e ra t ure I nform a t ion
The operation and maintenance manual should be
stored within the vicinity of the lifting device’s
operational area.
The operation and maintenance manual contains
safety, operation and maintenance information for the
lifting device. Read, study and keep the operation and
maintenance manual with the lifting device.
Whenever a question arises regarding the lifting
device, or the operation and maintenance manual,
please consult Australian Diversified Engineering Pty
Ltd for the latest available information.
1 .4 M a int e na nc e
The maintenance information is a guide to equipment
care. The illustrated, step-by-step instructions are
grouped by servicing intervals. Items without specific
intervals are listed under “When Required” topics.
Items in the Maintenance Interval Schedule are
referenced to detailed instructions that follow.
Calendar intervals shown (daily, weekly, monthly, etc.)
are to be used as they provide more convenient
servicing schedules. Recommended service should
always be performed at the interval that occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is specified
in the Maintenance Intervals schedule may be
necessary.

1 .2 Sa fe t y

The safety section lists basic safety precautions. In

addition, this section identifies the text and locations of
warning signs used on the lifting device.

Read and understand the basic precautions listed in

the Safety Section before operating or performing
maintenance on the lifting device.

1 .3 Ope ra t ion

The operation information is a reference for the new

operator and a refresher for the experienced one.

This information includes a description of the controls,

their location and operation with respect to the lifting
device. Photographs and illustrations are provided to
guide the operator through the correct operating
procedures for the lifting device.

Operating Instructions

Off-Highway Truck Lifting Device 1

 The meaning of this safety alert symbol is as follows:
2 Sa fe t y
2 .1 I m port a nt Sa fe t y I nform a t ion Attention! Become Alert! Your Safety is involved.
The message that appears under the warning,
Most accidents involving product operation, explaining the hazard, can be either written or
maintenance and repair are caused by failure to pictorially presented.
observe basic safety rules or precautions. An accident Operations that may cause product damage are
can often be avoided by recognising potentially identified by “NOTICE” labels on the product and in this
hazardous situations before an accident occurs. A publication.
person must be alert to potential hazards. This person
should also have the necessary training, skills and Australian Diversified Engineering cannot anticipate
tools to perform these functions properly. every possible circumstance that might involve a
potential hazard. The warnings in this publication and
Improper operation, lubrication, maintenance or on the product are therefore not all inclusive. If a tool,
repair of this product can be dangerous and could procedure, work method or operating technique not
result in injury or death. specifically recommended by Australian Diversified
Engineering is used, you must satisfy yourself that it is
Do not operate or perform any lubrication, safe for you and others. You should also ensure that
maintenance or repair on this product, until you the product would not be damaged or made unsafe by
have read and understood the operation, the operation, lubrication, maintenance or repair
lubrication, maintenance and repair information. procedures you choose.

Safety precautions and warnings are provided in this

manual and on the product. It these hazard warnings
are not heeded, bodily injury or death could occur to
you or other persons.
The hazards are identified by the Safety Alert Symbol"
and followed by a 'Signal Word" such as "WARNING"
as shown below.
Do not operate or work on this plant unless you
have read and understand the instructions and
warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or
heed the warnings could result in injury or
death. Contact Australian Diversified
Engineering for replacement manuals. Proper
care is your responsibility.

The information, specifications, and illustrations in this

publication are on the basis of information available at
the time it was written. The specifications, torques,
pressures, measurements, adjustments, illustrations,
and other items can change at any time. These
changes can affect the service given to the product.
Obtain the complete and most current information
before starting any job from Australian Diversified
Engineering.

Operating Instructions
Off-Highway Truck Lifting Device 2
2 .2 Sa fe t y Signs a nd La be ls

There are several specific safety signs on this device.

Their exact location and description of the hazard are
reviewed in this section. Please take the time to
This warning label is located at 8 places on the lifting
familiarise yourself with these safety signs. Make sure
device.
that you can read all safety signs. Clean or replace
these if you cannot read the words or see the pictures.
When cleaning the labels use a cloth, water and soap.
Do not use solvent, diesel etc.

You must replace a label if it is damaged, missing or

cannot be read. If a label is on a part that is replaced,
make sure a new label is installed on the replaced part.
Contact Australian Diversified Engineering for
replacement labels.

Three warning labels located on the front and rear of

the lifting device

This warning label is located on each side of the lifting

device

One warning label located at each end of the lifting

device

Operating Instructions
Off-Highway Truck Lifting Device 3
 2 .3 Ge ne ra l H a za rd I nform a t ion

Wear a hard hat, protective glasses and other

protective equipment as required by job conditions.

Do not wear loose clothing or jewellery that can catch

on controls or other parts of the machine.

Report all needed repairs and do not allow

unauthorised personnel to use this lifting device.

2 .4 Line s

Do not bend or strike any line.

Do not install bent or damaged lines.

Replace any damaged pneumatic lines.

Check lines, tubes and hoses carefully.

Replace if any of the following conditions are found:

• End fittings damaged or leaking.
• Lines chafed or cut.
• Evidence of kinking or crushing.
• End fittings displaced.

These two warning labels are located on the lifting

device control panel

Operating Instructions
Off-Highway Truck Lifting Device 4
 This lifting device can be attached to the following Off-
3 Produc t I nform a t ion Se c t ion Highway Trucks only:
• Caterpillar 777
3 .1 I nt e nde d U se & Applic a t ion • Caterpillar 785
• Caterpillar 789
•
Use of this lifting device for purposes other
than outlined in this manual may result in Caterpillar 793
personal injury or death. Use this lifting device
in accordance with instructions outlined in this
manual. The machine must be mechanically blocked when the
machine is held in a raised position for any purpose
including tyre and rim installation or removal or any
This lifting device is for raising the rear of other assembly, disassembly or maintenance
specified Caterpillar Off-Highway Trucks only. procedure. Refer to the Jacking Location Information
Alternate lifting methods must be employed for
raising the front of Caterpillar Off-Highway Section in the applicable Caterpillar Off-Highway Truck
Trucks. Refer to the machine specific Operation and Maintenance Manual for further
Caterpillar Operation and Maintenance Manual
for information on lifting the front of the information on jacking the machine.
machine.

This device is for raising the rear of one Caterpillar Off- 3 .2 Ra t e d Ca pa c it y

Highway Truck (with body removed) by attaching at the
body pivots of the truck chassis to allow for removal
and installation of rear tyre and rim assemblies and
other assembly requirements.
USE OF THIS LIFTING DEVICE FOR MACHINES
OTHER THAN CATERPILLAR 777, 785, 789 &
793 MAY RESULT IN PERSONAL INJURY.

This device may also be used in conjunction with the

Caterpillar recommended front lifting points to move The maximum rated capacity of this lifting device is:
the chassis for assembly and transport purposes.

Caterpillar 793 Off-Highway Truck

(Rear End)

(60T nominal)

Lifting device attached to lift the rear of a 793

Operating Instructions
Off-Highway Truck Lifting Device 5
4 Produc t I de nt ific a t ion
I nform a t ion
Data plates have been fitted to each support stand as
well as the lifting device which indicate the model and
serial numbers, tare weights, rated capacity and date
of manufacture.

4 .1 Lift ing De vic e

Data plate located on the horizontal section of the
lifting device.

Lifting device data plate

4 .2 Lift ing De vic e Support St a nds

Data plates located at the base of each support stand.

Support stand data plate

Operating Instructions
Off-Highway Truck Lifting Device 6
5 Ope ra t ion & U se 4

5 .1 Com pone nt I de nt ific a t ion

The major components of this lifting device include:

(1) Support Stands
(2) Air Operated Pins (operated by the remote
5
control panel)
(3) Crane Attachment Points
(4) Width Adjustment Point (to suit truck model)
(5) Width Adjustment Locking Pin
(6) Remote Control Panel

3 3

2 2

Operating Instructions
Off-Highway Truck Lifting Device 7
5 .2 Ope ra t ion & U se

5 .2 .1 V isua l I nspe c t ion

1. Visually inspect the lifting device and crane
attachment points paying particular attention to
wear, corrosion, weld cracks and deformation. If
any component is found to be deformed, cracked
or broken do not continue with the lifting operation.
Place an out of service tag on the device and
consult Australian Diversified Engineering.

5 .2 .2 Posit ioning & Se t up Lifting device positioned adjacent to the truck chassis
1. Check to ensure that the air operated pins are with the assembly just clear of the ground
extended completely through each of the support
stands. The pins must be fully extended through 1. Remove the width adjustment locking pin (5).
the support stands. This can be checked by
making a visual inspection of the ends of the pins
at each side of the lifting device. The red coloured
end of the pin must be seen protruding into the end
plates of the lifting device.

2. Using the forklift pockets provided at the top of the

lifting device and a forklift which is capable of lifting
600 kg, position the entire lifting assembly at the
5
side of the Off-Highway Truck which is to be
raised.
Lifting device width adjustment locking pin (5) being
3. Once positioned on flat level ground at the side of removed
the truck raise the lifting assembly so that it is just
clear of the ground. 2. Using the width adjustment point (4), wind the
assembly in or out so that the required width of the
lifting device is obtained. Refer to the table below
for lifting device width application.

TRUCK LIFTING DEVICE - PIN

POSITION
CAT 777 FULLY RETRACTED
CAT 785 CENTRE POSITION
CAT 789 CENTRE POSITION
CAT 793 FULLY EXTENDED

Operating Instructions
Off-Highway Truck Lifting Device 8
 4

Using the width adjustment point (4), adjust the width

Two lifting arrangements attached to the crane
of the lifting device to suit the truck chassis required to
attachment points of the lifting device
be raised

5. Remove the remote control panel from the toolbox

3. Replace the width adjustment locking pin (5).
removing the attached air line completely from the
box also.

Width adjustment locking pin (5) has been re-inserted

after width adjustment of the lifting device

Removal of the remote control panel and air hose from

4. Attach two lifting arrangements of suitable capacity
the tool box at the base of the support stand
for the machine which is to be lifted to the crane
attachment points at the top of the lifting device.
6. Attach a compressed air line (7) to the remote
This step must be performed by a qualified rigger.
control panel. Note: 80 psi is required however up
to 110 psi may be required.

Operating Instructions
Off-Highway Truck Lifting Device 9
 The remote control panel must be supervised
at all times whilst the compressed air line is
connected. All actions to the controls of the
remote control panel must be preceded by a
visual inspection of the lifting device to ensure
all personnel are clear.

Compressed air line (7) attached to the remote control

panel
Manoeuvring the lifting device into position at the rear
of the truck chassis using three personnel
7. Ensuring that the lifting device is free from
personnel, operate the remote control panel to
3. With the lifting device in position over the body
retract the air operated pins from the support
pivots use the remote control panel (6) to extend
stands.
the air operated pins completely through the truck
chassis and into the lifting device end plates. At
5 .2 .3 Lift ing De vic e I nst a lla t ion
this stage the operator of the remote control panel
must ensure that the pins have been fully extended
1. Ensure the park brake of the machine to be raised
by making a visual inspection of the ends of the
is applied and if applicable, chock the front wheels
pins at each side of the lifting device. The red
of the truck.
coloured end of the pin must be seen protruding
through the end plates of the lifting device. If the
2. Crane the lifting device and guide over the body
ends of the pins cannot be seen protruding through
pivots at the rear of the truck chassis by the ties
the end plates of the lifting device it means that the
provided at each end of the lifting device. NOTE:
lifting device has not been installed properly and
the lifting device can be orientated either way
the remote control panel must be operated again
round.
only after manoeuvring the lifting device to ensure
that the pins go through the body pivots.

Operating Instructions
Off-Highway Truck Lifting Device 10
 Incomplete installation of the air operated pins
through the truck chassis may result in
unintended machine movement during raising
or wheel changing operations. Personal injury
or death may result. It is the responsibility of
the person operating the remote control panel
to ensure that the pins are inserted completely
and the truck chassis held captive by
inspection after operation of the control.

Lifting device in position at the rear of the truck chassis

4. Once correctly installed disconnect the

compressed air line to the remote control panel (6).
Proper installation of the lifting device sees the red end
of the left and right side pins protruding through the
end plates of the lifting device

5 .2 .4 Ra ising t he Re a r of t he M a c hine
When raising the rear of the machine:
• Ensure that the area is free from personnel.
• Only lift the machine high enough to perform
the required manoeuvre.
• Never allow personnel to work beneath the
machine when raised with the lifting device.
• Do not operate the remote control panel whilst
the machine is raised.
•
Proper alignment of the lifting device before installation
Do not use this lifting device for purposes other
of the pins through the truck chassis
than outlined in the Operation and
Maintenance Manual.
• The combined weight of the lifting device and

Operating Instructions
Off-Highway Truck Lifting Device 11
 the load must not exceed the rated capacity of
the crane of hoist.
•
Only qualified, trained and authorised
operators should operate this lifting device.
• Ensure the lifting device (& rigging) is visually
inspected on a scheduled basis by qualified
personnel and defects corrected prior to use.
1. With the pins inserted through the truck chassis
and the area free from personnel, slowly begin to
raise the rear of the machine.
2. Raise the rear of the machine to allow sufficient
room for the task to be performed.
3. The machine must be mechanically blocked if
personnel are to work beneath the machine. Refer
to the Jacking Location Information Section in the
applicable Caterpillar Off-Highway Truck Operation
and Maintenance Manual for further information on
stand capacity and location.
4. Upon completion of task, slowly lower the machine
to ground level (supporting by blocks or stands if
wheel and rim assemblies have just been
removed) releasing the load on the air operated
pins of the lifting device.
Rear of truck chassis raised with the lifting device
Operating Instructions
Off-Highway Truck Lifting Device
5 .2 .5 Lift ing De vic e Re m ova l
1. Connect the compressed air line to the remote
control panel (6) and retract the pins.
2. Return the lifting device to the support stands (1).
5 .2 .6 St ora ge
1. With the lifting device nestled into the support
stands and ensuring that the area is free from
personnel use the remote control panel (5) to
extend the air operated pins through the left and
right stands.
2. Ensure that the red ends of the pins can be seen
protruding through the support stands and into the
end plates of the lifting device. This ensures the
stands are now captive and the assembly is ready
for storage or relocation.
3. Disconnect the compressed air line to the remote
control.
4. Replace the control panel to the tool box on the
support stand and retract the air line cable into the
box also.
5. If another chassis is required to be raised using the
lifting device, relocate the lifting assembly to the
next truck chassis using a forklift and repeat
procedures 5.2.2 to 5.2.5.
6. If finished with the lifting device use a forklift to
raise the assembly slightly off the ground and hold.
7. Using the width adjustment point completely retract
the lifting assembly. This helps conceal the sliding
surfaces from debris when not in use. Note: this
step is not required if previously used on a 777.
12
 cracked or broken do not continue with the
6 M a int e na nc e Se c t ion lifting operation. Place an out of service tag on
the device and consult Australian Diversified
Engineering.

Unintended component movement may result

in personal injury or death. Before performing 6 .3 M ont hly
maintenance on this devise ensure the
compressed air line is removed from the
remote control panel. 6 .3 .1 Gre a se

Grease the 4 sliding surfaces of the lifting device with

N OT I CE good quality molybdenum based grease. Inspect and
You must read and understand the warnings remove debris and replace removed grease.
and instructions contained in the Safety
Section of this manual, before performing any
maintenance procedures.

6 .1 Whe n Re quire d

6 .1 .1 Disa sse m bly for Cle a ning & Gre a sing

Disassemble the sliding components of the lifting
device for debris removal and cleaning. Reassemble
with good quality molybdenum based grease to the
sliding surfaces.

6 .2 Be fore U se
Grease all four sliding surfaces of the lifting device
6 .2 .1 Wa lk -Around I nspe c t ion
Perform a walk-around inspection of the lifting device
prior to operation.
• Check to ensure all labels can be read and are
visible in conjunction with the Safety Signs and
Labels section of this manual. Replace label/s
if they cannot be read or are missing.
• Visually inspect the air lines from the remote
control panel to the cylinders for damage,
deterioration and leaks. Have any faults
repaired immediately.
• Inspect the remote control panel for damage
and operation of the control. Have faults
repaired immediately.
• Visually inspect the lifting device and sling
attachment points paying particular attention to
wear, corrosion, weld cracks and deformation.
If any component is found to be deformed,

Maintenance Instructions
Off-Highway Truck Lifting Device 13
7 Lit e ra t ure Re fe re nc e
M a t e ria ls

7 .1 Re fe re nc e M a t e ria l

Machine specific Caterpillar Operation and

Maintenance Manual.

Reference Information
Off-Highway Truck Lifting Device 14
 1627A-013-002
REV-00

Pa rt ii:

Pa rt s M a nua l

Ca t e rpilla r Off-H ighw a y T ruc k

(7 7 7 , 7 8 5 , 7 8 9 & 7 9 3 M ode ls)

Lift ing De vic e

(Body Pivot At t a c hm e nt )

M ode l: 1 6 2 7 A

Ph: +61 7 3865 2660 www.ade.net.au

1 OVERVIEW..............................................................3

2 SPREADER BEAM & CONTROL PANEL ..........4

3 PNEUMATIC LINES & FITTINGS ......................8

4 TOOL BOX ...............................................................9

Parts
Off-Highway Truck Lifting Device 2
1 Ove rvie w

The Parts Manual is a compilation of replacement parts

for the spreader beam.

Refer to the Operation and Maintenance Manual

Supplement 1627-O&MMS-REV00 for operation and
maintenance procedures for the lifting device.

Consult Australian Diversified Engineering if

replacement manuals are required.

Parts
Off-Highway Truck Lifting Device 3
2 Spre a de r Be a m & Cont rol
Pa ne l

Parts
Off-Highway Truck Lifting Device 4
 1627A - SPREADER BEAM 19

18
20

11 2
10
19
7

12 6

19

15 13
14
8 4

16

17

9
22

Parts
Off-Highway Truck Lifting Device 5
 1627A-012 - REMOTE CONTROL PANEL

10

3
8

11

Parts
Off-Highway Truck Lifting Device 6
 1627A - SPREADER BEAM 1627A-012 - REMOTE CONTROL PANEL
ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION De fa ult/ QTY
.
1 1627A-001 INNER HALF 1 1 1627A-012-001 BASE PLATE 1
2 1627A-002 OUTER HALF 1 2 SMC VH210-02 2 Po sitio n SMC VH210-02 BODY 1
Switc h Bo d y
3 1627A-003 PIN 2 3 KGH06-02S-X2 6mm TUBE TO 1/ 4" 2
4 1627A-004-001 END PLATE 2 4 1627A-012-002 PROTECTOR 2
5 1627A-005 LOCKING PIN 1 5 SCREW M6 x 20 CSHS 4
6 1627A-006 PINION 1 6 SCREW M4 x 30 PANHEAD 4
7 1627A-007-001 PINION SPACER 2 7 AIRLINE MALE FITTING 1
8 1627A-008-001 WEAR STRIP 4 8 1627A-011-005 1
9 1627A-009 STAND 2 9 1627A-011-004 1
10 WASHER Ø25.4 8T-5361 1 10 1627A-011-003 1
11 ROLL PIN 6 x 40mm 1 11 1627A-011-006 1
12 PNEUMATIC CYLINDER - 275mm STROKE 2
CM2
13 BOLT M8 x 20 8T4189 8
14 WASHER Ø8 8T-4224 8
15 SCREW M6 x 20 CSSH 20
16 WASHER Ø6 20
17 NUT M6 NYLOCK 20
18 1627A-011-001 2
19 1627A-011-002 8
20 1627A-010-001 ID PLATE - SPREADER BEAM 1
21 1627A-010-002 ID PLATE - SUPPORT STAND 2 1
22 1627A-010-003 ID PLATE - SUPPORT STAND 1 1

Parts
Off-Highway Truck Lifting Device 7
3 Pne um a t ic Line s & Fit t ings

3 2
2

1 1

I T EM DESCRI PT I ON PART N O. QT Y
1 SUS316 MALE BRANCH TEE 6 MM TO RC1/8PT KQGT06-01S 2
2 SUS316 MALE ELBOW 6 MM TO RC1/8PT KQGL06-01S 2
3 COIL TUBE - BLACK TCU0604B-1 1
4 SUS316 MALE UNION 6 MM TO RC1/4PT KQGH06-02S 2
5 POLYURETHANE TUBE - BLACK TU0604B-20 1

Parts
Off-Highway Truck Lifting Device 8
4 T ool Box

I T EM DESCRI PT I ON PART N O. QT Y
1 Tradesman Toolbox ADE0001306 1

Parts
Off-Highway Truck Lifting Device 9