ENSAMBLE 777F

7/25/2019 ENSAMBLE 777F

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Procedimiento para la Asamblea 777F Camiones de Obras

{7000, 7006, 7960}SMCS - 7000-016 7006-016, 7960-016;

Camiones Fuera de Carretera:777F (S / N: JRP1-UP; JXP1-UP)

Introduction

Esta instrucción especial contiene información y procedimientos que se requieren para montar

777F Camiones de Obras.

Nota: Consulte la Instrucción Especial, REHS4445, "Mantenimiento de los Cilindros desuspensión para camiones fuera de carretera" para cualquier información referente a los cilindrosde suspensión. La Instrucción Especial incluye herramientas, las presiones y los procedimientoscorrectos para purgar (aceite y nitrógeno) y de carga (de petróleo y nitrógeno).

Las herramientas sugeridas deben estar disponibles. Sin herramientas y equipos, más tiempo seconsume cuando se arma la máquina.

Inspeccione todas las piezas y de información en los siguientes lugares:

Estación del operador •

Camión•

Contenedores de embarque•

Inspeccione todas las áreas para las partes y para obtener información. No se deshaga de cualquier material hasta que la máquina está montada.

Lesiones personales o la muerte puede ser resultado de los

procedimientos de montaje inadecuados.

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No intente hacer ningún conjunto hasta que haya leído y entendido las

instrucciones de montaje.

Lea la instrucción especial entero. Comprender la información antes de realizar cualquier procedimiento. Comprender la información antes de ordenar las piezas.

Nota: En esta publicación, las fotos son para propósitos ilustrativos. Imágenes para finesilustrativos, no puede estar en secuencia con el procedimiento de montaje.

Después de que la máquina está montada, se refieren al Manual de Operación y Mantenimiento,SEBU7790 ", 777F Camiones de Obras" con el fin de preparar la máquina para sufuncionamiento. Utilice el Manual de piezas y utilizar el Manual de servicio, además de estainstrucción especial.

Esta instrucción especial también contiene información para el arreglo de gran altura. Refiérase a

la del índice con el fin de encontrar procedimientos específicos para el montaje de esa máquina.

AVISO

No permita que la suciedad o material extraño entrar en el sistemahidráulico durante el montaje, la conexión de líneas, cuando los

componentes están llenos de líquido, o durante cualquier operación demantenimiento.

AVISO

Se debe tener cuidado para asegurar que los fluidos se encuentrandurante la realización de la inspección, mantenimiento, prueba, ajuste

y reparación del producto. Esté preparado para recoger el líquido concontenedores adecuados antes de abrir cualquiera de los

compartimientos o desmontar ningún componente que contengalíquidos.

Consulte la Publicación Especial, NENG2500, "Servicio de

distribuidores Catálogo de herramientas" para las herramientas ymateriales adecuados para recoger y contener fluidos sobre los

productos Cat.

Deshágase de todos los fluidos de acuerdo a las regulaciones locales y

mandatos.

Weights and Specifications

Tabla 1





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Peso aproximado de la máquina sin carga

Modelo de Venta Peso en vacío

777F 48581 kg (107.104 libras)

Pesos aproximados de los componentes

Nombre Peso

Cuerpo de la Asamblea15800 kg (34.830 libras)

Chasis18370 kg (40,500 libras)

Chasis y Cabina 1435 kg (3160 libras)

Skid y el Frente de Struts4220 kg (9300 lb)

Caja de partes765 kg (1680 libras)

Chasis y del tanque de combustible465 kg (1020 libras)

Skid y Pasamanos 535 kg (1180 lb)

Skid, dos neumáticos y llantas4050 kg (8930 libras)

Chasis y Escaleras1335 kg (2940 libras)

Caja del eje trasero y transmisión10605 kg (23,380 libras)

Puntal delantero 1475 kg (3250 libras)

Plataforma de la mano derecha320 kg (700 libras)

Parachoques mano derecha110 kg (245 libras)

Parachoques mano izquierda110 kg (245 libras)

Escalera de Mano Derecha 90 kg (200 lb)

Tabla 2





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Pasamanos derecho19 kg (42 libras)

Soporte delantero de la cabina160 kg (350 lb)

Apoyo a la cabina trasera 230 kg (500 lb)

Estándar de la cabina1320 kg (2910 libras)

Plataforma de la mano izquierda190 kg (420 libras)

Operador de Escalera de Acceso86 kg (190 libras)

Plataforma 64 kg (140 lb)

Mano Izquierda Riel de Escalera32 kg (70 lb)

Mano Izquierda Barandilla pasarela28 kg (62 libras)

Neumático y la llanta1960 kg (4320 libras)

Herramientas necesarias

Herramienta Número de pieza Descripción Cantidad

AA 4C-4188 La pintura y removedor de Decal 1

BB 222-3124 Limpiador de frenos y eléctrico 1

CC 148-0357 Grupo de elevación del puntal 1

DD 6V-4040 Equipo de nitrógeno inflación 1

EE 4C-5593 Anti-Seize 1

FF 7K-1181 Correas de cable 10

GG 3S-2093 Correas de cable 30

HH 9S-3263 Tema compuesto de bloqueo 1

Tabla 3

Parts List

De referencia de piezas de servicio, PECP9067 ", una fuente segura".

Tabla 4





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Componentes necesarios para la instalación de la carcasa del eje trasero

Cantidad Número de pieza Descripción

Bolsa de Componentes 262-6081

16 302-4536 Tornillos

16 9X-8399 Arandelas

Bolsa de componentes que se une al eje de transmisión

4 8B-5144 Tornillos (1)

Empaquetado en la caja de componentes

1 285-8713 Como tubo





8 175-7894 O-ring

16 8T-4184 Tornillos

40 8T-4223 Lavadoras duros

8 1P-4582 La mitad Bridas

4 4J-0527 O-ring


4 7X-0328 Tornillos

4 5P-2566 Tornillos


Los componentes que se unen a la del eje trasero

1 9C-4937 Como respiradero

1 030-7765 Adecuado

(1) Los pernos se adjuntan al eje de accionamiento en una bolsa.

Componentes necesarios para la instalación de la Plataforma Gp


1 280-6920 Plataforma Gp

Tabla 5





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Piezas necesarias para la instalación de las escaleras

Cantidad Número de pieza Descripción2 241-2699 Escalera Gp

Tabla 6

Piezas necesarias para la instalación de los cilindros de suspensión delanteros


2290-7232 (uno)

desde 290 hasta 7.233 (2) Suspensión del Grupo


2 9D-2498 Claves

28 7B-9215 Tornillos

28 3S-1356 Frutos de cáscara completa

56 3S-1349 Lavadoras duros


2 4J-8535 Abrazaderas

2 116-1949 Cubre

Tabla 7

(1) Número Europea

(2) No Europea Pieza número

Piezas necesarias para la instalación de las líneas del enfriador de aceite delantero y laslíneas de servicio del freno delantero



4 103-5422 Como la manguera


8 4J-0522 O-ring

Tabla 8

Piezas necesarias para la instalación del tanque de combustible


Tabla 9





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1223-5868 Tanque de combustible Gp (1)

219-9712 Tanque de combustible como (2)

(1) 1140 L (300 gal EE.UU.) Tanque(2) 1320 L (350 gal EE.UU.) Tanque

Piezas necesarias para la instalación de los soportes y el cierre de la


1 250-5930 Como apoyo




8 198-4782 Lavadoras duros



1 240-2263 Manga

8 117-8131 Como Montar

1 8T-5397 Atornillar

4 252-0080 Arandelas

3 3E-4898 Mangas

3 8T-0672 Tornillos

4 8T-4195 Tornillos

4 7X-7729 Arandelas

4 240-2261 Como Pin

Tabla 10

Piezas necesarias para la instalación del Acuerdo de escape


1 256-6757 Tubo de escape Gp


2 4N-9330 Abrazaderas

2 6V-3823 Tornillos

Tabla 11





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2 8T-4244 Nueces


6 7X-2563 Tornillos

6 8T-4123 Arandelas

Piezas necesarias para la instalación de la Plataforma de la mano derecha



Tabla 12

Piezas necesarias para la instalación de la escalera Gp


1 273-2398 Escalera Gp

17 7K-1181 Correas de cable

Tabla 13

Piezas necesarias para la instalación de los accesorios para el Servicio de Control deFreno Gp


2 148-8347 Como el codo


Tabla 14

Piezas necesarias para la instalación de los accesorios para las líneas de dirección Gp


2 148-8324 Como conector



Tabla 15

Piezas necesarias para la instalación del Grupo de Plataforma



Tabla 16





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Piezas necesarias para la instalación de la Pasarela Gp


1 273-2325 Paseo del Gp

3 3S-2093 Correas de cable

Tabla 17

Componentes necesarios para la instalación de la escalera Gp


1 255-2600 Ladder Gp

10 3S-2093 Cable Straps

Bag of Components 273-2387

2 8T-4137 Bolts

2 8T-4121 Hard Washers

1 169-5414 Clip

1 130-5300 Clip

Tabla 18

Required Parts for Installation of the Handhold Gp

Qty Part Number Description

1 273-8920 Handhold As







2 115-3580 Plates

4 5P-7468 Clips

4 5P-7469 Clips

4 8T-4183 Bolts


Table 19





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4 8T-4244 Nuts

4 8T-7087 Grommets

Required Parts for Installation of the Exhaust TubeQty Part Number Description

Packed in the Parts Box

1 280-4416 Tube As


4 8T-4183 Bolts


Table 20

Required Parts for Installation of the Mirror Gp




1 7X-7468 Convex Mirror

1 279-0467 Mirror Gp

1 322-7277 Mirror As



1 2G-1133 Grommet

1 284-5263 Wiring Harness

1 7G-7053 Grommet

Table 21

Required Parts for Installation of 328-9834 Mirror Group (if equipped)


1 330-5264 Tube As

2 329-7328 Convex Mirrors

10 7Y-5262 U-Bolts (M10X1.5)


Table 22

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20 8T-0389 Locknut

1 331-3268 Tube As

4 8T-4182 Bolts (M10X1.5)

4 198-4777 Hard Washers

2 334-1004 Tube Assemblies

2 144-2227 Mirror Assemblies

4 8T-4137 Bolt

4 7X-3391 Hard Washer

4 8T-6868 Bolt

4 7D-9969 Support

11 3S-2093 (1) Cable Straps

1 324-6674 (1) Wiring Harness

1 2G-1133 (1) Grommet

1 298-7329 Bracket As


4 8T-4196 Bolt

4 8T-4195 Bolt


2 134-0989 Blocks

4 8T-4133 Nut

1 7G-7053 (1) Grommet

( 1 ) Part of 247-5666 Mirror Wiring Gp

Required Parts for Installation of the 321-6518 Rear View Mirror Gp



1 338-9281 Plate

7 5P-1076 Hard Washer

4 3K-6060 Locknut

1 338-9280 Plate

Table 23





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2 8T-4198 Bolt

15 8T-4121 Hard Washer

2 8T-4133 Nut



3 8T-4136 Bolt

4 8T-4186 Bolt

2 134-0989 Block

1 8T-7087 Grommet

1 5P-7468 Clip

1 5P-7469 Clip

1 8T-4183 Bolt

1 129-3180 Locknut

1 295-8899 Plate


2 323-5341 Tube As

4 8T-4137 Bolt

6 7D-9969 Support

6 8T-6868 Bolt



6 3S-2093 Cable Strap




1 338-9281 Plate

1 5P-1076 Hard Washer

1 3K-6060 Locknut

1 338-9280 Plate

Table 24





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2 8T-4198 Bolt


22 8T-0389 Locknut



3 8T-4136 Bolt

4 8T-4186 Bolt

2 134-0989 Block

2 329-7328 Convex Mirror

1 330-5264 Tube As

10 7Y-5262 U-Bolt

1 350-7140 Tube As

4 8T-4182 Bolt

4 198-4777 Hard Washer


2 323-5341 Tube As

4 8T-4137 Bolt

6 7D-9969 Support

6 8T-6868 Bolt



6 3S-2093 Cable Strap

Required Parts for Installation of the Hydraulic Tank Gp


2 1P-3705 Rectangular Seals (1)

Table 25

( 1 ) Rectangular seals are in the bag that is attached to the steering tank.

Required Parts for Installation of the Fender Gp


Table 26





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1 273-2344 Support As

1 282-3022 Guard

1 275-9226 Guard

1 273-8918 Guard

1 282-9097 Guard

1 256-0639 Rubber Guard

Required Parts for Installation of the Front Wheels



40 5D-0765 Full Nuts

40 5D-0764 Hard Washers

Table 27

Required Parts for Installation of the Rear Wheels



2 272-7949 Tire Valve Gp

2 6G-8019 Tire Valve Gp


80 5D-0765 Full Nuts

80 5D-0764 Hard Washers

Table 28

Required Parts for Installation of the Truck Body Arrangement ( 308-0618 Truck BodyMounting Gp )


2 8W-8454 Pin As

1 8W-2897 (1) Thrust Washer

2 9D-3432 (1) Thrust Washers

2 8W-8456 Plates

4 5P-2566 Bolts

Table 29





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2 3B-8489 Grease Fittings

2 322-5067 Mud Guard

2 322-5068 Plate

2 331-5956 Plate

20 9B-7237 Bolt

20 6V-8801 Nut

8 8T-4183 Bolt


8 8T-4244 Nut

( 1 ) Use the 8W-2897 Thrust Washer only when the 9D-3432 Thrust Washer will not fit.

Required Parts for Installation of the Hoist Cylinders


2 5T-9266 Pin As

4 9D-2316 Spacers

2 5T-5528 Plates

4 5P-2566 Bolts


Table 30

Required Parts for Installation of the Retaining Pin ( 308-0618 Truck Body MountingGp )


4 5D-3887 Rods

4 6F-8499 Springs

4 054-3788 Orifices

8 3B-4615 Cotter Pins

2 270-7034 Pin As

Table 31

Required Parts for Installation of the Visual Body Down Indicator ( 308-0618 Truck BodyMounting Gp )

Table 32





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1113-1218

326-3097 (1)

Baffle As

Baffle As

2 031-9831 Bolts

( 1 ) Part of the 341-5471 Rear View Mirror Gp or the 328-9834 Rear View Mirror Gp

Required Parts for Installation of the Rock Ejectors ( 308-0618 Truck Body MountingGp )


2 253-7490 Ejectors

2 6G-7773 Pins

4 3B-4647 Cotter Pins

16 1D-0503 Washers

Table 33

Required Parts For Installation of the Pad Assembly (Dump Body) ( 308-0618 TruckBody Mounting Gp )


4 229-6177 Pad As

20 106-8227 Shims

20 5P-2566 Bolts


Table 34

Required Parts for Installation of the Central Lubrication Lines Group




12 5P-9085 Clips

10 5M-3062 Bolts


2 8T-4137 Bolts


Table 35





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Required Parts for Installation of the Automatic Lubrication Group




10 5M-3062 Bolts


12 5P-9085 Clips

2 8T-4137 Bolts


Table 36

Required Parts for Installation of the Film Gp


1 289-8453 Film

1 289-8455 Film

1 289-8454 Film

Table 37

Prepare to Assemble the Machine

Before you unload the chassis and related components, read the information that follows in orderto make the job easier.

In order to assemble the machine, select an area that is smooth and flat. The area should be25 m (82 ft) wide and 30 m (98 ft) long. The area should drain well. Place the chassis in thecenter of the area.

•

When you unload components, place the components near the chassis. However, keep an

area around the chassis clear in order to position the cranes for lifting the components.

•

Open all boxes and inspect the contents.•

Organize components and hardware in order to help reduce lost hardware and speedassembly.

•

Do not open plastic bags of hardware. The plastic bags are marked with yellow labels thatare printed with the group part number. Individual components are marked with yellowlabels that are printed with the component part number and with the group part number.Move each plastic bag of hardware to the chassis when the corresponding component is

installed.

•





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Illustration 1 g00638037

Approximate Weights

Personal injury or death can result from improper lifting or blocking.

When a hoist or jack is used to lift any part or component, stand clearof the area. Be sure the hoist or jack has the correct capacity to lift acomponent. Install blocks or stands before performance of any work

under a heavy component.

Approximate weights of the components are shown. Clean all surfaceswhere parts are to be installed.

The chassis weighs 21315 kg (47000 lb).•

The cab assembly weighs 1550 kg (3417 lb).•

The front suspension cylinder, the wheel, and brake assembly weighs 2070 kg (4565 lb).•

The rear axle assembly weighs 9389 kg (20700 lb).•

The tire and rim assembly weighs 1960 kg (4320 lb).•

The standard body and canopy assembly weighs 15780 kg (34900 lb).•

A body weighs 21180 kg (46700 lb).•

Torque Specifications

Tighten the bolts that mount the rear axle assembly to the suspension a-frame to a torque of

1800 ± 200 N·m (1330 ± 150 lb ft).

•





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Tighten the bolts that mount the rear axle assembly to the rear suspension cylinders to 620 ±

80 N·m (460 ± 60 lb ft).

•

Tighten the bolts that secure the control rod to the frame and to the rear axle assembly to atorque of 620 ± 80 N·m (460 ± 60 lb ft).

•

Tighten the bolts that mount the front suspension cylinder to a torque of 1175 ± 48 N·m

(870 ± 35 lb ft).

•

Tighten the front suspension cylinder cap mounting bolts to a torque of 370 ± 50 N·m (270± 35 lb ft).

•

Tighten the bolts that mount the front steering arm to a torque of 1800 ± 163 N·m (1325 ±120 lb ft).

•

Tighten the cab support mounting bolts at the front support to a torque of 800 ± 100 N·m

(600 ± 75 lb ft).

•

Tighten the cab support mounting bolts at the rear support to a torque of 1600 ± 200 N·m(1180 ± 150 lb ft).•

Tighten the cab mounting bolts at the front of the cab to a torque of 800 ± 100 N·m (600 ±

75 lb ft).

•

Tighten the cab mounting bolts at the rear of the cab to a torque of 800 ± 100 N·m (600 ± 75lb ft).

•

Tighten the nuts that mount the front wheel rim to a torque of 1210 ± 100 N·m (890 ± 75 lbft) if 4C-5592 Anti-Seize Compound is applied to the nuts.

•

Tighten the nuts that mount the front wheel rim to a torque of 2100 ± 200 N·m (1550 ± 150lb ft) if anti-seize compound is not applied to the nuts.

•

Tighten the nuts that mount the rear wheel rim to a torque of 1210 ± 100 N·m (890 ± 75 lbft) if 4C-5592 Anti-Seize Compound is applied to the nuts.

•

Tighten the nuts that mount the rear wheel rim to a torque of 2100 ± 200 N·m (1550 ± 150lb ft) if anti-seize compound is not applied to the nuts.

•

Tighten the bolts that mount the cover for the rear tire valve extension to a torque of 100 ±20 N·m (75 ± 15 lb ft).

•

Tighten the clamps on the steering tie rods to a torque of 285 N·m (210 lb ft).•

Hoist Capacity

Chassis Assembly

When the differential housing is on supports, a hoist with a capacity of 10000 kg (22000 lb) isnecessary in order to lift the chassis at the front lifting point.

When the front frame crossmember is on supports, a hoist with a capacity of 8600 kg (19000 lb) is

necessary in order to lift the chassis at the rear lifting point.





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Assembled Machine Without the Body

When the rear tires are on the ground, a hoist with a capacity of 17000 kg (38000 lb) is necessaryin order to lift the truck at the front lifting point.

When the front tires are on the ground, a hoist with a capacity of 16000 kg (35000 lb) is necessary

in order to lift the truck at the rear lifting points.

Machine Dimensions

The height dimension of the chassis assembly is 1676 mm (66 inch).•

When the tires are installed, the height dimension at the top of the hood is 3150 mm (124inch).

•

The distance from the center of the body to the outside wall is 2438 mm (96 inch).•

When the tires are installed, the height to the top edge of the body is 4288 mm (169 inch).•

When the tires are installed, the height to the top edge of the canopy is 5028 mm (198 inch).•

The length of the truck is 9780 mm (385 inch).•

The width of the truck is 6105 mm (240 inch).•

Required Tools

When you are instructed, apply 4C-5593 Anti-Seize Compound to threads.•

Use a 6V-6080 Torque Multiplier in order to tighten the components that follow: thesteering arm mounting nuts, the ball stud nuts and the wheel rim mounting nuts.

•

Use a 6V-8720 Torque Multiplier in order to tighten the rear axle housing nuts.•

Use a 6V-7915 Torque Wrench with the torque multipliers.•

Use a 194-7586 Pneumatic Wrench Gp with a 194-7886 Drive Extension on the bolts thathold the front suspension cylinder to the frame assembly.

•

Use an 8H-8548 Extension on the wheel rim mounting nuts.•

Use an 8H-8541 Socket on the steering arm mounting nuts.•

Use an 8H-8504 Socket on the ball stud nuts.•

Use an 8H-8540 Socket on the wheel rim mounting nuts.•

Use a 2P-2334 Socket on the bolts that hold the front suspension cylinder to the frameassembly.

•

Use an 8H-8537 Socket on the cab mounting bolts.•

Use a 7H-1680 Compressor Assembly in order to pump oil to the suspension cylinders.•

Use a 6V-4040 Inflation Group in order to inflate the tires with nitrogen.•





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Use an 8H-8536 Socket .•

Use an 8T-0859 Pressure Gauge on the front suspension cylinders.•

Use a 7S-5437 Nitrogen Charging Group in order to charge the tires and the suspensioncylinders.

•

Use a 8T-5230 Torque Wrench that is regulated by air pressure in order to obtain amaximum torque of 300 N·m (220 lb ft).

•

When you are instructed, apply 222-3124 Brake and Electrical Cleaner in order to cleancomponents.

•

Required Supplies and Required Equipment

Refer to the information that follows in order to gather supplies and equipment.

Have one 208 L (55 US gal) barrel of hydraulic oil (HYDO).•

Obtain 6 barrels of transmission/drive train oil (TDTO). Each barrel should have a capacityof 208 L (55 US gal). 3 barrels should contain SAE 10W oil. 3 barrels should contain SAE30 oil. Ambient temperatures that are extreme may require a different oil viscosity. Refer toService Manual, SEBU6250, "Caterpillar Machine Lubricant Recommendations".

•

Have 20 nitrogen bottles that are T-size in order to inflate the tires and charge thesuspension cylinders.

•

Have one portable air compressor. The air compressor should have enough capacity in orderto operate two 25.4 mm (1 inch) impact air guns. The air compressor should have a

minimum capacity of 3 CM (100 CFM).

•

Have one stepladder that is 1.8 m (6 ft) tall. Have another stepladder that is 3.6 m (12 ft)tall.

•

Have one lift truck that can lift 4082 kg (9000 lb).•

Have another lift truck that can lift 13608 kg (30000 lb).•

Have one crane that can lift 36320 kg (80000 lb).•

Have at least 12 hardwood blocks that are 101 mm (4.0 inch) tall. The blocks should be 203mm (8.0 inch) wide. The blocks should be 406 mm (16.0 inch) long.

•

Have at least 40 hardwood blocks that are 203 mm (8.0 inch) tall. The blocks should be 203mm (8.0 inch) wide. The blocks should be 914 mm (36.0 inch) long.

•

Have at least 30.5 m (100 ft) of rope that is 12.7 mm (0.50 inch) in diameter. When youinstall the body on the chassis, use the rope in order to guide the body into position.

•

Have several shackles. The shackles should have a working load limit of 27240 kg (60050lb).

•

Have cables, chains, and lifting devices that have adequate capacity.•





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Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to themanufacturers literature in order to determine the application when you select the items that

follow: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Referto the Illustration that follows in order to see the effect of the lift angle on the working load limit.


Lift angles for lifting slings.

(A) The load capacity is 100% of the working load limit for the sling.

(B) The load capacity is 86% of the working load limit for the sling.

(C) The load capacity is 70% of the working load limit for the sling.

(D) The load capacity is 50% of the working load limit for the sling.

Tire Inflation Pressure and Mounting

Refer to Operation and Maintenance Manual, SEBU7790, " 777F Off-Highway Truck" for

specific information.





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Chassis Lifting Points

Illustration 3

Lifting points on the 777F Off-Highway Trucks

Position the Chassis for Assembly





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Wooden Supports Under the Front Frame

When you remove the chassis from the truck, place supports under the chassis. Placesupports at the front of the chassis and place supports at the rear of the chassis.

1.

When you place the supports at the front of the chassis, provide 1117 mm (44 inch) of

ground clearance in order to install the tires.

2.


When you place the supports at the rear of the chassis, provide 1092 mm (43 inch) of

ground clearance in order to install the tires.

3.

Install the 262-6081 Rear Axle Housing Gp and the 246-2647Transmission Ar

Note: Parts from the 2G-4080 Drive Shaft and 247-3752 Hydraulic Oil Cooler Lines Gp are alsorequired.

Required Parts for the Installation of the Rear Axle Housing

Table 38





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Item Qty Part Number Description


1 16 302-4536 Bolt

2 16 9X-8399 Washer

Bag of Components that is Attached to the Drive Shaft

3 4 8B-5144 Bolts (1)


4 1 321-1386 Tube As

5 1 321-1387 Tube As

6 1 321-1389 Tube As

7 1 321-1388 Tube As


8 8 175-7894 O-Ring Seals

9 16 8T-4184 Bolts

10 40 8T-4223 Hard Washers

11 8 1P-4582 Half Flanges

12 4 4J-0527 O-Ring Seals


13 4 7X-0328 Bolts

14 4 5P-2566 Bolts


Components that are Attached to the Rear Axle

16 1 9C-4937 Breather As

17 1 030-7765 Fitting

( 1 ) Bolts are attached to the drive shaft in a bag.

Note: In order to obtain the proper torque values, apply Tooling (AA) on all mating surfaces.Remove any burrs, nicks, or rust before assembly. Retain all hardware.





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Remove nine bolts (A) and nine washers (B) that secure guard (C) to the frame. Removeguard (C) from the frame.

1.


Remove the attached bag of parts from drive shaft (D). Retain the attached bag of parts.2.






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Remove the straps that secure the suspension a-frame and the rear suspension cylinders.3.


Use Tooling (AA) to remove the paint from the rear axle assembly. Use Tooling (BB) toclean the mounting areas on the rear axle assembly.

4.


Use Tooling (AA) to remove the paint from the suspension a-frame. Use Tooling (BB) toclean the mounting areas on the suspension a-frame.

5.





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Remove the following components from the rear axle assembly: two nuts (E), four washers(F), two hard washers (G), two bolts (H) and two pins (J). Retain all hardware.

6.

Use Tooling (AA) to remove the paint from two pins (J) .7.


Remove the following components from the rear of the chassis: nut (K), hard washer (L),two washers (M), bolt (N) and pin (P). Retain all hardware.

8.

Use Tooling (AA) to remove the paint from pin (P) .9.





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Remove the wire ties from the hoses for the final drives and the transmission.10.



Place a suitable lift truck under the rear axle assembly or use a crane to lift the rear axleassembly. Lift the rear axle assembly to the frame. The weight of the rear axle assembly is10115 kg (22300 lb).

11.





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Note: Do not crush the hoses or do not pinch the hoses that are located in the rear of the

chassis.


Align control rod (R) with the frame. Install the following components to control rod (R)

and to the frame: pin (P), nut (K), hard washers (L), two washers (M) and bolt (N) .

12.


Install 16 bolts (1) and 16 washers (2). Bolts (1) will secure the rear axle assembly to thesuspension a-frame.

13.

Note: Tighten bolts (1) with an impact wrench. Do not torque bolts (1) at this time.

Align the rear suspension cylinders with the rear axle housing.14.





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Install pins (J) to the rear axle housing and to the rear suspension cylinders.15.

Note: Lubricate pins (J) with Tooling (EE) before installation.

Install the following components to the rear suspension cylinder and to the rear axle

housing: two nuts (E), four washers (F), two hard washers (G) and two bolts (H). Tighten bolts (H) to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

16.

Repeat Step 14 through Step 16 for the other rear suspension cylinder.17.


Torque bolts (1) that secure the rear axle assembly to the suspension a-frame. Tighten bolts(1) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

18.

Note: Use a 6V-6080 Torque Multiplier Gp in order to reach the correct torque.





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Tighten bolt (N) to a torque of 620 ± 80 N·m (460 ± 60 lb ft) in order to secure control rod(R) .

19.

Note: Check the torque value of existing bolt (NN) that secures the opposite end of controlrod (R). The proper torque value of existing bolt (NN) is 620 ± 80 N·m (460 ± 60 lb ft).


Align drive shaft (D) to the transmission. Install four bolts (3) in order to secure the driveshaft to the transmission. Tighten bolts (3) to a torque of 270 ± 15 N·m (200 ± 11 lb ft).

20.

Note: Bolts (3) are located in the bag of parts that was removed in Step 2.





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Reinstall guard (C) to the frame with nine bolts (A) and nine washers (B) that were removedin Step 1.

21.


Remove the link from the chain that secured the suspension a-frame to the chassis. Removethe chain from the chassis.

22.

Repeat Step 22 for the opposite side of the machine.23.





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(S) 11 mm (0.43 inch)

NOTICE

Do not grind through the weld or through the parent material of the

frame.

Carefully remove the two eyes from the side of the suspension a-frame and of the frame.Leave the weld and parent material to dimension (S) .

24.

Clean all affected areas. Paint the area in order to inhibit rust.25.

Slowly lower the rear axle assembly. Remove the lift truck from the rear axle assembly.26.





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Remove the four nuts and the four washers that secure the plate to the wheel. Remove the plate from the wheel. Reinstall the four nuts and washers once the plate has been removed.Repeat the procedure for the other wheel.

27.

Install the Brake Oil Cooler Lines


Remove the shipping caps from the final drives.1.





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Tubes for the right-hand brake oil cooler

Install O-ring seal (8) in the end of tube (4) .2.

Use the following components in order to secure tube (4) to the top port of the final drive:four bolts (9), four hard washers (10) and two half flanges (11) .

3.

Note: Install tube (4) before installing tube (5) .


Use the following components to secure tube (5) to the bottom port of the final drive: four bolts (9), four hard washers (10) and two half flanges (11) .

5.



Remove bolt (R), washer (S), and two clips (T) from the suspension a-frame. Secure tube(4) and tube (5) with bolt (R), washer (S), and clips (T) .

6.





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Tubes for the left-hand brake oil cooler



8.

Note: Install tube (6) before installing tube (7) .



10.



Remove bolt (R), washer (S), and clips (T) from the suspension a-frame. Secure tube (6)and tube (7) with bolt (R), washer (S), and clips (T) .

11.





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Remove the shipping caps from hose (U), hose (V), hose (W), and hose (X) for the finaldrives and the transmission. Retain all half flanges, bolts, washers, and nuts forreinstallation in Step 14 and Step 16.

12.




Connect the following tube assemblies to the following hose assemblies on the right side ofthe chassis: tube (4) to hose (U) and tube (5) to hose (W) .

13.

Use the following components in order to secure the tube assemblies to the hose assemblies:two O-ring seals (12), four half flanges that were removed in Step 12, four bolts that were

14.





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removed in Step 12, eight hard washers that were removed in Step 12, four bolts that were

removed in Step 12 and four nuts that were removed in Step 12.




Connect the following tube assemblies to the following hose assemblies on the left side ofthe chassis: tube (6) to hose (V) and tube (7) to hose (X) .

15.

Use the following components in order to secure the tube assemblies to the hose assemblies:

two O-ring seals (12), four half flanges that were removed in Step 12, four bolts that wereremoved in Step 12, eight hard washers that were removed in Step 12, four bolts that wereremoved in Step 12 and four nuts that were removed in Step 12.

16.

Install the Transmission Lines





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Remove the shipping caps from hoses (Y) and (Z) .1.


Connect Hose (Y) to the slack adjuster. Connect Hose (Z) to the return line.2.


Remove the shipping cap from hose (AB) .3.





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Connect hose (AB) to the transmission by routing hose (AB) through the clip located on thefront, left-hand corner of the transmission.4.


Remove the shipping caps from hose (AC) and hose (AD). Retain all half flanges for reinstallation in Step 6 and Step 7. Discard all bolts, washers, and nuts.

5.





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Connect hose (AC) to the transmission. Use four bolts (13), four washers (15), and the halfflanges that were removed in Step 5 in order to secure hose (AC) .

6.


Connect hose (AD) to the transmission. Use four bolts (14), four washers (15), and the halfflanges that were removed in Step 5 in order to secure hose (AD) .

7.

Install the Breather Assembly


Remove breather (16) and fitting (17) from the rear axle. Remove the pipe plug from theaxle housing. Install breather (16) and fitting (17) to the rear axle housing.

1.

Install the Electrical Connection





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Remove two bolts, and two washers (AE) from the transmission and the mounting bracket(AF) .

1.


Remove bracket (AG) from mounting bracket (AF) and the transmission. Remove twowashers (AH) from mounting bracket (AF) and the transmission. Discard two washers(AH) .

2.





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Install bracket (AG) onto bracket (AF) with the hardware that was removed in Step 1.3.

Install plug (AJ) into the receptacle and tighten the mounting screw.4.

Remove the nut, the bolt, two washers, and clip (AK) from bracket (AF). Install the clip tothe harness of plug (AJ) and reinstall the clip, the bolt, two washers, and the nut to bracket(AG) .

5.

Install the 280-6920 Platform Gp and 280-6930 Platform Gp

Required Parts for Installation of the Platform Gp


1 1 280-6920 Platform Gp


Table 39


Remove six bolts (A) and six washers (B) from the frame. Use tooling (AA) in order toremove all paint and rust from the mating surface.

1.





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Use tooling (AA) in order to remove all paint or rust from the mating surface.2.


Install a suitable lifting device and position platform group (2) into position. The weight ofeach platform is 112 kg (245 lb).

3.

Reinstall six washers (B) and six bolts (A) that were removed in Step 1. Tighten the bolts.4.

Repeat Step 1 through Step 4 for the other side.5.

Install the 241-2699 Ladder Gp

Required Parts for Installation of the Ladder Gp


1 2 241-2699 Ladder Gp

Table 40





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Right-hand bumper

Remove four bolts (A) and four washers (B) .1.


Position ladder (1) to the frame and reinstall four washers (B) and four bolts (A) that were

removed in Step 1. Tighten the bolts. Repeat this procedure for the other side.

2.

Install the Suspension Cylinders from the 264-5808 FrontSuspension (non-European part number) or from the 264-

5809 Front Suspension (European part number) and Install

the Steering Arms from the 9D-3030 Steering LinkTable 41





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Required Parts for Installation of the Front Suspension Cylinders


1 2290-7232 (1)

290-7233 (2) Suspension Group


2 2 9D-2498 Keys

3 28 7B-9215 Bolts

4 28 3S-1356 Full Nuts

5 56 3S-1349 Hard Washers


6 2 4J-8535 Clamps

7 2 116-1949 Covers

( 1 ) European part number ( 2 ) Non-European part number

Note: Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-

Highway Trucks" for any information concerning suspension cylinders. The Special Instructionincludes Tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging(oil and nitrogen).


Shipping skid

Remove the shipping brackets from the front suspension cylinders.1.

NOTICE





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DO NOT allow the steering arm assembly to hang unsupported,

stressing the ball studs. Support the steering arm assembly withsuitable tooling.


Remove the shipping bracket from the frame. Use Tooling (AA) to remove the paint. UseTooling (BB) in order to clean the mating surfaces.

2.

Remove any burrs from the mating surfaces. Make sure that mating surfaces are smooth.3.

NOTICE

DO NOT hang bearing cap by the lubrication line.


Remove four mounting bolts (A), eight washers (B), bearing cap (D), and shims (C) .4.





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Use Tooling (BB) in order to clean the bearing cap.5.


Install one key (2). Align the key in order to allow the bolts through the bolt holes.6.


Use Tooling (CC) in order to position suspension group (1) on the truck frame. Align the

charging valve for the suspension cylinder toward the front of the machine. The weight of afront strut assembly is 1475 kg (3250 lb).

7.





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Use the following components in order to secure suspension group (1) on the frame: sixteen

bolts (3), sixteen full nuts (4) and thirty-two hard washers (5) .

8.

Tighten 16 bolts (3) to a torque of 1175 ± 48 N·m (870 ± 35 lb ft).9.


Install bearing cap (D) to suspension group (2). Fit the required number of shims (C) behindthe bearing cap in order to eliminate any gap. Install two bolts (A) and eight washers (B).Tighten the bolts (A) for the bearing cap to a torque of 370 ± 50 N·m (275 ± 35 lb ft).Repeat the procedure for the other suspension cylinder.

10.





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Connect grease lines (E) to suspension group (1). Repeat the procedure for the other

suspension cylinder.

11.


Right-hand front suspension cylinder

Connect sensor (F) for the payload monitor for the truck to connector (G) .12.





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Left-hand front suspension cylinder

Connect the sensor (F) for the payload monitor for the truck to connector (H) .13.


Remove four bolts (J) and four hard washers (K). Clean the mating surface for the steeringarm on the spindle. Remove any burrs from the mating surface. Repeat the procedure for theother suspension cylinder.

14.





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Note: Before you install the steering arm, make sure that the mating surfaces are clean.

Reinstall four bolts (J) and four hard washers (K) that were removed in Step 14. Bolts (J)

and washers (K) are used to fasten the steering arms on the spindle of each front suspensioncylinders (2). Tighten four bolts (J) to a torque of 1800 ± 200 N·m (1325 ± 150 lb ft).Repeat the procedure for the other side.

15.

Note: If the ball studs are removed, clean the tapers and apply Tooling (EE). Next, installthe castle nuts. Tighten the castle nuts to a torque of 1360 N·m (1000 lb ft). Insert the cotter

pin through the castle nut. If the hole for the cotter pin is not aligned, tighten the castle nutuntil the hole for the cotter pin is in alignment.

Note: In order to prevent damage to the ball studs, support the steering cylinders duringassembly. Do not allow the rods to fall out of the steering cylinders.


Install cover (7). Secure cover (7) with clamp (6). Repeat the procedure for the other suspension cylinder.

16.

Installation of the Hydraulic Oil Cooler Lines and the Front

Service Brake Lines

Note: The 247-3752 Hydraulic Oil Cooler Lines Gp are part of the 234-2647 Brake Arrangement .The 229-2093 Service Brake Lines Gp are also part of the 234-2647 Brake Arrangement .Machines that are equipped with 243-5551 Service Brake Gp are not equipped with front oil

cooler lines. 243-5551 Service Brake Gp are disc type brakes. Machines that are equipped with243-5551 Service Brake Gp also have 254-3356 Service Brake Lines Gp instead of 229-2093Service Brake Lines Gp .

Required Parts for Installation of the Front Oil Cooler Lines and Front Service BrakeLines

Table 42





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1 4 103-5422 Hose As


2 8 4J-0522 O-Ring Seals


Remove eight bolts (A), eight hard washers (B), and four half flanges (C). Discard covers.1.


Install two hoses (1) to the bulkhead with two seals (2), four half flanges (C), eight hardwashers (B), and eight bolts (A) that were removed in Step 1. Tighten the bolts.

2.

Note: Install hoses (1) with the 67.5 degree angle to the top. Ensure that the hoses areinstalled tightly against the support bars.





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Remove eight bolts (A), eight hard washers (B), and four half flanges (C). Discard covers.3.

Install two hoses (1) to the brakes with two seals (2). Use four half flanges (C), eight hardwashers (B), and eight bolts (A) that were removed in Step 3. Tighten the bolts.

4.


Remove bolts (F), washers (G), and block (E). Remove the cap from fitting on the brakesand remove the plug from hose (C). Install hose (D) .

5.

Reinstall block (E), washers (G), and bolts (F) that were removed in Step 5.6.

Repeat Step 1 through Step 6 for the other side of the machine.7.

Front Service Brake Lines (Dry Brakes)

Note: The 247-3752 Hydraulic Oil Cooler Lines Gp are part of the 234-2647 Brake Arrangement .The 229-2093 Service Brake Lines Gp are also part of the 234-2647 Brake Arrangement .





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Machines that are equipped with 243-5551 Service Brake Gp are not equipped with front oil

cooler lines. 243-5551 Service Brake Gp are disc type brakes. Machines that are equipped with243-5551 Service Brake Gp also have 254-3356 Service Brake Lines Gp instead of 229-2093Service Brake Lines Gp .


Remove all caps and plugs. Install hose (A) to brake assembly. Repeat the procedure for the

other side of the machine.

1.

Install the Fuel Tank

Required Parts for Installation of the Fuel Tank


1 1

223-5868 Fuel Tank Gp (1)

219-9712 Fuel Tank As (2)

Table 43

( 1 ) 1140 L (300 US gal) Tank

( 2 ) 1320 L (350 US gal) Tank





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Use Tooling (AA) to remove the paint from the mating surfaces. Use Tooling (BB) to cleanthe mating surfaces. Remove any burrs that are present.

1.


Remove four bolts (A), four hard washers (B), and two caps (C). Use Tooling (AA) toremove any paint from the mating surfaces. Use Tooling (BB) in order to clean the mating

surfaces. Remove any burrs that are present.

2.





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Remove two bolts (E), two lock washers (F), two hard washers (G), two washers (H), and

four mountings (D) .

3.



Use a suitable lifting device to position fuel tank (1). Position fuel tank (1) on the right side

of the truck.

4.

Note: 223-5868 Fuel Tank Gp weighs 336 kg (740 lb).

Note: 219-9712 Fuel Tank As weighs 448 kg (990 lb).





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Note: Ensure to center fuel tank (1) on the mounts before securing.

Reinstall two caps (C), four bolts (A), and four hard washers (B) that were removed in Step

2 in order to secure the fuel tank. Tighten the bolts.

5.


Position two mountings (D) on each side of the bracket. Use the components that wereremoved in Step 3 in order to secure fuel tank (1). Tighten the bolts.

6.





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Connect the fuel line (J) and fuel line (K) to the outlets on the back of the fuel tank. Attachhose (K) from the primary fuel filter to the outlet that has the shutoff valve.

7.



Connect harness (L) through the clip to connector (M) .8.

Install the 241-7779 Cab Mounting Gp , and the 240-2262Cab Mounting Gp

Required Parts for Installation of the Cab Mounts and the Cab


1 1 250-5930 Support As

2 1 241-7777 Support As

Table 44





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3 8 173-9684 Bolts

4 8 198-4782 Hard Washers

5 10 129-3175 Bolts


7 1 240-2263 Sleeve

8 8 117-8131 Mount As

9 1 8T-5397 Bolt

10 4 252-0080 Washers

11 3 3E-4898 Sleeves

12 3 8T-0672 Bolts

13 4 8T-4195 Bolts

14 4 7X-7729 Washers

15 4 240-2261 Pin As


Remove the mounting bolts, washers, and lifting eyes from the front support mountingsurface. Discard the bolts, washers, and the lifting eye. These parts will not be used again.

1.

Use Tooling (AA) to remove the paint from the mounting surfaces of the cab supports andthe mating surfaces on the chassis. Use Tooling (BB) to clean the mounting surfaces of the

cab supports and the mating surfaces on the chassis. Remove any burrs that are present.

2.





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Attach a suitable lifting device to support (1). Position support (1) to the chassis. Use eight bolts (3) and eight washers (4) in order to secure support (1) on the chassis. Tighten the bolts to a torque of 800 ± 110 N·m (590± 80 lb ft). The weight of support (1) is 148 kg (325lb).

3.

Note: When you install the cab support, do not use the bolts that secured the lifting eye.


Attach a suitable lifting device to support (2). Position support (2) to the chassis. Use ten bolts (5) and ten washers (6) in order to secure support (2) on the chassis. Tighten the boltsto a torque of 1600 ± 200 N·m (1180 ± 150 lb ft). The weight of support (2) is 230 kg (500lb).

4.





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Install two sleeves (11) and four cab mounts (8) on support (1), on the front cab mount and

the chassis. Install one sleeve (11) and two cab mounts (8) on support (3) .

5.


Install one sleeve (7) and two cab mounts (8) on the rear cab mount of the chassis.6.





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Install suitable lifting devices to the cab. Use the lifting points on the cab in order to raisethe cab. Align the cab on the frame and on the support assemblies. The weight of the cab is1320 kg (2910 lb).

7.

Note: Once the cab is installed, remove all lifting devices. Reinstall the mounting bolts thatwere used to attach the lifting devices to the cab.


Use two washers (10) and two bolts (12) in order to secure the cab on the front cab mounts.Apply Tool (HH) to the bolts. Tighten the bolts to a torque of 800 ± 110 N·m (590± 80 lb

ft).

8.

Use one washer (10) and one bolt (12) in order to secure the cab to the cab mount on therear support. Apply Tool (HH) to the bolts. Tighten the bolt to a torque of 800 ± 110 N·m

(590± 80 lb ft).

9.





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Use one washer (10) and one bolt (9) in order to secure the cab on the rear cab mount on thechassis. Apply Tool (HH) to the bolt. Tighten the bolt to a torque of 800 ± 110 N·m (590±

80 lb ft).

10.


Install cab bolts (13), washers (14), and pins (15) at four locations. Tighten the bolts.11.

Installation of the Exhaust Arrangement

Required Parts for Installation of the Exhaust Arrangement


1 1 256-6757 Exhaust Pipe Gp

Table 45





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2 2 4N-9330 Clamps

3 2 6V-3823 Bolts


5 2 8T-4244 Nuts

6 1 256-9400 Tube As

7 6 7X-2563 Bolts

8 6 8T-4123 Washers


Remove four bolts, four washers, and one cover plate. Discard all parts.1.

Use Tooling (AA) to remove the paint from the mating surfaces. Use Tooling (BB) to cleanthe mating surfaces. Remove any burrs that are present.

2.






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Install clamp (2), bolt (3), two hard washers (4) and nut (5) to the end of tube assembly (6).

Install tube (6) onto the muffler.

3.

Install a suitable lifting device to the assembly. The weight of exhaust pipe group (2) is 155kg (340 lb).

4.



Use six bolts (7) and six washers (8) to secure the assembly to the truck. Install clamp (2), bolt (3), two hard washers (4) and nut (5) to the slotted end of tube (6) .5.

Tighten bolts (3) on two clamps (2) .6.

Install the Right Hand Platform

Required Parts for Installation of the Right Hand Platform



Table 46





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Remove eight mounting bolts (A) and eight hard washers (B). Use Tooling (AA) to removethe paint from the mating surfaces. Use Tooling (BB) to clean the mating surfaces. Removeany burrs that are present.

1.


Install a suitable lifting device to right-hand platform (1). The weight of right-hand platform

(1) is 230 kg (510 lb).

2.

Install right-hand platform (1) .3.





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Secure right-hand platform (1) with four bolts (A) and four hard washers (B) at the rear ofthe platform.

4.


Secure right-hand platform (1) with four bolts (A) and four hard washers (B) at the front ofthe platform.

5.






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Remove five cable straps (C) .6.


Install plug (D) into the receptacle.7.




1 1 273-2398 Ladder Gp

FF 10 7K-1181 Cable Straps

Table 47


Remove four bolts (A) and four washers (B) that are used to mount the ladder group.1.





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Remove two nuts (C), two washers (D), and two bolts (E) that are used to mount ladder group (1) .

2.


Install a suitable lifting device to ladder group (1). The weight of ladder group (1) is 68 kg(150 lb).

3.





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Position ladder group (1). Reinstall two bolts (A) and two washers (B) that were removed inStep 1.

4.


Reinstall two bolts (E), two washers (D), and two nuts (C) that were removed in Step 2.5.





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Route wiring harness (F) from the right-hand bumper extension inside the right-hand enginecompartment and along the right-hand platform for the ladder.

6.

Install the connector on harness (F) to the connector on harness (G). Secure wiring harness(F) to the right-hand platform for the ladder with two cable straps (FF) .

7.

Install the 237-0288 Service Brake Control Gp Fittings

Required Parts for Installation of the Fittings for the Service Brake Control Groups



1 2 148-8347 Elbow As

2 1 153-6237 Elbow As

Table 48





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Bottom of the cab

Remove all plugs from the brake control valve that is located on the bottom of the cab.Discard all plugs.

1.


Install two elbow assemblies (1) and elbow assembly (2) to the brake control valve.2.

Install the 237-0288 Service Brake Control Gp





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Left-hand front side of the chassis


Bottom of the cab

Connect hose (A) to the brake control valve.1.

Connect hose (B) to the brake control valve.2.

Connect hose (C) to the brake control valve.3.

Install the 267-4707 Steering Lines Gp Fittings

Required Parts for Installation of the Fittings for the Steering Lines Gp



1 2 148-8324 Connector As

Table 49





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2 1 148-8326 Connector As

3 2 148-8359 Elbow As


Front of the cab

Remove all plugs from the hand metering unit that is located on the front of the cab. Discardall plugs.

1.






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Install two elbow assemblies (1), elbow assembly (2), and two elbow assemblies (3) to the

hand metering unit (HMU).

2.

Install the 267-4707 Steering Lines Gp


Left-hand front side of the chassis





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Front of the cab

Connect hose (A) to the back of the hand metering unit (HMU).1.

Connect hose (B) to the back of the hand metering unit (HMU).2.

Connect hose (C) to the back of the hand metering unit (HMU).3.

Connect hose (D) to the back of the hand metering unit (HMU).4.

Connect hose (E) to the back of the hand metering unit (HMU).5.

Install the 273-2359 Platform Gp

Required Parts for Installation of the Platform Gp



Table 50





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Remove four bolts (A) and four washers (B) in order to remove cover (C). Retain all

hardware.

1.






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Remove six bolts (D) and six washers (E) .2.


Install a suitable lifting device to platform (1). The weight of platform (1) is 65 kg (140 lb).3.

Position platform (1) to the cab. Reinstall six washers (D) and six bolts (E) that wereremoved in Step 2.

4.


Reinstall cover (C) with four bolts (A) and four washers (B) that were removed in Step 1.5.





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Remove six bolts (F) and six washers (G) from the bumper extension. Remove plate (H)from the bumper extension.

6.


Position guard (J) and plate (H) under the bumper extension. Install six washers (G) and six bolts (F) that were removed in Step 6. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7lb ft).

7.





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Disconnect harness (K) from light (L) .8.


Install harness (K) through grommet (M) that is located on platform (1) .9.

Connect harness (K) on light (L) .10.

Install the 273-2325 Walkway Gp

Required Parts for Installation of the Walkway Gp


1 1 273-2325 Walkway Gp

GG 3 3S-2093 Cable Straps

Table 51






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Remove eight bolts (A) and eight washers (B). Retain all hardware.1.

Use Tooling (AA) to remove the paint from the mating surfaces. Remove any burrs that are present.

2.


Install a suitable lifting device to walkway group (1). The weight of walkway group (1) is190 kg (420 lb).

3.





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Position walkway group (1) as Illustration 126 shows.4.



Install walkway group (1) with eight bolts (A) and eight washers (B) that were removed inStep 1.5.





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1 1 255-2600 Ladder Gp

FF 17 3S-2093 Cable Straps


3 2 8T-4137 Bolts


5 1 169-5414 Clip

6 1 130-5300 Clip

Table 52


Remove two bolts (A) and two washers (B) from the left-hand support. Retain all hardware.1.





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Remove two bolts (C), two washers (D), and two nuts (E) from left-hand ladder (1). Retainall hardware.

2.


Install a suitable lifting device to left-hand ladder (1). The weight of left-hand ladder (1) is60 kg (130 lb).

3.






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Install ladder (1) with two bolts (A) and two washers (B) that were removed in Step 1.Reinstall two bolts (C), two washers (D), and two nuts (E) that were removed in Step 2.Tighten all fasteners.

4.






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Secure wiring harness (F) with 13 cable straps (FF) to the mounting clips on left-hand

ladder and left-hand platform. Secure wiring harness (F) with four cable straps (FF) to themounting clips on platform (G) .

5.


Connect the electrical connections on the following components: wiring harness (F), engineshutdown switch (H), left-hand ladder light (J), and left hand driving lights (K) .

6.


Connect the electrical connections on the following components: wiring harness (F), sidemarker light (L), and left-hand indicator light (M) .

7.





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Install the 273-2387 Handhold Gp

Required Parts for Installation of the Handhold Gp


1 1 273-8920 Handhold As







7 2 115-3580 Plates

8 4 5P-7468 Clips

9 4 5P-7469 Clips

10 4 8T-4183 Bolts


12 4 8T-4244 Nuts

13 4 8T-7087 Grommets

Table 53





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Illustration 139





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View of Area (P)

Remove 12 bolts (M) and 12 washers (N). Install handrail (5) and reinstall 12 bolts (M) and12 washers (N) .

6.

Remove eight bolts (R) and eight washers (S). Install two handrails (6) and reinstall eight bolts (R) and eight washers (S) .

7.

Note: Install plate (7) on the outside of the handrail. Orient the hardware in order to preventa hazard or pinch point.

Install two grommets (13), two clips (8), two clips (9), and plate (7) with two bolts (10),four washers (11), and two nuts (12) .

8.

Install 280-4416 Tube As , that is part of 256-9394 Muffler

Gp

Required Parts for Installation of the Exhaust Tube



Table 54





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1 1 280-4416 Tube As


2 4 8T-4183 Bolts



Remove four bolts (A), four washers (B), and one cover (C) from box (D). Discard all parts.1.





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Install tube assembly (1) to box (D) with four bolts (2) and four hard washers (3) .2.

Install the 276-4002 Mirror Gp (if equipped)

Required Parts for Installation of the Mirror Gp




1 1 7X-7468 Convex Mirror

2 1 279-0467 Mirror Gp

3 1 322-7277 Mirror As

4 2 144-2227 Mirror As


5 1 2G-1133 Grommet

6 1 284-5263 Wiring Harness

7 1 7G-7053 Grommet

Table 55





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Remove six bolts (C) and six hard washers (D) from bracket assembly on the right-hand railassembly. Install mirror group (2) to the bracket and reinstall six hard washers (D) and six

bolts (C) .

2.

Install grommet (5) to the walkway group. Route electrical cable from mirror (2) down thehandrail and through the grommet on the walkway group. Secure the electrical cable withcable straps (GG) .

3.





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Connect the electrical cable to connector (E). Secure the harness with cable straps (GG) .4.





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(A) 30 ± 5 mm (1.2 ± 0.2 inch)

(B) 152 ± 5 mm (6.0 ± 0.2 inch)

In order to install the mirror group (3), ensure that the following conditions are met:5.

Surface temperature is between 21 °C (70 °F) and 38 °C (100 °F).

The surface is clean and dry. Clean the surface with a 50:50 solution of isopropylalcohol and water. Wipe the surface with a clean paper towel until the surface is dry.

Remove the backing from the adhesive on mirror assembly (3). Position mirror assembly (3)to dimension (A) and dimension (B) on mirror (2).

6.





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Right-hand mirrors

Remove four bolts (F) and four hard washers (G) from mirror supports (H) on the right-hand handrail assembly. Install two mirror assemblies (4) to mirror supports (H) and

reinstall four hard washers (G), and four bolts (F) .

8.

Install grommet (7) to the right-hand platform. Route harness (6) down the mirror support.Secure the harness with cable straps (GG) .

9.

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Wiring harness for the mirror that is on the left-hand walkway group

Route harness (6) through grommet (7). Secure the harness with cable straps (GG). Connectcable (6) to harness (J) .

10.

Install the 328-9834 Mirror Group (if equipped)

Required Parts for Installation of 328-9834 Mirror Group (if equipped)


1 1 330-5264 Tube As

2 2 329-7328 Convex Mirrors

3 10 7Y-5262 U-Bolts (M10X1.5)


5 20 8T-0389 Locknut

6 1 331-3268 Tube As

7 4 8T-4182 Bolts (M10X1.5)

Table 56





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9 2 334-1004 Tube Assemblies

10 2 144-2227 Mirror Assemblies

11 4 8T-4137 Bolt

12 4 7X-3391 Hard Washer

13 4 8T-6868 Bolt

14 4 7D-9969 Support

15 11 3S-2093 (1) Cable Straps

16 1 324-6674 (1) Wiring Harness

17 1 2G-1133 (1) Grommet

18 1 298-7329 Bracket As

19 1 300-5512 Mirror As

20 4 8T-4196 Bolt

21 4 8T-4195 Bolt

22 1 300-0560 Mirror As

23 2 134-0989 Blocks

24 4 8T-4133 Nut

25 1 7G-7053 (1) Grommet

( 1 ) Part of 247-5666 Mirror Wiring Gp





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View of catwalk assembly next to cab

(1) 330-5264 Tube As

(2) 329-7328 Convex Mirror

(3) 7Y-5262 U-Bolt

(4) 8T-4121 Hard Washer

(5) 8T-0389 Locknut

Use the following parts in order to install tube as (1) : six U-bolts (3), twelve hard washers(4) and twelve nuts (5) .

1.

Install front left convex mirror (2) onto tube as (1) .2.





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View of front right corner of truck

(1) 330-5264 Tube As


(3) 7Y-5262 U-Bolt


(5) 8T-0389 Locknut





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(6) 331-3268 Tube As

(7) 8T-4182 Bolt

(8) 198-4777 Hard Washer

Use the following parts in order to install tube as (6) : four U-bolts (3), eight hard washers(4), eight nuts (5), four bolts (7) and four hard washers (8) .

3.

Install front right convex mirror (2) onto tube as (6) .4.



(9) 334-1004 Tube As

(10) 144-2227 Mirror Gp

(11) 8T-4137 Bolt

(12) 7X-3391 Hard Washer

(13) 8T-6868 Bolt

(14) 7D-9969 Support





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Use four bolts (11) and four hard washers (4) in order to assemble each right-hand mirror as

(10) to one of the tube assemblies (9).

5.



(9) 334-1004 Tube As

(10) 144-2227 Mirror Gp

(11) 8T-4137 Bolt


(13) 8T-6868 Bolt


Use four bolts (13) and four hard washers (12) in order to secure both tube assemblies (9)and four supports (14) to the rail assembly.

6.





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(9) 334-1004 Tube As

(10) 144-2227 Mirror Gp

(15) 3S-2093 Cable Strap

(16) 324-6674 Wiring Harness

(17) 2G-1133 Grommet

Attach the connectors from each mirror as (10) to wiring harness (16). Use cable straps (15)in order to secure the wiring harness to the appropriate locations on the hand rail.

7.





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(18) 298-7329 Bracket As

(19) 300-5512 Mirror As

(20) 8T-4196 Bolt

(21) 8T-4195 Bolt

(22) 300-0560 Rear View Mirror Gp

(23) 134-0989 Block

(24) 8T-4133 Nut

Assemble upper left mirror as (19) to bracket as (18). Use two bolts (21), four hard washers(4), and two nuts (24) .

9.

Assemble lower left mirror as (22) to bracket as (18). Use two bolts (21), four hard washers(4), and two nuts (24) .

10.

Install bracket as (18) to the rail assembly. Use four bolts (20) and four hard washers (4) inorder to secure two blocks (23) to bracket as (18) .

11.





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(22) 300-0560 Rear View Mirror Gp

(25) 7G-7053 Grommet

Use cable straps (15) in order to secure the wiring harness to the appropriate locations on

the hand rail.

12.


Install grommet (25) on the left-hand side of the catwalk. Insert the wiring for the left-handmirror through grommet (25). Connect the wiring for the mirror to the appropriate connectoron platform harness as (B) beneath the catwalk.

13.

Install the 321-6518 Rear View Mirror Gp (if equipped)



1 2 7X-7468 Convex Mirror

2 1 338-9281 Plate

3 7 5P-1076 Hard Washer

4 4 3K-6060 Locknut

5 1 338-9280 Plate

6 2 8T-4198 Bolt

7 15 8T-4121 Hard Washer

8 2 8T-4133 Nut

Table 57





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9 1 311-7059 Mirror Gp

10 1 134-0987 Bracket As

11 3 8T-4136 Bolt

12 4 8T-4186 Bolt

13 2 134-0989 Block

14 1 8T-7087 Grommet

15 1 5P-7468 Clip

16 1 5P-7469 Clip

17 1 8T-4183 Bolt

18 1 129-3180 Locknut

19 1 295-8899 Plate

20 2 144-2227 Mirror Gp

21 2 323-5341 Tube As

22 4 8T-4137 Bolt


24 6 8T-6868 Bolt



27 6 3S-2093 Cable Strap

Left Side Mirror Installation






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7/25/2019 ENSAMBLE 777F




(9) 311-7059 Mirror Gp

(10) 134-0987 Bracket As

(11) 8T-4136 Bolt

Secure mirror group (9) to bracket assembly (10) by using three bolts (11) and threewashers (7) .

3.


View of the left-hand catwalk assembly





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Secure convex mirror (1) to handrail assembly (A) by using three washers (3), one locknut

(4), one grommet (14), one clip (15), one clip (16), one bolt (17), one locknut (18), and one plate (19). Tighten locknut (4) to a torque of 25 ± 5 N·m (220 ± 44 lb in).

1.

Right Side Mirror Installation



(20) 144-2227 Mirror Gp

(21) 323-5341 Tube As

(22) 8T-4137 Bolt

Secure two mirror groups (20) to two tube assemblies (21) by using four bolts (22) and fourwashers (7) .

1.





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19 4 198-4777 Hard Washer

20 2 144-2227 Mirror Gp

21 2 323-5341 Tube As

22 4 8T-4137 Bolt


24 6 8T-6868 Bolt



27 6 3S-2093 Cable Strap



(1) 7X-7468 Convex Mirror

(2) 338-9281 Plate

(3) 5P-1076 Hard Washer

(4) 3K-6060 Locknut

Secure plate (2) to convex mirror (2) by using one hard washer (3) and one locknut (4).Tighten locknut (4) to a torque of 25 ± 5 N·m (221 ± 44 lb in).

1.





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(9) 311-7059 Mirror Gp

(10) 134-0987 Bracket As

(11) 8T-4136 Bolt

Secure mirror group (9) to bracket assembly (10) by using three bolts (11) and threewashers (7) .

3.



(A) Handrail assembly


(10) 134-0987 Bracket As

(12) 8T-4186 Bolt

(13) 134-0989 Block

Secure bracket assembly (10) to handrail assembly (A) by using two blocks (13), four bolts(12), and four washers (7) .

4.

Installation of the Front Mirrors





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7/25/2019 ENSAMBLE 777F


(15) 330-5264 Tube As

(16) 7Y-5262 U-Bolt

Secure tube assembly (15) to handrail assembly (A) by using six U-bolts (16), 12 hard

washers (7), and 12 locknuts (8) .

2.



(17) 350-7140 Tube As

Secure convex mirror (14) to tube assembly (17) by using the clamping screws that are part

of convex mirror (14). Tighten the clamping screws to a torque of 2.25 ± 0.5 N·m (20 ± 4.4lb in).

3.





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(8) 8T-0389 Locknut

(16) 7Y-5262 U-Bolt

(17) 350-7140 Tube As

(18) 8T-4182 Bolt


Secure tube assembly (17) to handrail assembly (B), handrail assembly (C), and supportassembly (D). Use four U-bolts (16), eight hard washers (7), eight nuts (8), four bolts (18),and four hard washers (19) .

4.




(20) 144-2227 Mirror Gp

(21) 323-5341 Tube As

(22) 8T-4137 Bolt

Secure two mirror groups (20) to two tube assemblies (21) by using four bolts (22) and fourwashers (7) .

1.





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(B) Handrail assembly

(21) 323-5341 Tube As


(24) 8T-6868 Bolt


Secure two tube assemblies (21) to handrail assembly (B) by using six supports (23), six bolts (24), and six washers (25) .

2.






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(20) 144-2227 Mirror Gp

(21) 323-5341 Tube As

(26) 338-5116 Wiring Harness


Connect two wiring harnesses (26) to mirror groups (20) and the chassis wiring harnessassembly.

3.

Secure wiring harnesses (26) to the bottom of tube assemblies (21) by using six cable straps(27) .

4.

Install the 272-2552 Antenna Mounting Group that is a Partof the 268-7809 Communication Installation Group or the

313-5951 Communication Installation Group (if equipped)

Required Parts for the Installation of the Antenna Mounting Group


1 1 284-8533 Antenna Assembly

2 1 283-5837 Plate

3 17 3S-2093 Cable Straps

4 1 4P-7581 Clip

5 3 4P-8134 Clips

6 1 061-8844 Grommet

Table 59





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Install plate (2) to the mirror with the hardware for mounting the mirror.1.

Install antenna assembly (1) to plate (2) .2.

Route the wire from antenna assembly (1) downward through the catwalk. Use cable straps(3) to secure the wire to the handrail.

3.

Secure wire from antenna assembly (1) to clip (4) and to the weld links beneath the catwalk

with cable straps (3) .

4.

Use cable straps (3) in order to secure antenna assembly (1) to clips (5) .5.

Route antenna assembly (1) through the hole in the cab floor by using grommet (6) .6.

Connect the reverse TNC connector to the port closest to the LED output on the radio.7.

Connect the TNC connector to the remaining port on the radio.8.

Connect the 270-2660 Hydraulic Tank Gp

Required Parts for Installation of the Hydraulic Tank Gp


1 2 1P-3705 Rectangular Seals (1)

Table 60

( 1 ) Rectangular seals are in the bag that is attached to the steering tank.





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Remove eight bolts (A), eight hard washers (B), eight nuts (C), and four half flanges (D)from the bulkhead. Remove all caps and covers from the bulkhead. Discard all caps andcovers.

1.


Remove eight bolts (E), eight hard washers (F), eight nuts (G), and four half flanges (H)from the steering lines. Remove all caps and covers from the steering lines. Discard allremoved parts.

2.





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Hydraulic tank

Position guard (2). Reinstall plate (H), four washers (G), and four bolts (F) that wereremoved in Step 4. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

6.

Right Hand Fender Guards


Right-hand cowl

Remove two bolts (J), two hard washers (K), and backing plate (L).1.





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Remove three bolts (M), three hard washers (N), and backing plate (P) .2.


Right-hand cowl

Position rubber guard (3) and backing plate (L) behind the platform. Reinstall two hardwashers (K) and two bolts (J) that were removed in Step 1. Tighten the bolts to a torque of55 ± 10 N·m (40 ± 7 lb ft).

3.





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Position rubber guard (1) and backing plate (P) under the bumper. Reinstall three hardwashers (N) and three bolts (M) that were removed in Step 2. Tighten the bolts to a torqueof 55 ± 10 N·m (40 ± 7 lb ft).

4.


Right-hand ladder

Remove four bolts (Q), four hard washers (R), and backing plate (S).5.


Remove two bolts (T), two hard washers (U), and backing plate (V) .6.





7/25/2019 ENSAMBLE 777F



Underside of the right-hand platform

Remove two bolts (W), two washers (X), and plate (Y) .7.


Right-hand ladder

Position rubber guard (4). Reinstall plate (S), two bolts (Q), and two washers (R) that wereremoved in Step 5. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

8.





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Position rubber guard (4). Reinstall plate (V), two washers (U), and two bolts (T) that wereremoved in Step 6. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

9.


Underside of the right-hand platform

Position guard (4) and reinstall plate (Y), two washers (X), and two bolts (W) that wereremoved in Step 7. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

10.





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Rear of right-hand platform

Remove four bolts (Z), four washers (HH), and plate (JJ) .11.


Remove two bolts (KK) and two washers (LL) .12.


Front of fuel tank

Remove four bolts (MM), four washers (NN), and plate (PP) .13.





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Rear of right-hand platform

Position guard (5) and reinstall plate (JJ), four washers (HH), and four bolts (Z) that wereremoved in Step 11. Position guard assembly (5) to the exhaust diverter and reinstall twowashers (LL) and two bolts (KK) that were removed in Step 12. Tighten the bolts to a

torque of 55 ± 10 N·m (40 ± 7 lb ft).

14.


Front of fuel tank

Position guard (5) and reinstall plate (PP), four washers (NN), and four bolts (MM) that

were removed in Step 13. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

15.





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Right-hand platform

Remove six bolts (QQ), six washers (RR), and plate (SS) .16.


Right-hand platform

Position rubber guard (6) and reinstall plate (SS), six washers (RR), and six bolts (QQ) thatwere removed in Step 16. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

17.

Connect the 298-4577 Chassis Harness As and the 251-4169Coaxial Cable Assembly to the Right Side of the Cab





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Remove all caps and plugs from the cab. Discard all caps and plugs.1.


Connections at the right side of the cab

Install 298-4577 Chassis Harness As (A) to the receptacles on the right-hand side of the cab.2.

Note: The openings for the electrical plugs are not marked. However, each connector only

fits into one plug.

Install 251-4169 Coaxial Cable Assembly (B) to the receptacle on the right-hand side of the

cab.

3.



https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb

7/25/2019 ENSAMBLE 777F



Remove bolt (C) and washer (D). Position ground cable (E) and reinstall washer (C) and bolt (C) .

4.

Connect the Cable Harnesses for the Caterpillar IntegratedObject Detection System (CIODS) (If Equipped)


View of the right side of the cab





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Remove six bolts (A) and six washers (B) that secure plate (C) to the side of the cab. Retainthe hardware.

1.

Remove plate (C). Retain plate (C) .2.


Typical view from the right side of the cab

Insert cable harnesses (D) for the cameras through the bottom hole in plate (C) .3.





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Side view of plate (C)

Secure cable harnesses (D) to plate (C) by using grommet assembly (E). Tighten grommetassembly (E) to a torque of 20 ± 2 N·m (175 ± 17.5 lb in).4.

Note: Grommet assembly (E) is shipped attached to cable harnesses (D) .

Connect cable harnesses (D) to the cable harnesses that are located in the cab. Use Table 62to help connect the cable harnesses.

5.

Video Cables to Display Video Cables to Camera Cable Color

1 Front Red

2 Right Blue

3 Rear Green

4 Left Yellow

Table 62





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View of the right side of the cab

Secure plate (C) to the side of the cab by using six bolts (A) and six washers (B) that wereremoved in Step 1.

6.

Install the 247-3754 Air Conditioner Lines Gp

Locate the heater lines and the air conditioner lines that are strapped to the frame.1.


Right-hand side of the cab under the hood

Remove all caps from the air conditioner hose connections. Discard all caps.2.







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Install hose (A) and hose (B) to the fittings on the cab.3.


Right-hand side of the engine



Install heater hose (C) that is from the water pump outlet. Install heater hose (D) from theinlet port on the water pump. Secure heater hose (C) and heater hose (D) with clamps (E) .

4.

Use the 243-5549 Front Wheel Group to Install the Front

Tires

Required Parts for Installation of the Front Wheels



Table 63





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1 40 5D-0765 Full Nuts

2 40 5D-0764 Hard Washers

Make sure that all the paint, debris, and, blue shipping grease have been removed from thewheel studs and from the mating surfaces.

1.

Note: Use Tooling (AA) in order to remove paint. Use Tooling (BB) in order to clean themating surfaces.

Raise the front of the truck 1117 mm (44 inch) above the ground. Support the truck with

suitable blocks or suitable stands. Leave the hoist attached to the truck until the tires areinstalled.

2.



Use a tire handler in order to install a tire and rim on the wheel at each side of the truck.3.





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Use Tooling (AA) in order to remove paint and clean the mounting surfaces. Make sure thatall paint, shipping grease, and burrs have been removed from the wheel studs and themating surfaces.

4.

Install rim (A) with 20 hard washers (2) and 20 full nuts (1) .5.

If you apply 4C-5592 Anti-Seize Compound to the threads of the full nuts, tighten thefull nuts to a torque of 1210 ± 100 N·m (890 ± 75 lb ft).

a.

If anti-seize compound is not used, tighten the full nuts to a torque of 2100 ± 200 N·m(1550 ± 150 lb ft).

b.

Note: Leave the truck on stands in order to align the front wheels and charge thesuspension cylinders.

Use Tooling (DD) in order to inflate the front tires. Refer to Special Instruction,SMHS7867, "Use of 6V-4040 Nitrogen Tire Inflation Group ".

6.

Repeat Step 1 through Step 6 for the other front tire and rim.7.

Use the 243-5544 Rear Wheel Gp to Install the Rear Wheels

Required Parts for Installation of the Rear Wheels



1 2 272-7949 Tire Valve Gp

2 2 6G-8019 Tire Valve Gp


3 80 5D-0765 Full Nuts

4 80 5D-0764 Hard Washers

Table 64





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Use Tooling (AA) in order to remove paint and clean the mounting surfaces. Make sure that

all paint, shipping grease, and burrs have been removed from the wheel studs and themating surfaces.

1.

Raise the rear of the truck 1118 mm (44 inch). Support the truck with suitable blocks orsuitable stands. Leave the hoist attached to the truck until the tires are installed.

2.

Inner Rear Tires

Note: Remove paint and use Tooling (BB) in order to clean the mating surfaces.


Mark the final drives in order to locate the extension cover for the valve stem. Mark theinner tire and rim in order to locate the valve stem.

1.

Remove two bolts (A), two hard washers (B), and plate (C) .2.





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Use a tire handler in order to install an inner tire and rim on the truck.3.

Align the marks in order to install the inner rear tire and rim on the truck.4.




5.

Use 20 hard washers (4) and 20 full nuts (3) in order to secure the inner rear tire and rim tothe final drive.

6.


a.


b.

Note: The ring should be facing outward.






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Install tire valve (1) on the inner rear rim. Reinstall plate (C), two hard washers (B), and two

bolts (A) over tire valve (1). Tighten two bolts (A) to 100 ± 20 N·m (75 ± 15 lb ft).

7.

Use Tooling (DD) in order to inflate the inner rear tire. Refer to Special Instruction,SMHS7867, "Use of 6V-4040 Nitrogen Tire Inflation Group ".

8.

Repeat Step 1 through Step 8 for the other inner rear tire.9.

Outer Rear Tires

Note: Use Tooling (AA) in order to remove paint. Use Tooling (BB) in order to clean the matingsurfaces.


Mark the outer tire and rim in order to locate the valve stem.1.

Install tire valve (2) on the outer rear rim.2.


Use a tire handler in order to install an outer tire and rim on the truck.3.





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Align the marks in order to install the inner rear tire and rim on the truck.4.



5.

Use 20 hard washers (4) and 20 full nuts (3) to secure the outer rear tire and rim to the rear

wheel assembly.

6.


a.


b.

Note: The ring should be facing inward. Inward facing rings will cause the rims to

face each other between the tires.

Use Tooling (DD) in order to inflate the outer rear tire. Refer to Special Instruction,SMHS7867, "Use of 6V-4040 Nitrogen Tire Inflation Group ".

7.

Repeat Step 1 through Step 7 for the other outer rear tire and rim.8.

Front Wheel Alignment

Note: The front wheels must be off the ground. Ensure that the suspension cylinders are fullyextended.

NOTICE





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The tie rods must be tightened to a torque of 285 N·m (210 lb ft). The

tie rods must be tightened regardless of whether an adjustment hasbeen made.

Move the wheels until the wheels face straight ahead.1.


Measure the distance (D) between the front tires.2.

Mark location (D) on each front tire. Rotate the tires until the marks are 180 degrees from point (D) .

3.

Measure the distance (E) between the marks on the tires.4.

Subtract distance (E) from distance (D). This value will be 64.3 mm (2.53 inch) when the

toe-out is correct.

5.

If necessary, adjust the tie rods in order to set the toe-out. Loosen clamps (F) on the leftside. Loosen clamps (G) on the right side. Turn each tie rod by the same amount. Make surethat the tie rods are the same length.

6.

When the toe-out is set, tighten clamps (F) and clamps (G) to a torque of 285 N·m (210 lb

ft).

7.

Note: Make sure that there is a gap of at least 3.18 mm (0.125 inch) before you tighten theclamps on the tie rods.

Lower the front of the truck to the ground.8.





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Use the 308-0618 Truck Body Mounting Gp to Install the

Truck Body

Install the Truck Body

Required Parts for Installation of the Truck Body Arrangement ( 308-0618 Truck BodyMounting Gp )


1 2 8W-8454 Pin As

2 1 8W-2897 (1) Thrust Washer

3 2 9D-3432 (1) Thrust Washers

4 2 8W-8456 Plates

5 4 5P-2566 Bolts


7 2 3B-8489 Grease Fittings

8 2 322-5067 Mud Guard

9 2 322-5068 Plate

10 2 331-5956 Plate

11 20 9B-7237 Bolt

12 20 6V-8801 Nut

13 8 8T-4183 Bolt


15 8 8T-4244 Nut

Table 65

( 1 ) Use the 8W-2897 Thrust Washer only when the 9D-3432 Thrust Washer will not fit.

Remove the paint from the mating surfaces of the truck body and the frame. Remove alllifting eyes and lugs prior to installation.

1.





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View of the bottom of the truck body

(1) 8W-8454 Pin As

Insert one pin (1) into the outer pivot pin bore on each side of the truck body.2.





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Illustration 229

Use a suitable lifting device in order to position the truck body on the truck frame.3.

Align the pivot pin bores of the truck body and the pivot pin bores of the truck frame.4.


At each side of the machine, insert one thrust washer (3) between the outer ear of the truck body and the truck frame.

5.

Note: If thrust washer (3) does not fit, insert one thrust washer (2). Thrust washer (2) is 2.0

mm (0.079 inch) thinner than thrust washer (3) .


Drive pins (1) through the pivot pin bores of the truck body and of the truck frame.6.

Use the components that follow in order to secure the pins (1) in place: two plates (4), four bolts (5) and four hard washers (6) .

7.

Install two grease fittings (7) .8.





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(8) 322-5067 Mud Guard

(9) 322-5068 Plate

(10) 331-5956 Plate

(11) 9B-7237 Bolt

(12) 6V-8801 Nut

Secure two mud guards (8) to two plates (9) and two plates (10) by using 20 bolts (11) and20 washers (12) .

9.





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View of the bottom of the body

(9) 322-5068 Plate

(13) 8T-4183 Bolt


(15) 8T-4244 Nut

Secure two plates (9) to the bottom of the body by using eight bolts (13), eight hard washers

(14), and eight nuts (15) .

10.

Note: Tighten eight bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

Use the 9D-2725 Hoist Cylinder and Mounting Gp to Install

the Hoist Cylinders

Required Parts for Installation of the Hoist Cylinders


1 2 5T-9266 Pin As

Table 66





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2 4 9D-2316 Spacers

3 2 5T-5528 Plates

4 4 5P-2566 Bolts


Remove the protective caps from the bolt holes in the body near the pin bores. Remove the paint from the contact surfaces around the pin bores in the body. Remove the paint from thecontact surfaces on the hoist cylinders.

1.

Before you remove the shipping brackets from the hoist cylinders, use a chain and a lever puller in order to stabilize the hoist cylinders.

2.

Use a suitable lifting device in order to align the pin bores of the truck body and the hoistcylinders.

3.


Place one spacer (2) on each side of the hoist cylinder bearing. At each side of the machine,insert one pin (1) through the truck body and through the hoist cylinder bearing.

4.

Note: Before you install pins (1), apply Tooling (EE) to the pins.

Use the components that follow in order to secure each pin (1) : one plate (3), two bolts (4)and two hard washers (5) .

5.

Use the 308-0618 Truck Body Mounting Gp to Install the

Truck Body





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Install the Body Retaining Pins

Required Parts for Installation of the Retaining Pin


1 4 5D-3887 Rods

2 4 6F-8499 Springs

3 4 054-3788 Orifices

4 8 3B-4615 Cotter Pins

5 2 270-7034 Pin As

Table 67


Use the components that follow in order to install rods (1) on the right-hand side and left-

hand side of the truck body: springs (2), orifices (3) and eight cotter pins (4) .

1.

Install two pins (5) to the truck body. Secure the pins with rods (1) .2.

Install the Rock Ejectors

Required Parts for Installation of the Rock Ejectors ( 308-0618 Truck Body MountingGp )


1 2 253-7490 Ejectors

2 2 6G-7773 Pins

3 4 3B-4647 Cotter Pins

4 16 1D-0503 Washers

Table 68





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Use the components that follow in order to install one rock ejector (1) in each plateassembly: one pin (2), two cotter pins (3) and eight washers (4) .

1.

Note: Use washers (4) in order to center rock ejectors (1) between the two rear tires on eachside of the machine.

Install the Visual Body Down Indicator

Required Parts for Installation of the Visual Body Down Indicator


1 1113-1218

326-3097 (1)

Baffle AsBaffle As

2 2 031-9831 Bolts

Table 69

( 1 ) Part of the 341-5471 Rear View Mirror Gp or the 328-9834 Rear View Mirror Gp





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Note: Machine equipped with the 341-5471 Rear View Mirror Gp or the 328-9834 Rear View

Mirror Gp should use the 326-3097 Baffle As . The 326-3097 Baffle As is used on coal bodies.Machines without coal bodies should use the 113-1218 Baffle As .


Typical view

(1) 113-1218 Baffle As or 326-3097 Baffle As

(2) 031-9831 Bolt

Use two bolts (2) in order to install baffle assembly (1) on the canopy.1.

Install the Pad Assembly (Dump Body)

Required Parts For Installation of the Pad Assembly (Dump Body)


1 4 229-6177 Pad As

2 20 106-8227 Shims

3 20 5P-2566 Bolts


Table 70

NOTICE

An improper hydraulic oil level can result in machine damage.





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Raise and secure the dump body.1.


(A) Pad assembly

(B) Plate

Remove two pad assemblies (A) and two plates (B) from the two shoes on the frame. Retain pad assemblies (A), plates (B), and the hardware.

2.

Note: Pad assemblies (A) and plates (B) are shipped attached to the two shoes.





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(1) 229-6177 Pad As

(2) 106-8227 Shim

Stack one pad assembly (1) and one shim (2) at each pad mounting location on the framerails.

3.





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(1) 229-6177 Pad As

(2) 106-8227 Shim

Remove the safety devices and slowly lower the dump body until the body touches the pad

assemblies and shims.

4.





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Add shims (2) one at a time, until there are no gaps between pad assemblies (1) and the

dump body.

5.

Raise the dump body. Secure the dump body.6.

Illustration 242

(1) 229-6177 Pad As

(2) 106-8227 Shim

(3) 5P-2566 Bolt


Secure pad assemblies (1) and shims (2) to the dump body by using 20 bolts (3) and 20washers (4). Tighten bolts (3) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

7.





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(A) Pad assembly

(B) Plate

Return two pad assemblies (A) and two plates (B) to the shoes.8.

Remove the safety devices and slowly lower the dump body until the pad assemblies contactthe frame rails.

9.

Add shims (2) one at a time, until there are no gaps between pad assemblies (A) and thedump body.

10.

Note: Each shim (2) is 2 mm (0.079 inch) thick.

Raise the dump body. Secure the dump body.11.

Add one additional shim (2) beneath each pad assembly (A).12.

Secure pad assemblies (A) to the shoes with the hardware that was removed in Step 2.

Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

13.

Remove the safety devices and lower the body in order to make sure that all mounted padassemblies have even contact with the frame. Add shims (4) as needed.

14.





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Adjust the Position Sensor for the Dump Body (Lever Switch)

Raise the dump body and install the body retaining pins in order to secure the dump body inthe UP position.

1.


(A) 45 degrees

(1) Body down or up switch

(2) Lever

(3) Plate

Adjust lever (2) initially to a 45 degree angle from horizontal.2.

Note: Ensure that plate (3) is adjusted all the way toward the rear of the truck.

Remove the body retaining pins and lower the dump body into the DOWN position.3.

In order to adjust the snub position of the dump body to approximately 200 to 300 mm (8 to12 inch) between the front of the body pads and the frame rail, cycle the dump body andobserve the SNUB position. If the dump body reaches the SNUB position too early, move

lever (2) downward by one notch. If the dump body reaches the SNUB position too late,move lever (2) upward by one notch.

4.

Repeat Step 4 until the desired SNUB position of the dump body is obtained.5.

Adjust the Position Sensor for the Dump Body (Magnetic

Switch)





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Raise the dump body and install the body retaining pins in order to secure the dump body in

the UP position.

1.


(1) Body up switch

(2) Magnet

(3) Plate


(A) 10 mm (0.394 inch)





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(1) Body up switch

(2) Magnet

Adjust plate (3) so the gap between switch (1) and magnet (2) is 10 mm (0.394 inch).2.

Remove the body retaining pins and lower the dump body into the DOWN position.3.

In order to adjust the snub position of the dump body to approximately 200 to 300 mm (8 to12 inch) between the front of the body pads and the frame rail, cycle the dump body andobserve the SNUB position. If the dump body reaches the SNUB position too early, movemagnet (2) upward. If the dump body reaches the SNUB position too late, move magnet (2)downward.

4.

Repeat Step 4 until the desired SNUB position of the dump body is obtained.5.

Install the 237-4151 Central Lubrication Lines Gp (If Equipped)

Required Parts for Installation of the Central Lubrication Lines Group




1 12 5P-9085 Clips

2 10 5M-3062 Bolts


4 2 8T-4137 Bolts


Table 71





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Inside of the frame in the rear

Remove two bolts (A) and two washers (B). Rotate grease block (C) under the frame.1.


Rear view

Position grease block (C) to the mounting bosses on the rear axle housing. Reinstall twowashers (B) and two bolts (A) .

2.





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Illustration 249

Rear view

Remove two bolts (E), two washers (F) and two clips (G) from the frame.3.

Position two clips (G) to hose (H) and hose (J). Install two clips (G), two washers (F) andtwo bolts (E) to the rear frame. Refer to Illustration 247.

4.

Route two hoses (J) to the body pivot pins. Connect the hoses (J) to the grease ports.5.

Route two hoses (H) to the rod end of the suspension cylinders. Connect the hoses (H) to thegrease ports.

6.

Route two hoses (K) to the head end of the suspension cylinders. Connect the hoses (K) to

the grease ports.

7.

Position two clips (1) to two hoses (K). Install two clips (1), two hard washers (3) and two bolts (2) to the rear axle housing.

8.





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Illustration 250

Right side view

Route hoses (D) to the head ends of the hoist cylinders. Connect hoses (D) to the grease

ports. Refer to Illustration 247 and Illustration 250.

9.

For the right-hand side, Position one clip (1) to hose (D). Install one clip (1), one hardwasher (5) and one bolt (4) to the frame. Refer to Illustration 250.

10.

For the right-hand side, Position four clips (1) to hose (D). Install four clips (1), four hard

washers (3) and four bolts (2) to the dump body. Refer to Illustration 250.

11.

Repeat Step 10 and Step 11 for the left-hand side.12.

Use cable straps (GG) to secure hose (H) to hose (D). Refer to Illustration 247.13.





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Route hose (L) to the inboard sway bar. Connect hose (L) to the grease port.14.


Route hose (M) to the outboard sway bar. Connect hose (M) to the grease port.15.

Install the 273-1141 Automatic Lubrication Gp (If Equipped)

Required Parts for Installation of the Automatic Lubrication Gp




2 10 5M-3062 Bolts

Table 72





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4 12 5P-9085 Clips

5 2 8T-4137 Bolts


Illustration 253

Rear view

Remove two bolts (D), two washers (E) and two clips (F) from the frame.1.

Position two clips (F) to hoses (A), hoses (B) and hoses (C). Install two clips (F), twowashers (E) and two bolts (D) to the rear frame. Refer to Illustration 252.

2.





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Route two hoses (B) to the body pivot pins. Connect the hoses (B) to the grease ports.3.

Route two hoses (C) to the rod end of the suspension cylinders. Connect the hoses (C) to thegrease ports.

4.

Route two hoses (J) to the head end of the suspension cylinders. Connect the hoses (J) to thegrease ports.

5.

Position two clips (4) to two hoses (J). Install two clips (4), two hard washers (3) and two

bolts (2) to the rear axle housing.

6.

Route hose (G) to the inboard sway bar. Connect hose (G) to the grease port.7.


Route hose (H) to the outboard sway bar. Connect hose (H) to the grease port.8.





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Illustration 255

Right side view

Route hoses (A) to the head ends of the hoist cylinders. Connect hoses (A) to the grease ports. Refer to Illustration 252 and Illustration 255.

9.

For the right-hand side, position one clip (4) to hose (A). Install one clip (4), one hardwasher (6) and one bolt (5) to the frame. Refer to Illustration 255.

10.

For the right-hand side, position four clips (4) to hose (A). Install four clips (4), four hardwashers (3) and four bolts (2) to the dump body. Refer to Illustration 255.

11.


Use cable straps (1) to secure hose (C) to hose (A). Refer to Illustration 252.13.





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Remove plugs from the end of tube assembly and the hose assembly. Connect the tubeassembly (L) with O-ring Seal (M) to the hose assembly (K). The hose assembly (K) isattached to the fuel tank. Tighten the hose assembly to 65 to 72 N·m (48 to 53 lb ft). Refer

to Illustration 256.

14.

Note: If a machine is shipped from the factory with the 273-1141 Automatic Lubrication Gp , the278-7067 Hose As (K) that is used in the automatic lubrication group is assembled to the fueltank. If the machine is equipped with 273-1141 Automatic Lubrication Gp only, leave the hoseassembly in the same location. If the machine is equipped with both the 273-1141 Automatic

Lubrication Gp and the 258-0673 Service Center Gp , install the hose assembly (K) and thecoupler that is connected to the hose assembly to the 258-0673 Service Center Gp by using theunused hole in the service center box.

Install Lubrication Hose to the 258-0673 Service Center Gp (If Equipped)

Use the following procedure to install the hose assembly (K) to the 258-0673 Service Center Gp :






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Detail N

Remove one bolt (V), one hard washer (U), one clip (P), one clip (R), and grommet (T) thatare used to attach the hose assembly (K) to the fuel tank. Discard the parts.

1.

Disconnect the hose assembly (K) from the adapter (X). Remove the O-ring seal (M) fromthe adapter. Remove the bulkhead nut (W). Disassemble the coupler (S) from the adapter(X). Retain the parts.

2.


Service center





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Assemble the box (AA) to the fuel tank by using four bolts (Y) and four hard washers (Z).

Tighten bolts to 47 ± 9 N·m (35 ± 7 lb ft).

3.

Insert the adapter (X) through the unused hole (BB) in the box (AA). Assemble the adapterto the box with the bulkhead nut (W). Assemble the coupler (S) to the adapter (X) .

4.

If 5P-3413 Pipe Sealant is used, tighten the coupler to 45 to 50 N·m (33 to 37 lb ft). Ifsealant is not used, tighten the coupler to 60 to 66 N·m (44 to 48 lb ft).

5.

Install O-ring seal (M) to the adapter (X). Connect the hose assembly (K) to the adapter.Tighten the hose assembly to 65 to 72 N·m (48 to 53 lb ft).

6.

Install the 289-2182 Film Gp



1 1 289-8453 Film

2 1 289-8455 Film

3 1 289-8454 Film

Table 73

The following conditions must be met in order to install the films.

Surface temperature is between 15 °C (60 °F) and 27 °C (80 °F).•

The painted surface is fully dried.•

The surface is clean and dry.•





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Preparation for Installing the Films

Clean the surfaces with a 50:50 solution of isopropyl alcohol and water.1.

Use a cleaning agent in order to clean any oily surface or any surface that is covered with

grease.

2.

Note: Use water in order to remove the cleaning agent.

Wipe the surface with a clean paper towel until the surface is dry.3.

Procedure for Installing the Films

Apply an application fluid.1.

Note: Use only a pure soap and clean water that is mixed in a low concentration. Therecommended mixture for the solution is 1 to 3 drops of Ivory Soap per 1 L (1 qt).Additional information about Ivory Soap is available at the following address.

The Procter & Gamble Company

1 Proctor & Gamble PlazaCincinnati, OH 45201USA

Expose the adhesive by removing the liner from the back of the film. Align that end of the

film and position and lightly press onto the sprayed surface.

2.

Remove the rest of the liner paper and press the other end into position.3.

Use a squeegee in order to apply pressure to the film. By using firm, overlapping strokeswith the squeegee, start from the middle and work toward the edges of the film.

4.

Note: The adhesive needs between three and five minutes to set up.

Peel back the backing of the film, starting in a top corner and pulling at a 45 degree angle.5.

Continue to apply the squeegee to the film after the backing has been removed. Make surethat the film is securely applied to the proper location on the truck.

6.

Wipe the film and the surrounding area in order to remove the excess application fluid.7.

Locations for the Installation of the Films





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Install film (1) on the front of the canopy.1.

Note: Center the films in the available space.

Install film (2) on the right side of the truck body.2.

Note: Center the films in the available spaces.

Install film (3) on the left side of the truck body.3.






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Purge the Air from the Hydraulic Brake System

In order to purge the brake system of air, refer to the Testing and Adjusting, RENR8315, " 777FOff-Highway Truck Hydraulic System Testing and Adjusting".

Suspension Cylinder Charging ProcedureRefer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-HighwayTrucks" for any information concerning suspension cylinders. The Special Instruction,REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" Service Manual

includes tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging(oil and nitrogen), that is used on the 777F off-highway truck suspension cylinders.

Brake Accumulator Test and Charge

Refer to Systems Operation, Testing and Adjusting, RENR8315, "Brake Accumulator - Test andCharge" for any information concerning brake accumulator charge. The Systems Operation,Testing and Adjusting includes Tooling, pressures, and the correct procedures for testing andcharging (oil and nitrogen), that are used on 777F Off-Highway Truck brake accumulators.

Installation of the Caterpillar Integrated Object Detection

System (CIODS)

The information that is contained in this Special Instruction guides the user in the installation ofthe Caterpillar Integrated Object Detection System for Off-Highway Trucks.

The following Special Instruction will cover the installation of the following arrangements:

365-8470 Monitor Display Ar •

365-8471 Monitor Display Ar•

365-8472 Object Detection Installation Ar•

Do not perform any of the procedures until you have read the information in this publication.

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures" for additional welding

instructions.





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Illustration 263

View of the object detection locations

ReferenceRefer to Special Instruction, KENR8668 for the orientation of the radar. The radar orientation is critical for the operation of the object detection system.

Safety Information

Do not perform any procedure in this Special Instruction until you have read this SpecialInstruction and you understand this information. Use only proper tools and observe all precautionsthat pertain to the use of those tools. Failure to follow these procedures can result in personalinjury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused byfailure to observe basic safety rules or precautions. An accident can often be avoided byrecognizing potentially hazardous situations before an accident occurs.





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A person must be alert to potential hazards. This person should also have the necessary training,

skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If thesehazard warnings are not heeded, bodily injury or death could occur to you or to other persons.Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not allinclusive. Ensure that any tool, procedure, work method, or operating technique you use that is notrecommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by theoperation, lubrication, maintenance, or repair procedures used.

Prepare the Machine

Raise the truck body and install the body retaining pin for the truck body.1.

Set the parking brake.2.

Turn the key start switch and the disconnect switch to the OFF position.3.

Required Parts

Required Parts for Assembling the 347-1668 Camera Gp to the Brackets


4 347-1668 Camera Gp

3 305-3748 Plate As

8 n/a (1) Bolt

8 n/a (1) Washer

1 271-6768 Plate

1 305-3747 Plate As

6 8T-6466 Bolt


6 8T-4133 Nut


Table 74

( 1 ) Part of the 347-1668 Camera Gp

Required Parts for Assembling the Object Detection Box Groups to the Brackets


Table 75





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4 365-8490 Object Detection Box Gp

4 348-8760 Bracket

32 8T-4137 Bolt

32 7X-7729 Washer

4 347-7917 Object Detection Box Gp (RADAR)

4 348-8759 Bracket

Required Parts for Installing the Front Hardware



4 7X-0818 Bolt

4 9N-0869 Hard Washer

8 8T-9655 Isolation Mount


4 8T-4956 Bolt


2 8T-4195 Bolt


3 8T-5005 Bolt


3 8T-4133 Nut

1 067-2551 Clip

Table 76

Required Parts for Installation of the Left Side Hardware



6 (1) 8T-4194 Bolt

6 (1) 198-4778 Hard Washer

6(1)

8T-4223 Hard Washer

6 (1) 8T-4244 Nut

Table 77





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4 7X-0818 Bolt



4 8T-4195 Bolt


2 7K-1181 Cable Strap

4 8T-4195 Bolt

1 8T-4136 Bolt

1 8M-2773 Clip

( 1 ) Machines that are equipped with Truck Payload Measurement System (TPMS) will only require 2

Required Parts for Installation of the Right Side Hardware



4 7X-0818 Bolt




10 8T-4195 Bolt


1 8T-4136 Bolt

1 8M-2773 Clip

Table 78

Required Parts for the Installation of the Rear Hardware



4 7X-0818 Bolt



Table 79





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2 8T-4195 Bolt


2 8T-4136 Bolt

1 4P-8134 Clip


Assemble the Camera Groups



1 4 347-1668 Camera Gp

2 3 305-3748 Plate As

3 8 n/a (1) Bolt

4 8 n/a (1) Washer

5 1 271-6768 Plate

6 1 305-3747 Plate As

7 6 8T-6466 Bolt


9 6 8T-4133 Nut

10 1 365-8501 Bracket As

Table 80


Note: An arrow is located at the top of the camera lens which indicates the up direction of thecamera. The camera that is going to be installed on the rear of the truck needs to have this arrowinstalled facing up.





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Typical view of the front and side cameras

(1) 347-1668 Camera Gp

(2) 305-3748 Plate As

(A) Camera harness

Route camera harness (A) and the connector through the hole that is in plate assembly (2).Place the grommet that is provided on camera harness (A) through the hole. Repeat this

procedure for all the cameras.

1.






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(1) 347-1668 Camera Gp

(2) 305-3748 Plate As

(3) Bolt

(4) Washer

Use six bolts (3) and six washers (4) to secure three camera groups (1) to three plateassemblies (2) .

2.

Note: The three camera groups in Step 2 are for the front and the side camera locations.


Typical view of the rear camera

(1) 347-1668 Camera Gp

(3) Bolt

(4) Washer

(5) 271-6768 Plate

Use two bolts (3) and two washers (4) to secure one camera group (1) to one plate (5) .3.





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Left side camera and plate assembly

(2) 305-3748 Plate As

(6) 305-3747 Plate As

(7) 8T-6466 Bolts


(9) 8T-4133 Nuts

For the left-hand side camera, mount plate assembly (2) to plate assembly (6) by using three bolts (7), six washers (8), and three nuts (9) .

4.





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(2) 305-3748 Plate As

(7) 8T-6466 Bolts


(9) 8T-4133 Nuts

(10) 365-8501 Bracket As

Secure one plate assembly (2) to bracket assembly (10) by using three bolts (7), six washers(8), and three nuts (9) .

5.

Secure the Object Detection Box Groups to the Brackets

Note: The following section only applies to machines with the 365-8472 .



1 4 365-8490 Object Detection Box Gp

2 4 348-8760 Bracket

3 32 8T-4137 Bolt

4 32 7X-7729 Washer

5 4 347-7917 Object Detection Box Gp (RADAR)

6 4 348-8759 Bracket

Table 81





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Note: Mounting location is important. Each radar box must be mounted in the designated location

that is labeled on the harness connector for each box.

The sensors for the Caterpillar Object Detection System are assembled before shipping. Use thefollowing procedure in order to assemble the mounting brackets to the radar boxes.

Note: Inspect the grommet on the bottom of the radar box to ensure that the sealant has not been

disturbed during shipment. If the seal is not intact, use silicone sealant in order to seal thegrommet.


View of the front and rear object detection box group

(1) 365-8490 Object Detection Box Gp

(2) 359-7444 Bracket As

(3) 6V-7357 Bolt


Secure two object detection box groups (1) to two bracket assemblies (2) by using eight bolts (3) and eight washers (4) .

1.





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View of the side object detection box group


(3) 6V-7357 Bolt


(5) 364-5738 Bracket As


2.

Installation of the Front Hardware



1 1 360-3915 Bracket As

2 4 7X-0818 Bolt

3 4 9N-0869 Hard Washer

4 8 8T-9655 Isolation Mount

5 1 361-6088 Bracket As

6 4 8T-4956 Bolt


8 2 8T-4195 Bolt

Table 82





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10 3 8T-5005 Bolt


12 3 8T-4133 Nut

13 1 067-2551 Clip


Each radar box has a specific mounting location. The radar sensors have individual part numberslocated on the harnesses at the bottom of the box.

Installation of the Box Group for the Object Detection (Front)


(A) 359-7444 Bracket As

(1) 360-3915 Bracket As

(2) 7X-0818 Bolt

(3) 9N-0869 Hard Washer

(4) 8T-9655 Isolation Mount

Secure bracket assembly (A) to bracket assembly (1) by using four bolts (2), four washers

(3), and eight isolation mounts (4) .

1.





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(5) 361-6088 Bracket As

(6) 8T-4956 Bolt


Secure bracket assembly (5) to the front of the bumper assembly by using four bolts (6) andfour washers (7) .

2.





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(1) 360-3915 Bracket As

(5) 361-6088 Bracket As

(8) 8T-4195 Bolt


Secure bracket assembly (1) to bracket assembly (5) by using two bolts (8) and two washers(9) .

3.





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(B) Harness assembly

Connect harness assembly (B) to the sensor that is inside the object detection box group.4.

Installation of Camera Group (Front)





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View of the top of the cowling group

(C) Camera group


(10) 8T-5005 Bolt


(12) 8T-4133 Nut

(13) 067-2551 Clip

Secure the front camera that was previously assembled to the front of the cowling group byusing three bolts (10), six washers (9), three washers (11), and three nuts (12) .

1.

Secure the harness assembly for the camera by using one clip (13), and existing bolt (10) .2.

Connect existing cable assembly to the harness assembly for the camera assembly.3.

Installation of the Left Side Hardware


Table 83





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1 1 361-4972 Bracket As

2 6 (1) 8T-4194 Bolt

3 6 (1) 198-4778 Hard Washer

4 6 (1) 8T-4223 Hard Washer

5 6 (1) 8T-4244 Nut

6 1 359-7850 Bracket As

7 4 7X-0818 Bolt



10 4 8T-4195 Bolt


12 2 7K-1181 Cable Strap

13 4 8T-4195 Bolt

14 1 8T-4136 Bolt

15 1 8M-2773 Clip



Installation of the Box Group for the Object Detection (Left Hand Side)





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(A) Lamp assembly for the Truck Payload Measurement System (TPMS)

Note: If the machine is equipped with lamp (A) for the Truck Payload Measurement System(TPMS), complete Step 1 that follows.

If equipped, remove lamp (A) for the Truck Payload Measurement System (TPMS). Retain

lamp (A) and the hardware that secures lamp (A) to the catwalk assembly.

1.







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(1) 361-4972 Bracket As

(2) 8T-4194 Bolt



(5) 8T-4244 Nut

Secure one bracket assembly (1) to the left side of the catwalk assembly by using six bolts(2), six washers (3), six washers (4), and six nuts (5) .

2.

Note: If the machine is equipped with TPMS, refer to Step 2.a.




(1) 361-4972 Bracket As

(2) 8T-4194 Bolt



(5) 8T-4244 Nut

If the machine is equipped with TPMS, secure one bracket assembly (1) and one lamp

assembly (A) to the left side of the catwalk assembly by using two bolts (2), twowashers (3), two washers (4), two nuts (5) and the hardware that was removed in Step1.

a.





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Note: Two bolts (2) go through the two lowest holes on bracket assembly (1). The

upper four holes are for the bolts that were removed in Step 1.



(B) Radar box assembly

(1) 361-4972 Bracket As

(6) 359-7850 Bracket As

(7) 7X-0818 Bolt



(10) 8T-4195 Bolt


Secure radar box assembly (B), that was previously assembled, to one bracket assembly (6) by using four bolts (7), four washers (8), and eight isolation mounts (9) .

3.

Secure bracket assembly (6) to bracket assembly (1) by using four bolts (10) and fourwashers (11) .

4.





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(C) Harness assembly

(12) 7K-1181 Cable Strap

Connect the existing harness assembly (C) to the harness assembly from radar box assembly(B) .

5.

Secure harness assembly (C) to the side of bracket assembly (1) by using two cable straps(12) .

6.

Installation of Camera Group (Left Hand Side)





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(D) Camera and plate assembly

(E) Camera harness assembly

(F) Chassis harness assembly


(13) 8T-4195 Bolt

(14) 8T-4136 Bolt

(15) 8M-2773 Clip

Secure camera and plate assembly (D) to the catwalk assembly by using four bolts (13) andfour washers (11) .

1.

Note: Camera and plate assembly (D) was previously assembled.

Connect camera harness assembly (E) to chassis harness assembly (F) .2.

Secure chassis harness assembly (F) and camera harness assembly (E) to the side of cameraand plate assembly (D) by using one bolt (14), one washer (11), and one clip (15) .

3.

Installation of the Right Side Hardware



1 1 359-7850 Bracket As

2 4 7X-0818 Bolt



5 1 360-3919 Bracket As

6 10 8T-4195 Bolt


8 1 8T-4136 Bolt

9 1 8M-2773 Clip

Table 84






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Installation of the Box Group for the Object Detection (Right Hand Side)


(A) Radar box assembly

(1) 359-7850 Bracket As

(2) 7X-0818 Bolt



Secure radar box assembly (A) to bracket assembly (1) by using four bolts (2), four washers


1.

Note: Radar box assembly (A) was previously assembled.





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View of the right-hand support assembly

(5) 360-3919 Bracket As

(6) 8T-4195 Bolt


Secure bracket assembly (5) to the right-hand support assembly by using four bolts (6) andfour washers (7) .

2.


(1) 359-7850 Bracket As





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(5) 360-3919 Bracket As

(6) 8T-4195 Bolt



3.



(B) Chassis harness assembly

Connect the wiring harness from radar box assembly (A) to existing chassis wiring harnessassembly (B) .

4.

Installation of the Camera Group (Right Hand Side)





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(C) Camera and bracket assembly

(D) Wiring harness assembly

(6) 8T-4195 Bolt


(8) 8T-4136 Bolt

(9) 8M-2773 Clip

Secure camera and bracket assembly (C) to the right side of the support assembly by usingfour bolts (6) and four washers (7) .

1.

Connect the wiring harness for the camera to wiring harness assembly (D) .2.

Secure the wiring harness assemblies to camera and bracket assembly (C) by using one bolt(8), one washer (7), and one clip (9) .

3.

Installation of the Rear Hardware



1 1 359-7850 Bracket As

2 4 7X-0818 Bolt



Table 85





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5 2 8T-4195 Bolt


7 2 8T-4136 Bolt

8 1 4P-8134 Clip


Install the Box Groups for the Object Detection (Rear)

ReferenceRefer to Special Instruction, KENR8668 for the orientation of the radar. The radarorientation is critical for the operation of the object detection system.



(1) 359-7850 Bracket As

(2) 7X-0818 Bolt




Secure radar box assembly (A) to bracket assembly (1) by using four bolts (2), four washers(3), and eight isolation mounts (4) .

1.





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View of the rear of the truck

(B) Wiring harness assembly

(1) 359-7850 Bracket As

(5) 8T-4195 Bolt


Secure bracket assembly (1) to the rear of the frame by using two bolts (5) and two washers(6) .

2.

Connect the wiring harness for the camera assembly to existing wiring harness assembly(B) .

3.

Installation of the Camera Group (Rear)





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(C) Plate and camera assembly

(D) Bracket assembly

(E) Wiring harness assembly


(7) 8T-4136 Bolt

(8) 4P-8134 Clip


Secure plate and camera assembly (C) to the top of bracket assembly (D) by using two bolts(7) and two washers (6) .

1.

Note: Plate and camera assembly (C) was previously assembled.

Connect the wiring harness for the camera assembly to wiring harness assembly (E) .2.

Secure wiring harness assembly (E) to the top of bracket assembly (D). Use one clip (8),one cable strap (9), existing bolt (7), and existing washer (6) .3.

Flash the Caterpillar Integrated Object Detection System

(CIODS) Software onto the Display

The display is shipped with the application software installed. Use the following procedure inorder to flash the application software into the display.

Note: Flashing the software may be required.

Required Material

Caterpillar Electronic Technician CAT (ET)•





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Communication Adapter •

345-7489 Monitor Harness As•

Software

Part NumberSystem Notes

361-8176 Caterpillar Integrated Object Detection SystemRadar and Camera

362-3942Caterpillar Integrated Object Detection System (VisionOnly)

Cameras only

Table 86

Perform the following procedure in order to flash program the ECM. The ECM is flashed in order

to upgrade the software. Flash programming of the ECM must be done if the ECM has beenreplaced. Caterpillar Electronic Technician (Cat ET) contains the program WinFlash. WinFlash isused in order to load the software into the ECM. The following procedure is used in order to flashthe software into the display.

Procedure

Ensure that the key start switch and the disconnect switch are in the OFF position.1.

Disconnect the center 12-pin connector from the display.2.

Connect the 345-7489 Monitor Harness As between the system harness for the display andthe center connector on the display.

3.

Connect the 7X-1425 Data Link Cable As between the 7X-1700 Communication Adapter

Gp and Cat ET.

4.

Connect the 139-4166 Data Link Cable As between the 7X-1700 Communication AdapterGp and the diagnostic connector of the 345-7489 Monitor Harness As .

5.

Turn power back on to the display.6.

Use WinFlash in order to load the software.7.

Disconnect the 345-7489 Monitor Harness As from the system harness for the display andthe center connector on the display.

8.

Connect the 12-pin connector of the system harness to the center connector of the display.9.

Turn the disconnect switch and the key start switch to the ON position.10.

Verify that the display turns on and the Caterpillar Integrated Object Detection systemstarts.

11.

Note: Refer to Special Instruction, REHS5191 regarding information for the CIODS.





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Perform the Commissioning Procedure for the Machine

This section contains assembly checks and functional checks of systems. Perform the checks before you deliver the machine to a customer.

Prepare the Machine Before the Machine Is Started

NOTICE



Diagnostic connector

Connect a laptop computer to the Caterpillar Diagnostic Connector (1) on the fuse panel behind the operator seat. The laptop computer should have JERD2142 or JERD2129 datasubscription. Use a 139-4166 Data Link Cable As , 171-4400 Communication Adapter Gp ,

NEXG4523 Service Program Module, and a 7X-1425 Data Link Cable As in order to

connect the laptop computer.

1.

In order to power the electrical system of the truck, perform the steps that follow:2.

Connect the batteries.a.

Turn the battery disconnect switch ON. b.

Turn the key of the machine ON.c.

DO NOT START THE TRUCK.d.

Start the Electronic Technician (ET). ET will list all of the electronic control modules forthe machine. There will be at least an "ENGINE CONTROL" and a "TRANSMISSION

3.





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CONTROL". If the truck has the Automatic Retarder Control (ARC) or the Automatic

Electronic Traction Aid (AETA), the ET screen should show the features.

ET should also display the truck model for each control. Make sure that the model is correctfor each control.

4.

Choose the "ENGINE CONTROL". Next, choose "CONFIGURATION".5.

Change the Equipment Identification Number in order to correspond to the Product

Identification Number (PIN) of the truck.

6.

Perform the steps under the Section ""Test Product Link (if equipped)" " if the machine isequipped.

7.

Choose "ACTIVE CODES" from the ET menu. Click on the button on the bottom of thescreen. The button reads "INCLUDE ALL ECMS". If "NO ACTIVE CODES" appears, then

continue. If active fault codes are present, resolve the active faults.

8.

Choose "LOGGED CODES" from the ET menu. Click on the button at the bottom of thescreen that reads "INCLUDE ALL ECM's". Clear all logged codes.9.

Choose "DIAGNOSTICS" and choose "EVENTS" from the ET menu. Click on the button

that reads "INCLUDE ALL ECM's". Clear all logged events.

10.

Choose "DIAGNOSTICS" and choose "DIAGNOSTIC TESTS" from the ET menu. Next,choose "OVERRIDE PARAMETERS".

11.

If the truck has a starting aid or an ether aid, choose "STARTING AID" or choose "ETHERAID". Choose "CHANGE" and turn on the feature. You should hear the click of the etheraid or the starting aid solenoid on the chassis. Choose "CHANGE" again and turn off the

feature.

12.

From the ET menu, select" DATA LINK". Next, select "SELECT ECM". Next, select"TRANSMISSION CONTROL". Next, select "CONFIGURATION".

13.



a.

Check the "BODY UP GEAR LIMIT" parameter. The parameter should be set to 1. b.

If the truck has the AUTOMATIC RETARDER system, select "DATA LINK" from the ET

menu. Next, select "CHOOSE ECM". Next, select "AUTOMATIC RETARDER". Finallyselect "CONFIGURATION".

14.

Activation of the Hoist Controls for the Truck Body

The truck might appear to have a problem with the body hoist controls. The 247-7746 PowerTrain Software will set the parameters for the hoist system.

Note: The software for the Electronic Technician (ET) must be used to set these parameters. Usethe latest version of the ET software.

Enable the Hoist System (An Adjustable Parameter)

The Hoist Enable Parameter is set at a value of "2" for all trucks that are shipped from the factorywith the 247-7746 Power Train Software and with a body that is not installed. Parameter Value 2





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will prevent the hoist cylinders from being activated by accident. After the body is installed,

change the Parameter Value to "1". The hoist system should function properly. When the hoistsystem does not work, check the items below.

Settings for the Hoist Enable Parameter

ParameterValue

Description

0

This value is used when the hoist system is not installed. The hoist lever will

not function, and no diagnostics will be logged on the hoist lever or on thesolenoids.

1This value is used for normal operation when the hoist system is installed and

enabled.

2

This value is the default value that is set in the factory when the hoist system is

installed but disabled. The solenoids and the hoist lever have diagnostics, butthe hoist lever is ignored. The solenoids are kept in the HOLD position.

Table 87

Verify that the hoist system is enabled in the Configurable Parameters Screen through the pull-down service menu in the Electronic Technician (ET).

1.

Disconnect ET and then reconnect the line if the Hoist Enable Status does not appear on theconfiguration screen. The hoist enable parameter flexes with the 3.0 ET Software when the

parameter connects. Occasionally, ET misses the flexed parameters at the time of theconnection.

2.

Note: The hoist enable parameter is standard on the configuration screen of the 3.1 ETSoftware.

If the Hoist Enable Status does not change, check the following potential causes:3.

The engine should not be running. When the engine is running, the engine may causethe signal from the Transmission Output Speed (TOS) to fluctuate. The TOS must bezero in order to change the Hoist Enable Status.

The truck should not be moving.

Note: Press the "F5" key on the laptop computer in order to access the configuration screen

on ET.

Adjustment for Hoist Lower Valve

The command for the hoist lower valve is adjustable. An adjustable command can compensate forthe differences between the valves. The adjustment range is -5 to +5 with zero as the default. A

positive adjustment factor will increase the lower valve command. This causes the body to comedown harder. A negative adjustment factor will decrease the lower valve command. This causesthe body to come down softer.

The Adjustment for the Hoist Lower Valve may not be available on earlier ECM systems. The

adjustment range may be from 0 to 10 with 5 as the default on some early ECM systems.





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Note: When the Adjustment for the Hoist Lower Valve is set too high, too much oil can be

diverted to the hoist system while the hoist system is in float mode. This causes the brake oil toheat up faster. Retarding capability is also decreased. To set the Adjustment for the Hoist LowerValve, follow the procedure below.

Raise the body of the truck and install the body retaining pins.1.

Place a 6V-7830 Tetragauge or place a 3.45 MPa (500 psi) gauge with a hose extension onthe outlet port of the hoist pump.

2.

Note: Remove the body pins and lower the body to the frame.

While the body is down, place the hoist lever in the HOLD position.3.

Enter the configure parameter screen through the pull-down service menu in the ElectronicTechnician (ET).

4.

Change the Adjustment for the Hoist Lower Valve to a setting that is desired from -5 to 5.

The procedure begins at 0. Adjust the settings in increments of 1 in the positive position orin the negative position.

5.

Note: If you are using a 3.45 MPa (500 psi) gauge, remove the gauge from the extension.

Raise the body to the middle position.6.

Lower the body to the frame.7.

If a 6V-7830 Tetragauge is not installed, shut off the engine and install a 3.45 MPa (500 psi)gauge. Start the engine and run the engine to high idle. Cycle the hoist lever to the FLOAT

position and to the HOLD position. Do not power down or raise the bed if you are using a

3.45 MPa (500 psi) gauge. Damage may occur to the gauge.

8.

While the engine is running, place the hoist lever in the FLOAT position.9.

Run the engine to high idle. Verify that the pressure at the hoist outlet port is less than 1724kPa (250 psi).

10.

Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. Thiscauses too much oil to be diverted to the hoist valve. This causes the brake oil to overheat whenthe body is in the FLOAT position. Lower the adjustment setting and repeat Step 4 through Step10. This lowers the pressure below 1724 kPa (250 psi).

Note: If you change the adjustment setting and there is no corresponding change in pressure, cyclethe hoist lever again. A change will occur in the settings between 2 and 5.

Body Down Snub Function (A Parameter That Is Not Adjustable)

The body down snub function cushions the shock when the body hits the bed of the truck. Whenthe body is lowered, the body up switch detects the position of the body when the body is close tothe rail of the truck. This causes the ECM to go into snub mode.

When the operator's request is less than the snub mode, the ECM will use the operators request.This ensures that the snub function will never cause the body to go down faster than the hoist levermodulation (operator's request).





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The body down snub function will be Canceled as the operator moves the hoist lever out of the

FLOAT position or out of the LOWER position. The body down snub function will not start untilthe body goes above the body up switch activation level.

Check the Suspension Cylinders

Note: Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" for any information concerning suspension cylinders. The Special Instructionincludes Tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging(oil and nitrogen).

Transmission and Torque Converter Filters

The transmission system uses 343-4465 Oil Filter Elements , which have to be replaced by aservice filter element after 8 hours of machine operation. Failure to change to a serviceelement may result in clogging of the filter.

Replace the 343-4465 Oil Filter Element with a 343-4465 Oil Filter Element or a 1R-0741 OilFilter Element Assembly .

Note: The 343-4465 Oil Filter Element is recommended for replacement, however the 1R-0741

Oil Filter Element Assembly is also an acceptable replacement.

Note: The 343-4465 Oil Filter Element is for power train use only and not approved forhydraulic applications.

Contamination is one of the major causes of transmission control system failure. Some power train

oil systems were cleaned with fine cleanout filters, which frequently caused oil to bypass the filter.The use of cleanout filters in power train oil systems is no longer recommended. A new line of

advanced efficiency Caterpillar transmission filters have been introduced for use in power trainapplication.

Replacing the Cleanout Filters

Cleanout filters are installed on some of the 777F hydraulic systems at the factory. Replace allcleanout filters with the standard filters that have been provided with the truck after the truck has

been continuously operated for 8 hours. Failure to replace cleanout filters can cause a pluggedfilter condition causing oil to enter the transmission, torque converter, steering, hoist, or brake

hydraulic systems.

Use the following chart for replacing the filters.

Hydraulic System Cleanout Filter Standard Filter Qty

Parking Brake Release 132-8875 (6µ max.) 1R-0773 (20µ) 1

Steering Case Drain 126-1813 (5µ max.) 4I-3948 (25µ max.) 1

Steering Return Line 144-0832 (5µ max.) 4T-6788 (27µ max.) 1

Torque Converter Charge 343-4465 343-4465

(1)

1R-0778 (2) 2

Table 88





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Transmission Charge 343-4465343-4465 (1)

1R-0778 (2) 2

( 1 ) Recommended( 2 ) Acceptable

Calibrate the Transmission

In order to calibrate the transmission refer to the Testing and Adjusting, RENR8342, " 773F,775F, and 777F Trucks/Tractor and Quarry Truck Chassis Electronic Control System".

Duo-Cone Break-In Procedure

The Break-In procedure must be run as a continuous section. Time that is required to carry out theBreak-In procedure is 25 minutes. This procedure should be performed when the wheels turn forthe first time. This procedure may also be done after you purge the air from the brake system aslong as the wheels are not turned before you purge the air from the brake system. Follow the break

-in procedure in the sequence that is mentioned below:

Note: If testing is performed on stands instead of tires, do not exceed SECOND GEAR.

Operate the machine at low idle rpm in the FIRST GEAR for 5 minutes.1.

Operate the machine at high idle rpm in the FIRST GEAR for 5 minutes.2.

Operate the machine at high idle rpm in the SECOND GEAR for 5 minutes.3.

Operate the machine at high idle rpm in the THIRD GEAR for 5 minutes.4.

Operate the machine at high idle rpm in the FOURTH GEAR for 5 minutes.5.

Test Product Link (if equipped)







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Connect a laptop computer to the Caterpillar Diagnostic Connector (1) on the fuse panel

behind the operator seat. The laptop computer should have JERD2142 or JERD2129 datasubscription. Use a 139-4166 Data Link Cable As , 171-4400 Communication Adapter Gp ,

NEXG4523 Service Program Module, and a 7X-1425 Data Link Cable As in order toconnect the laptop computer.

1.






Start the Electronic Technician (ET). ET will list all of the electronic control modules for

the machine. There will be at least an "ENGINE CONTROL" and a "TRANSMISSION

CONTROL". If the truck has the Automatic Retarder Control (ARC) or the AutomaticElectronic Traction Aid (AETA), the ET screen should show the features.

3.

ET should also display the truck model for each control. Make sure that the model is correct

for each control.

4.

Illustration 292

Choose the "Product Link" ECM.5.





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Illustration 293

Note: The communication status of product link needs tested. Since there can be up to a 15

minute delay in satellite coverage, the wiggle test in ET can be used to save time bydetecting the changes in status while other activities in the commissioning procedure are performed. Leave the wiggle test running and check the status during the ""Final Check" "

at the end of this Special Instruction. The wires do not need to be wiggled.

Choose "Diagnostics" from the ET menu. Choose "Diagnostic Tests" from the menu. Thenchoose the "Wiggle Test" from the test menu.

6.

Illustration 294

Read the warning and select the "OK" button.7.





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Illustration 295

From the "Wiggle Test" screen, select the "Groups" button.8.





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Illustration 296

Choose the "New" button in order to create a group for the product link.9.

Note: The product link group needs to be created one time.

Illustration 297

Type "Product Link" and select the "OK" button.10.





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Illustration 298

In the left-hand column of available parameters, select the "Number of GPS Satellites"

under "Product Link" and then select the right arrow. In the left-hand column, select"Satellite Communications Status" that is under the "Product Link" title and then select theright arrow.

11.

Select the "OK" button.12.





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Illustration 299






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Illustration 300

Note: In order to confirm the two types of the satellite communication, the "Numberof GPS Satellites" should be greater than "0" and the "Satellite CommunicationStatus" should be "Established". The screen shows that the GPS communication is

established. The screen shows that the satellite communication is established.

If the "Number of GPS Satellites" is greater than "0" and the " SatelliteCommunication Status" is "Established", then the communication status of productlink is confirmed. Record this information in the ""Final Check" " at the back of thisSpecial Instruction.

a.





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Illustration 301

Note: If the "Number of GPS Satellites" is greater than "0" and the "SatelliteCommunication Status" is "Not Established", the wiggle test can be run in order tomonitor the communication status.

Select "Start" in order to start the wiggle test if the parameters do not confirm thecommunication status.

b.

Note: Leave ET running and do not navigate to a different screen in ET while thewiggle test is running. These actions will end the wiggle test.





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Illustration 302

When a parameter changes during a wiggle test the parameter will be highlighted in red. A 2 second bee





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Illustration 303

The parameter will stay red even if "the parameter" changes back to the original value. The "Satellite Codisplayed in red text. This means that communication was established during the wiggle test.

Note: Satellite communication may have a 15 minute gap in communication. Make

sure that you leave the wiggle test running longer than 15 minutes before failing the product link.

Note: In order to establish communication, the antenna for the product link must havea clear view of the sky. Objects that obstruct the antennas view of the sky may resultin a failure. If the antenna was obstructed during the test, retest the product link withan unobstructed view of the sky. Satellites can be seen from the horizon to 15 degrees

above the horizon. Check the following web address for satellite coverage in yourarea: http://corneroftheuniverse.net/orbcomm/sats/sat_coverage.html

Check the parameters later during the commissioning procedure. Record this

information in the""Final Check" " at the back of this Special Instruction. Allow thetest to run for a minimum of 15 minutes or allow the test to run until thecommunication is established. The parameters will be highlighted in red if the statuschanged during the test.

c.

If no communication is established and the test has been running longer than 15minutes, check the antenna for damage and check the connection from the antenna to

the radio. If the cable did not have a good connection to the radio, establish a goodconnection and repeat the test.

d.

If there is a good connection from the antenna to the radio but no communication isestablished, Refer to Troubleshooting, RENR7911, "Product Link 121/321".

e.

Final Check

Use the Service Manual and use the Operation and Maintenance Manual in order to correct anysystem problems before you deliver the truck.

Note: After eight hours of continuous operation, replace the cleanout filter elements with standardfilter elements for the systems that follow: the parking brake filter, the transmission filter, the

steering system filter and the torque converter charging oil filter.

After you complete the final check, sign your name and the name of the dealer.

Make copies of the check procedure. Mail the copies to the following address:

Caterpillar Inc. Attention: CMT Product Support

777F Truck N. 27th and Pershing Road Decatur, IL 62525

Dealer:____________________

Customer:____________________

Product Identification Number:____________________



http://corneroftheuniverse.net/orbcomm/sats/sat_coverage.html




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Before you start the engine, make sure that all hydraulic systems are full. Also, make sure

that all pump case drains are full.

1.

Establish a satellite communication (if equipped).2.

YES ____ NO ____

Establish a GPS communication (if equipped).3.

Number of GPS Satellites ____

Check that the system pressures are set correctly.4.

Pump

YES ____ NO ____

Brake

YES ____ NO ____

Steering Pressure

YES ____ NO ____

Transmission

YES ____ NO ____

Torque Converter

YES ____ NO ____

Differential

YES ____ NO ____

Check that the brake accumulators are correctly charged.5.

YES ____ NO ____

Check the machine lights.6.

Operational

YES ____ NO ____

Cab and Dash

YES ____ NO ____

Check the controls in the cab.7.

Check if the cab door opens. Check if the cab door closes.

YES ____ NO ____





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Check if the Operation and Maintenance Manual is in the literature pouch on the back

of the operator seat.

YES ____ NO ____

Check if the horn functions.

YES ____ NO ____

Check if the front window wipers and front window washers function.

YES ____ NO ____

Check if the seat belts operate.

YES ____ NO ____

Check if the fan switch operates.

YES ____ NO ____

Check if the heater functions.

YES ____ NO ____

Check if the air conditioner functions.

YES ____ NO ____

Check the test light. The test light is for the EMS.

YES ____ NO____

Check if the hour meter operates.

YES ____ NO ____

Check if the implements operate:

Hoist

YES ____ NO ____

Steering Action

YES ____ NO ____

Check if the steering column functions.

YES ____ NO ____

Check if the parking brake functions.

YES ____ NO ____

Check if all fluid levels are full.8.





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YES ____ NO ____

Correct any unusual noises or unusual leaks.9.

YES ____ NO ____

Check if all lubrication lines are filled with grease.10.

YES ____ NO ____

Check if all clean-out filters have been replaced as specified by assembly procedure.11.

YES ____ NO ____

Check if all quality requirements are fulfilled. Check if all variances have been corrected.12.

YES ____ NO ____

Check if the backup alarms function.13.

YES ____ NO ____

Check if the machine is repainted to the factory specifications.14.

YES ____ NO ____

Check if there was damage to the machine from shipment.15.

YES ____ NO ____

Check if all required parts were shipped with the machine.16.

YES ____ NO ____

Sign your name in the space below.17.

Hydraulic

____________________

Electrical

____________________

Structural

____________________

Other

____________________

Comments18.

________________________________________

________________________________________





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________________________________________

________________________________________

________________________________________

________________________________________

________________________________________

________________________________________

________________________________________

________________________________________

Specifications for the Commissioning Procedure

Description Specifications Actual Comments

Engine Low Idle rpm 700 +30 -10 rpm

Engine High Idle 1935 ± 30 rpm

Pressure of Brake Retract Pump at High

Idle 4690 ± 200 kPa (680 ± 30 psi)

Relief Pressure of Hoist Pump 18950 ± 520 kPa (2750 ±75 psi)

Steering High Pressure Cutoff21200 ± 350 kPa (3075 ±

50 psi)

Steering Cycle Time 6.5 seconds at66 °C (150 °F)

Relief Pressure of Transmission Pressure

at High Idle 3200 kPa (465 psi)Maximum

Pressure of Transmission Lubrication at

High Idle110 ± 30 kPa (16 ± 4 psi)

Pressure of Transmission Lubrication atLow Idle 22.4 ± 19 kPa (3.25 ±

2.75 psi)

Torque Converter Outlet Pressure at Stall(Wet Front Brakes) 760 ± 69 kPa (110 ± 10 psi)

Table 89





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Torque Converter Outlet Pressure at Stall

(Dry Front Brakes) 550 ± 69 kPa (80 ± 10 psi)

Predelivery Worksheet

Date Employee I.D. Model Serial Number Hours Inspector Name

Table 90

Note: All safety product improvement programs (PIP) must be completed.

VisualInspection

Service Points

and FluidLevels

Operation AfterOperation

Engine (1) (2)

_ Paint _ Outside

Damage

_ Oil _ Coolant _ Fuel

_ Batteries OVC> (12.45) _VDC1 _ VDC2

_ Air Filters _ Drain Water

from Fuel Tank _ Drain Water Separator

_ Open Coolant

conditionerValves

_ GreaseFittings

_ Priming Pump _ Governor Control _ Air Compressor

_ Smoke Color _ Unusual Noise

_ Air CleanerIndicator

_ V-Belt

Tension _ Leaks (Oil,Air, Fuel,Coolant)

_ Friction on

Hoses _ Friction onWires

_ Loose Wire

Connections _ Loose orLost Fasteners

Power Train

_ Paint _ OutsideDamage

_ Tires -Cuts, gouges

_ Transmission _ Differential _ Final Drives

_ Tire Pressure _ GreaseFittings

_ Front & Rear

Axle BoltTorques

_ Front & RearUniversalTorques

_ Wheel to RimTorques

_ Transmission - EachGear

_ Neutral Start _ Transmission Lever

Lock _ Back - Up Alarm _ Neutralizer Valve _ Unusual Noise

_ Leaks (Oil) _ Loose or lost

Fasteners _ Tires - Cuts,Gouges

Table 91





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Steering andBrakes


_ Brake Fluid

_ Drain Water from Air Tank

_ GreaseFittings

_ Steering

_ Retarder _ Service Brakes _ Parking Brakes _ Air Dryer _ Unusual Noise

_ Leaks - Oil,

Air _ Loose orLost Fasteners

Chassis _ Sheet Metal _ Paint _ Damage

_ Grease

Fittings

_ Enclosure Doors -

Locks and Latches

_ Loose orLost Fasteners

_ Welds

Hydraulic _ CylinderRods

_ HydraulicTank

_ GreaseFittings

_ Controls _ Too much Drift _ Unusual Noise

_ Leaks - Oil _ Friction orLost Fasteners

Truck Body

_ Paint

_ Damage _ Liners

_ Grease

Fittings

_ Body Pads _ RetentionCable

_ Body Positions

_ Welds

_ Loose orLost Fasteners _ Damage

Cab

_ Sheet Metal _ Paint

_ Glass

_ Front Window

Washer _ Air Filters _ GreaseFittings

_ Torque onROPS Support

_ Disconnect Switch _ VIMS _ Hoist Control _ Horn _Seat Belts _ Seat Adjustments _ All Switches &

Controls _ Doors and Windows _ Locks and Latches _ Mirror Adjustment

_ Front Window Wipers _ Front Window Washers _ Heater _ (AirConditioner/Pressurizer)Lights - Outside and Cab

_ Gauges _ Unusual Noise _ Steering ColumnAdjustment

_ OperationGuide

_ Maintenance

Guide

_ Parts Book _ Seat Cover _ Steps &Grab Irons


_ Loose WireConnections

_ Leaks -Water

Misc. and

Attachments

_ SpecialAssemblyParts

_ S/N Plates _ CorrectAttachments

_ Hand Tools _ Paint

_ Attachment

Fluid Levels _ Charge forFireSuppressionSystem

_ GreaseFittings

_ AutomaticLubrication

System

_ Attachments _ Engine ShutdownSwitch

_ Test Switch for FireSuppression

_ WarningPlates

_ Films _ Leaks _ Loose orLost Fasteners





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( 1 ) If the machine was in storage, lubricate the engine before starting the engine.

( 2 ) For cold-weather operation, refer to Operation and Maintenance Manual, 5338.





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Cerrar SIS

Pantalla anterior

Procedimiento para la Asamblea 777F Camiones de Obras

{7000, 7006, 7960}SMCS - 7000-016 7006-016, 7960-016;

Camiones Fuera de Carretera:777F (S / N: JRP1-UP; JXP1-UP)

Introduction

Esta instrucción especial contiene información y procedimientos que se requieren para montar

777F Camiones de Obras.

Nota: Consulte la Instrucción Especial, REHS4445, "Mantenimiento de los Cilindros desuspensión para camiones fuera de carretera" para cualquier información referente a los cilindrosde suspensión. La Instrucción Especial incluye herramientas, las presiones y los procedimientoscorrectos para purgar (aceite y nitrógeno) y de carga (de petróleo y nitrógeno).

Las herramientas sugeridas deben estar disponibles. Sin herramientas y equipos, más tiempo seconsume cuando se arma la máquina.

Inspeccione todas las piezas y de información en los siguientes lugares:

Estación del operador •

Camión•

Contenedores de embarque•

Inspeccione todas las áreas para las partes y para obtener información. No se deshaga de cualquier material hasta que la máquina está montada.

Lesiones personales o la muerte puede ser resultado de los

procedimientos de montaje inadecuados.





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No intente hacer ningún conjunto hasta que haya leído y entendido las

instrucciones de montaje.

Lea la instrucción especial entero. Comprender la información antes de realizar cualquier procedimiento. Comprender la información antes de ordenar las piezas.

Nota: En esta publicación, las fotos son para propósitos ilustrativos. Imágenes para finesilustrativos, no puede estar en secuencia con el procedimiento de montaje.

Después de que la máquina está montada, se refieren al Manual de Operación y Mantenimiento,SEBU7790 ", 777F Camiones de Obras" con el fin de preparar la máquina para sufuncionamiento. Utilice el Manual de piezas y utilizar el Manual de servicio, además de estainstrucción especial.

Esta instrucción especial también contiene información para el arreglo de gran altura. Refiérase a

la del índice con el fin de encontrar procedimientos específicos para el montaje de esa máquina.

AVISO

No permita que la suciedad o material extraño entrar en el sistemahidráulico durante el montaje, la conexión de líneas, cuando los

componentes están llenos de líquido, o durante cualquier operación demantenimiento.

AVISO

Se debe tener cuidado para asegurar que los fluidos se encuentrandurante la realización de la inspección, mantenimiento, prueba, ajuste

y reparación del producto. Esté preparado para recoger el líquido concontenedores adecuados antes de abrir cualquiera de los

compartimientos o desmontar ningún componente que contengalíquidos.

Consulte la Publicación Especial, NENG2500, "Servicio de

distribuidores Catálogo de herramientas" para las herramientas ymateriales adecuados para recoger y contener fluidos sobre los

productos Cat.

Deshágase de todos los fluidos de acuerdo a las regulaciones locales y

mandatos.

Weights and Specifications

Tabla 1





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Peso aproximado de la máquina sin carga

Modelo de Venta Peso en vacío

777F 48581 kg (107.104 libras)

Pesos aproximados de los componentes

Nombre Peso

Cuerpo de la Asamblea15800 kg (34.830 libras)

Chasis18370 kg (40,500 libras)

Chasis y Cabina 1435 kg (3160 libras)

Skid y el Frente de Struts4220 kg (9300 lb)

Caja de partes765 kg (1680 libras)

Chasis y del tanque de combustible465 kg (1020 libras)

Skid y Pasamanos 535 kg (1180 lb)

Skid, dos neumáticos y llantas4050 kg (8930 libras)

Chasis y Escaleras1335 kg (2940 libras)

Caja del eje trasero y transmisión10605 kg (23,380 libras)

Puntal delantero 1475 kg (3250 libras)

Plataforma de la mano derecha320 kg (700 libras)

Parachoques mano derecha110 kg (245 libras)

Parachoques mano izquierda110 kg (245 libras)

Escalera de Mano Derecha 90 kg (200 lb)

Tabla 2





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Pasamanos derecho19 kg (42 libras)

Soporte delantero de la cabina160 kg (350 lb)

Apoyo a la cabina trasera 230 kg (500 lb)

Estándar de la cabina1320 kg (2910 libras)

Plataforma de la mano izquierda190 kg (420 libras)

Operador de Escalera de Acceso86 kg (190 libras)

Plataforma 64 kg (140 lb)

Mano Izquierda Riel de Escalera32 kg (70 lb)

Mano Izquierda Barandilla pasarela28 kg (62 libras)

Neumático y la llanta1960 kg (4320 libras)

Herramientas necesarias

Herramienta Número de pieza Descripción Cantidad

AA 4C-4188 La pintura y removedor de Decal 1

BB 222-3124 Limpiador de frenos y eléctrico 1

CC 148-0357 Grupo de elevación del puntal 1

DD 6V-4040 Equipo de nitrógeno inflación 1

EE 4C-5593 Anti-Seize 1

FF 7K-1181 Correas de cable 10

GG 3S-2093 Correas de cable 30

HH 9S-3263 Tema compuesto de bloqueo 1

Tabla 3

Parts List

De referencia de piezas de servicio, PECP9067 ", una fuente segura".

Tabla 4





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16 9X-8399 Arandelas


4 8B-5144 Tornillos (1)







8 175-7894 O-ring

16 8T-4184 Tornillos


8 1P-4582 La mitad Bridas

4 4J-0527 O-ring


4 7X-0328 Tornillos

4 5P-2566 Tornillos



1 9C-4937 Como respiradero

1 030-7765 Adecuado


Componentes necesarios para la instalación de la Plataforma Gp



Tabla 5





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Piezas necesarias para la instalación de las escaleras

Cantidad Número de pieza Descripción2 241-2699 Escalera Gp

Tabla 6



2290-7232 (uno)



2 9D-2498 Claves

28 7B-9215 Tornillos

28 3S-1356 Frutos de cáscara completa

56 3S-1349 Lavadoras duros


2 4J-8535 Abrazaderas

2 116-1949 Cubre

Tabla 7

(1) Número Europea


Piezas necesarias para la instalación de las líneas del enfriador de aceite delantero y laslíneas de servicio del freno delantero



4 103-5422 Como la manguera


8 4J-0522 O-ring

Tabla 8



Tabla 9





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1223-5868 Tanque de combustible Gp (1)


(1) 1140 L (300 gal EE.UU.) Tanque(2) 1320 L (350 gal EE.UU.) Tanque










1 240-2263 Manga

8 117-8131 Como Montar


4 252-0080 Arandelas

3 3E-4898 Mangas

3 8T-0672 Tornillos

4 8T-4195 Tornillos

4 7X-7729 Arandelas

4 240-2261 Como Pin

Tabla 10



1 256-6757 Tubo de escape Gp


2 4N-9330 Abrazaderas

2 6V-3823 Tornillos

Tabla 11





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2 8T-4244 Nueces


6 7X-2563 Tornillos

6 8T-4123 Arandelas




Tabla 12




17 7K-1181 Correas de cable

Tabla 13

Piezas necesarias para la instalación de los accesorios para el Servicio de Control deFreno Gp




Tabla 14






Tabla 15

Piezas necesarias para la instalación del Grupo de Plataforma



Tabla 16





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1 273-2325 Paseo del Gp


Tabla 17

Componentes necesarios para la instalación de la escalera Gp





2 8T-4137 Tornillos


1 169-5414 Recortar

1 130-5300 Recortar

Tabla 18

Piezas necesarias para la instalación de la Agarradera Gp


1 273-8920 Como asidero







2 115-3580 Placas

4 5P-7468 Clips

4 5P-7469 Clips

4 8T-4183 Tornillos


Tabla 19





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4 8T-4244 Nueces

4 8T-7087 Ojales

Piezas necesarias para la instalación del tubo de escapeCantidad Número de pieza Descripción




4 8T-4183 Tornillos


Tabla 20

Piezas necesarias para la instalación de la Gp Espejo




1 7X-7468 Espejo convexo

1 279-0467 Espejo Gp

1 322-7277 Como Espejo



1 2G-1133 Ojal

1 284-5263 Mazo de cables

1 7G-7053 Ojal

Tabla 21

Piezas necesarias para la instalación de 328-9834 Mirror Group (si está equipado)



2 329-7328 Espejos convexos

10 7Y-5262 U-Bolts (M10X1.5)


Tabla 22





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20 8T-0389 Contratuerca


4 8T-4182 Tornillos (M10X1.5)


2 334-1004 Conjuntos de tubos

2 144-2227 Conjuntos de espejo


4 7X-3391 Lavadora duro


4 7D-9969 Apoyar

11 3S-2093 (1) Correas de cable

1 324-6674 (1) Mazo de cables

1 2G-1133 (1) Ojal

1 298-7329 Como soporte de





2 134-0989 Bloques

4 8T-4133 Tuerca

1 7G-7053 (1) Ojal

(1) Parte del cableado 247-5666 Espejo Gp

Piezas necesarias para la instalación de la 321-6518 trasero Gp Ver Espejo



1 338-9281 Placa

7 5P-1076 Lavadora duro

4 3K-6060 Contratuerca

1 338-9280 Placa

Tabla 23





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15 8T-4121 Lavadora duro

2 8T-4133 Tuerca





2 134-0989 Bloquear

1 8T-7087 Ojal

1 5P-7468 Recortar

1 5P-7469 Recortar


1 129-3180 Contratuerca

1 295-8899 Placa




6 7D-9969 Apoyar




6 3S-2093 Cable Correa




1 338-9281 Placa

1 5P-1076 Lavadora duro

1 3K-6060 Contratuerca

1 338-9280 Placa

Tabla 24





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22 8T-0389 Contratuerca





2 134-0989 Bloquear

2 329-7328 Espejo convexo


10 7Y-5262 U-Bolt



4 198-4777 Lavadora duro




6 7D-9969 Apoyar




6 3S-2093 Cable Correa

Piezas necesarias para la instalación del tanque hidráulico Gp


2 1P-3705 Los sellos rectangulares (1)

Tabla 25

(1) Sellos rectangulares están en la bolsa que está unida al tanque de dirección.

Piezas necesarias para la instalación de la Gp Fender


Tabla 26





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1 282-3022 Guardia

1 275-9226 Guardia

1 273-8918 Guardia

1 282-9097 Guardia

1 256-0639 De goma de la Guardia

Piezas necesarias para la instalación de las ruedas delanteras



40 5D-0765 Frutos de cáscara completa

40 5D-0764 Lavadoras duros

Tabla 27

Piezas necesarias para la instalación de las ruedas traseras



2 272-7949 Tire de la válvula Gp

2 6G-8019 Tire de la válvula Gp


80 5D-0765 Frutos de cáscara completa

80 5D-0764 Lavadoras duros

Tabla 28

Piezas necesarias para la instalación del Acuerdo de Consejo de camiones ( 308-0618Truck Body montaje Gp)


2 8W-8454 Como Pin

1 8W-2897 (1) Arandela de empuje

2 9D-3432 (1) Las arandelas de empuje

2 8W-8456 Placas

4 5P-2566 Tornillos

Tabla 29





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2 3B-8489 Engrasadores

2 322-5067 Lodo de la Guardia

2 322-5068 Placa

2 331-5956 Placa

20 9B-7237 Atornillar

20 6V-8801 Tuerca



8 8T-4244 Tuerca

(1) Utilice la arandela de empuje 8W-2897 cuando la arandela de empuje 9D-3432 no se ajusta.

Piezas necesarias para la instalación de los cilindros de elevación de la


2 5T-9266 Como Pin

4 9D-2316 Espaciadores

2 5T-5528 Placas

4 5P-2566 Tornillos


Tabla 30

Componentes necesarios para la instalación del pasador de retención ( 308-0618 Camiónde montaje Gp)


4 5D-3887 Varillas

4 6F-8499 Springs,

4 054-3788 Orificios

8 3B-4615 Chavetas

2 270-7034 Como Pin

Tabla 31

Piezas necesarias para la instalación del Consejo de Visual Indicador de Down ( 308-0618Truck Body montaje Gp)

Tabla 32





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1113-1218

326-3097 (1)

Como bafle

bafle Como


(1) Parte de la 341-5471 retrovisor médico de cabecera o al 328-9834 retrovisor Gp

Piezas necesarias para la instalación de los eyectores de Rock ( 308-0618 Truck Bodymontaje Gp)


2 253-7490 Eyectores

2 6G-7773 Pines

4 3B-4647 Chavetas

16 1D-0503 Arandelas

Tabla 33

Las piezas requeridas para la instalación de la Asamblea Pad (Caja volcadora) ( 308-0618Truck Body montaje Gp)


4 229-6177 Como Pad

20 106-8227 Cuñas

20 5P-2566 Tornillos


Tabla 34

Piezas necesarias para la instalación de la Central de Lubricación Grupo de Líneas




12 5P-9085 Clips

10 5M-3062 Tornillos


2 8T-4137 Tornillos


Tabla 35





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Piezas necesarias para la instalación del Grupo de lubricación automática




10 5M-3062 Tornillos


12 5P-9085 Clips

2 8T-4137 Tornillos


Tabla 36

Piezas necesarias para la instalación del GP de Cine


1 289-8453 Película



Tabla 37

Prepare to Assemble the Machine

Antes de descargar los componentes del chasis y relacionada, lea la siguiente información con elfin de facilitar el trabajo.

Con el fin de montar la máquina, seleccionar un área que es lisa y plana. El área debe ser de25 m (82 pies) de ancho y 30 m (98 pies) de largo. El área debe escurrir bien. Coloque elchasis en el centro de la zona.

•

Cuando se descarga componentes, coloque cerca de los componentes del chasis. Sin

embargo, tenga un área alrededor del chasis claro con el fin de posicionar las grúas para laelevación de los componentes.

•

Abra todas las cajas e inspeccionar el contenido.•

Organizar los componentes y el hardware con el fin de ayudar a reducir el hardware y el

conjunto pierde velocidad.

•

No abra las bolsas de plástico de hardware. Las bolsas de plástico están marcadas conetiquetas de color amarillo que se imprimen con el número de grupo. Los componentesindividuales están marcados con las etiquetas de color amarillo que se imprimen con el

número de componentes y con el número de grupo. Mueva cada bolsa de plástico dehardware para el chasis cuando el componente correspondiente está instalado.

•





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Ilustración 1 g00638037

Approximate Weights

Lesiones personales o la muerte puede ser resultado de la elevaciónincorrecta o de bloqueo.

Cuando una grúa o jack se utiliza para levantar cualquier pieza ocomponente, manténgase alejado de la zona. Asegúrese que el elevadoro gato tiene la capacidad correcta para levantar un componente. Instale

bloques o trancas antes de la realización de trabajos en virtud de uncomponente pesado.

Pesos aproximados de los componentes se muestran. Limpie todas lassuperficies donde las piezas se van a instalar.

El chasis pesa 21315 kg (47.000 libras).•

El conjunto de la cabina pesa 1550 kg (3417 libras).•

El cilindro de suspensión delantera, la rueda, y el equipo de frenos pesa 2070 kg (4565libras).

•

El eje trasero pesa 9389 kg (20.700 libras).•

El conjunto de neumático y la llanta pesa 1960 kg (4320 lb).•

El conjunto estándar de cuerpo y el techo pesa 15780 kg (34,900 libras).•

Un cuerpo pesa 21180 kg (46.700 libras).•

Torque Specifications





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Apriete los pernos que sujetan el conjunto del eje trasero a la suspensión de un marco con

un par de 1800 ± 200 N · m (1330 ± 150 lb-pie).

•

Apriete los pernos que sujetan el montaje del eje trasero a los cilindros de la suspensióntrasera a 620 ± 80 N · m (460 ± 60 lb-pie).

•

Apriete los tornillos que sujetan la barra de control a la estructura y el tren trasero con un

par de 620 ± 80 N · m (460 ± 60 lb-pie).

•

Apriete los pernos que sujetan el cilindro de suspensión delantera con un par de 1175 ± 48 N · m (870 ± 35 lb-pie).

•

Apriete la tapa del cilindro de suspensión delantera de los pernos de montaje con un par de370 ± 50 N · m (270 ± 35 lb-pie).

•

Apriete los pernos que sujetan el brazo de dirección frente a un par de 1800 ± 163 N · m

(1325 ± 120 lb-pie).

•

Apriete el apoyo taxi los pernos de montaje en el soporte delantero con un par de 800 ± 100 N · m (600 ± 75 lb-pie).•

Apriete el apoyo taxi los pernos de montaje en el soporte trasero con un par de 1600 ± 200

N · m (1180 ± 150 lb-pie).

•

Apriete los pernos de montaje de la cabina en la parte delantera de la cabina con un par de800 ± 100 N · m (600 ± 75 lb-pie).

•

Apriete los pernos de montaje de la cabina en la parte trasera de la cabina con un par de 800± 100 N · m (600 ± 75 lb-pie).

•

Apretar las tuercas que sujetan el aro de la rueda delantera con un par de 1210 ± 100 N · m(890 ± 75 lb-pie) en caso de 4C-5592 compuesto antiadherente se aplica a los frutos secos.

•

Apretar las tuercas que sujetan el aro de la rueda delantera con un par de 2100 ± 200 N · m(1550 ± 150 lb-pie) si el anti-adherente compuesto no se aplica a los frutos secos.

•

Apretar las tuercas que sujetan el aro de la rueda trasera con un par de 1210 ± 100 N · m(890 ± 75 lb-pie) en caso de 4C-5592 compuesto antiadherente se aplica a los frutos secos.

•

Apretar las tuercas que sujetan el aro de la rueda trasera con un par de 2100 ± 200 N · m(1550 ± 150 lb-pie) si el anti-adherente compuesto no se aplica a los frutos secos.

•

Apriete los pernos que sujetan la cubierta de la extensión de los neumáticos traseros de laválvula con un par de 100 ± 20 N · m (75 ± 15 lb-pie).

•

Apriete las abrazaderas de las barras de dirección vinculados a un par de 285 N · m (210 lb- pie).

•

Hoist Capacity

Chassis Assembly

Cuando la caja del diferencial es sobre soportes, un polipasto con una capacidad de 10000 kg(22.000 libras) es necesario para levantar el chasis en el punto de elevación frontal.





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Cuando el frente del bastidor travesaño es sobre soportes, un polipasto con una capacidad de 8600

kg (19.000 libras) es necesario para levantar el chasis en el punto de elevación trasera.

Assembled Machine Without the Body

Cuando los neumáticos traseros están en el suelo, un elevador con una capacidad de 17000 kg

(38.000 libras) es necesario para levantar el camión en el punto de elevación frontal.

Cuando los neumáticos delanteros están en el suelo, un elevador con una capacidad de 16000 kg(35.000 libras) es necesario para levantar el camión en los puntos de elevación trasera.

Machine Dimensions

La dimensión de la altura del conjunto de chasis es 1676 mm (66 pulgadas).•

Cuando los neumáticos están instalados, la dimensión de la altura en la parte superior de lacampana es 3150 mm (124 pulgadas).

•

La distancia desde el centro del cuerpo a la pared exterior es de 2438 mm (96 pulgadas).•

Cuando los neumáticos están instalados, la altura del borde superior del cuerpo es 4288 mm(169 pulgadas).

•

Cuando los neumáticos están instalados, la altura del borde superior de la cubierta es 5028mm (198 pulgadas).

•

La longitud del camión es 9780 mm (385 pulgadas).•

La anchura del camión es 6105 mm (240 pulgadas).•

Required Tools

Cuando se le indique, aplicar 4C-5593 compuesto antiadherente a las roscas.•

Use un 6V-6080 multiplicador de par para apretar los componentes que siguen: el brazo dedirección las tuercas de montaje, las tuercas de los espárragos de bola y la rueda de la llantade tuercas de montaje.

•

Use un 6V-8720 multiplicador de par para apretar las tuercas del eje trasero de la vivienda.•

Utilice una de 6V-7915 Llave de par con los multiplicadores de par.•

Use un 194-7586 neumática Llave Gp con un 194-7886 ampliación de la unidad de lostornillos que sujetan el cilindro de suspensión delantera de la unidad del armazón.

•

Use un 8H-8548 Ampliación de la llanta de la rueda las tuercas de montaje.•

Use un 8H-8541 Socket en el brazo de dirección las tuercas de montaje.•

Use un 8H-8504 Socket las tuercas de rótula.•

Use un 8H-8540 Socket en la llanta de la rueda las tuercas de montaje.•





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Use un 2P-2334 Socket de los tornillos que sujetan el cilindro de suspensión delantera de la

unidad del armazón.

•

Use un 8H-8537 Socket en los pernos de montaje de la cabina.•

Use un 7H-1680 de la Asamblea del compresor con el fin de bombear petróleo a loscilindros de suspensión.

•

Use un 6V-4040 Grupo de inflación con el fin de inflar los neumáticos con nitrógeno.•

Use un 8H-8536 Socket.•

Use un 8T-0859 medidor de presión en los cilindros de suspensión delanteros.•

Use un 7S-5437 Grupo de Carga de Nitrógeno con el fin de cobrar los neumáticos y loscilindros de suspensión.

•

Use un 8T-5230 llave de torque que está regulada por la presión del aire a fin de obtener un

par motor máximo de 300 N · m (220 lb-pie).

•

Cuando se le indique, se aplican 222-3124 Limpiador de frenos y eléctrico con el fin delimpiar los componentes.

•

Required Supplies and Required Equipment

Consulte la siguiente información con el fin de reunir los suministros y equipos.

Tener un 208 l (55 gal EE.UU.) barril de aceite hidráulico (HYDO).•

Obtenga 6 barriles de transmisión / aceite de la unidad de tren (TDTO). Cada barril debetener una capacidad de 208 l (55 gal EE.UU.). 3 de barriles debe contener aceite SAE 10W.3 de barriles debe contener aceite SAE 30. La temperatura ambiente que son extremos

pueden requerir una viscosidad del aceite diferente. Consulte el Manual de servicio,SEBU6250 "Caterpillar recomendaciones de lubricantes de la máquina".

•

Tiene 20 botellas de nitrógeno que son T-tamaño con el fin de inflar los neumáticos y cargarlos cilindros de suspensión.

•

Tiene un compresor de aire portátil. El compresor de aire debe tener suficiente capacidad para operar dos de 25,4 mm (1 pulgada) de armas de aire de impacto. El compresor de airedebe tener una capacidad mínima de 3 cm (100 CFM).

•

Tiene una escalera de tijera que es de 1,8 m (6 pies) de altura. Tiene otra escalera que es de3,6 m (12 pies) de altura.

•

Ha una carretilla elevadora que puede levantar 4082 kg (9000 lb).•

Tiene otra carretilla elevadora que puede levantar 13608 kg (30.000 libras).•

Tiene una grúa que puede levantar 36320 kg (80.000 libras).•

Tener por lo menos 12 bloques de madera que son 101 mm (4,0 pulgadas) de altura. Los

bloques deben ser de 203 mm (8,0 pulgadas) de ancho. Los bloques deben ser de 406 mm(16,0 pulgadas) de largo.

•





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Tener por lo menos 40 bloques de madera que son 203 mm (8,0 pulgadas) de altura. Los

bloques deben ser de 203 mm (8,0 pulgadas) de ancho. Los bloques deben ser de 914 mm(36,0 pulgadas) de largo.

•

Tener un mínimo de 30,5 m (100 pies) de cuerda que es de 12,7 mm (0,50 pulgadas) dediámetro. Cuando se instala el cuerpo en el chasis, utilice la cuerda con el fin de guiar elcuerpo en su posición.

•

Tiene varias cadenas. Las cadenas deben tener un límite de carga de trabajo de 27240 kg(60,050 libras).

•

Tiene los cables, cadenas, y los dispositivos de elevación que tienen la capacidad adecuada.•

Specifications for Cables, Chains, and Lifting Devices

Utilice cables aprobados, cadenas, y los dispositivos de elevación para levantar los componentes.Consulte la literatura del fabricante para determinar la aplicación cuando se seleccionan loselementos que siguen: Los dispositivos de cable, cadena y elevación. Al levantar un componente,

el ángulo de elevación es crítica. Consulte la ilustración que sigue con el fin de ver el efecto delángulo de elevación en el límite de carga de trabajo.


Levante los ángulos de elevación las eslingas.

(A) La capacidad de carga es de 100% de la carga máxima de trabajo de la eslinga.





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(B) La capacidad de carga es del 86% de la carga máxima de trabajo de la eslinga.

(C) La capacidad de carga es de 70% de la carga máxima de trabajo de la eslinga.

(D) La capacidad de carga es de 50% de la carga máxima de trabajo de la eslinga.

Tire Inflation Pressure and Mounting

Consulte el Manual de Operación y Mantenimiento, SEBU7790, "777F Camiones Fuera deCarretera" para obtener información específica.

Chassis Lifting Points

Ilustración 3

Puntos de elevación sobre los 777F Camiones de Obras





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Position the Chassis for Assembly


Soportes de madera bajo el marco del Frente

Cuando se quita el chasis del camión, ponga apoyos debajo del chasis. Coloque los soportesen la parte delantera del chasis y el lugar apoya en la parte posterior del chasis.

1.

Cuando se colocan los soportes en la parte delantera del chasis, proporcionan 1117 mm (44 pulgadas) de altura sobre el suelo con el fin de instalar los neumáticos.

2.


Al colocar los soportes en la parte trasera del chasis, proporcionan 1.092 mm (43 pulgadas)de altura sobre el suelo con el fin de instalar los neumáticos.

3.





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Install the 262-6081 Rear Axle Housing Gp and the 246-2647

Transmission Ar

Nota: Las partes de la 2G-4080 Drive Shaft y 247-3752 del enfriador de aceite hidráulico Líneas

Gp también se requieren.


Artículo Cantidad Número de pieza Descripción


1 16 302-4536 Atornillar

2 16 9X-8399 Lavadora


3 4 8B-5144 Tornillos (1)


4 1 321-1386 Como tubo

5 1 321-1387 Como tubo

6 1 321-1389 Como tubo

7 1 321-1388 Como tubo


8 8 175-7894 O-ring

9 16 8T-4184 Tornillos

10 40 8T-4223 Lavadoras duros

11 8 1P-4582 La mitad Bridas

12 4 4J-0527 O-ring


13 4 7X-0328 Tornillos

14 4 5P-2566 Tornillos



16 1 9C-4937 Como respiradero

17 1 030-7765 Adecuado

Tabla 38






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Nota: Con el fin de obtener los valores apropiados de tensión, aplicar herramientas (AA) en todas

las superficies de contacto. Elimine las rebabas, mellas, o el óxido antes del montaje. Guarde todoel hardware.


Retire nueve pernos (A) y las arandelas de nueve (B) que la guardia de seguridad (C) en el bastidor. Quite el protector (C) de la estructura.

1.


Retire la bolsa adjunta de piezas de eje de transmisión (D). Guarde la bolsa adjunta de las piezas.

2.





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Retire las correas que sujetan la suspensión de un marco y los cilindros de la suspensióntrasera.

3.


El uso de herramientas (AA) para quitar la pintura del eje trasero. El uso de herramientas(BB) para limpiar las áreas de montaje en el eje trasero.

4.






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El uso de herramientas (AA) para quitar la pintura de la suspensión de un marco. El uso de

herramientas (BB) para limpiar las áreas de montaje de la suspensión de un marco.

5.


Quite los siguientes componentes del eje trasero: dos tuercas (E), cuatro arandelas (F), dos

arandelas de disco duro (G), dos tornillos (H) y dos pines (J). Guarde todo el hardware.

6.

El uso de herramientas (AA) para quitar la pintura a partir de dos pasadores (J).7.


Quite los siguientes componentes de la parte trasera del chasis: tuerca (K), la arandela dura(L), dos arandelas (M), de los pernos (N) y el pin (P). Guarde todo el hardware.

8.

El uso de herramientas (AA) para quitar la pintura de la patilla (P).9.





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Retire los amarres de alambre de las mangueras de las unidades finales y la transmisión.10.



Coloque una carretilla elevadora adecuada debajo del conjunto del eje trasero, o usar unagrúa para levantar el conjunto del eje trasero. Levante el conjunto del eje trasero al chasis.El peso del conjunto del eje trasero es de 10115 kg (22,300 libras).

11.





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Nota: No aplaste las mangueras o no pellizque las mangueras que se encuentran en la parte

trasera del chasis.


Alinear de barras de control (R) con el marco. Instale los siguientes componentes de la barra

de control (R) y para el marco: el pasador (P), la tuerca (K), las arandelas de disco duro (L),dos arandelas (M) y el tornillo (N).

12.


Instale pernos de 16 (1) y 16 arandelas (2). Tornillos (1) se asegure el conjunto del ejetrasero a la suspensión de un marco.

13.

Nota: Apretar los tornillos (1) con una llave de impacto. No apriete los pernos (1) en estemomento.

Alinear los cilindros de la suspensión trasera con la carcasa del eje trasero.14.





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Instale los pasadores (J) a la carcasa del eje trasero y los cilindros de la suspensión trasera.15.

Nota: Engrase los pernos (J) con herramientas (EE) antes de la instalación.

Instale los siguientes componentes para el cilindro de suspensión trasera y la caja del eje

trasero: dos tuercas (E), cuatro arandelas (F), dos arandelas de disco duro (G) y dos tornillos(H). Apretar los tornillos (H) con un par de 620 ± 80 N · m (460 ± 60 lb-pie).

16.

Repita el paso 14 al paso 16 para el cilindro de la suspensión trasera.17.


Apriete los pernos (1) que fijan el conjunto del eje trasero a la suspensión de un marco.Apretar los tornillos (1) con un par de 1800 ± 200 N · m (1330 ± 150 lb-pie).

18.

Nota: Utilice un 6V-6080 Multiplicador de par Gp con el fin de alcanzar el par de apriete

correcto.





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Apretar el tornillo (N) con un par de 620 ± 80 N · m (460 ± 60 lb-pie) con el fin de asegurarel control de la varilla (R).

19.

Nota: Compruebe el par de apriete del perno existente (NN) que sujeta el extremo opuestode la barra de control (R). El valor de par de apriete correcto del perno existente (NN) es de620 ± 80 N · m (460 ± 60 lb-pie).


Alinear eje de accionamiento (D) para la transmisión. Instalar cuatro pernos (3) con el fin de

asegurar el eje de accionamiento a la transmisión. Apriete los pernos (3) con un par de 270± 15 N · m (200 ± 11 lb-pie).

20.

Nota: Los pernos (3) se encuentran en la bolsa de piezas que se retiró en el paso 2.





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Vuelva a instalar el protector (C) a la estructura con nueve pernos (A) y nueve arandelas (B)que se retiró en el paso 1.

21.


Elimine el enlace de la cadena que aseguraba la suspensión de un marco en el chasis. Retirela cadena del chasis.

22.

Repetir el paso 22 para el lado opuesto de la máquina.23.





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(S) 11 mm (0,43 pulgadas)

AVISO

No moler a través de la soldadura o por el material principal del

fotograma.

Retirar con cuidado los dos ojos desde el lado de la suspensión un bastidor y del marco.Deja la soldadura y el material parental a la dimensión (S).

24.

Limpie todas las áreas afectadas. Pintar el área con el fin de inhibir la oxidación.25.

Baje lentamente el conjunto del eje trasero. Retire la carretilla elevadora de la asamblea deleje trasero.

26.





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Quite las cuatro tuercas y arandelas de los cuatro que sujetan la placa a la rueda. Retirar la placa de la rueda. Vuelva a colocar los cuatro tornillos y arandelas vez que la placa se haeliminado. Repetir el procedimiento para la otra rueda.

27.

Install the Brake Oil Cooler Lines


Retire los tapones de transporte de las unidades finales.1.





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Tubos para el enfriador de freno de mano derecha del petróleo

Instalar la junta tórica (8) en el extremo del tubo (4).2.

Utilizar los siguientes componentes con el fin de asegurar el tubo (4) al puerto de la partesuperior de la unidad final: cuatro tornillos (9), cuatro arandelas duros (10) y dos medias

bridas (11).

3.

Nota: Instalar el tubo (4) antes de instalar el tubo (5).


Utilice los siguientes componentes para fijar el tubo (5) al puerto de la parte inferior de la

unidad final: cuatro tornillos (9), cuatro arandelas de disco duro (10) y dos medias bridas

(11).

5.



Quitar el perno (R), la arandela (S), y dos clips (T) a partir de la suspensión un marco. Tubosegura (4) y el tubo (5) con el perno (R), la arandela (S), y los clips (T).6.





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Tubos para el enfriador de freno izquierda de aceite



bridas (11).

8.

Nota: Instalar el tubo (6) antes de instalar el tubo (7).



bridas (11).

10.



Quitar el perno (R), la arandela (S), y los clips (T) a partir de la suspensión un marco.Asegure el tubo (6) y el tubo (7) con el perno (R), la arandela (S), y los clips (T).

11.





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Retire los tapones de transporte de la manguera (U), mangueras (V), mangueras (W), y lamanguera (X) para los mandos finales y la transmisión. Conserve toda la mitad bridas, pernos, arandelas y las tuercas para la reinstalación en el paso 14 y paso 16.

12.







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Conectar los conjuntos de tubos siguientes para los conjuntos de manguera siguientes en el

lado derecho del chasis: tubo (4) a la manguera (U) y tubo (5) a la manguera (W).

13.

Utilice los siguientes componentes con el fin de asegurar los conjuntos de tubos a losconjuntos de mangueras: dos juntas tóricas (12), cuatro pestañas medio que se retiró en el

paso 12, los cuatro pernos que se quitaron en el Paso 12, ocho arandelas de disco duro quese han eliminado en el Paso 12, los cuatro pernos que se quitaron en el paso 12 y cuatrotuercas que se quitaron en el Paso 12.

14.







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Conectar los conjuntos de tubos siguientes para los conjuntos de manguera siguientes en ellado izquierdo del chasis: tubo (6) a la manguera (V) y tubo (7) a la manguera (X).

15.

Utilice los siguientes componentes con el fin de asegurar los conjuntos de tubos a losconjuntos de mangueras: dos juntas tóricas (12), cuatro pestañas medio que se retiró en el

paso 12, los cuatro pernos que se quitaron en el Paso 12, ocho arandelas de disco duro quese han eliminado en el Paso 12, los cuatro pernos que se quitaron en el paso 12 y cuatrotuercas que se quitaron en el Paso 12.

16.

Install the Transmission Lines


Retire las tapas de las mangueras (y) y (Z).1.





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Conecte la manguera (Y) para el ajustador. Conecte la manguera (Z) para la línea deretorno.

2.


Retire la tapa protectora de la manguera (AB).3.






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Conecte la manguera (AB) para la transmisión mediante el enrutamiento de manguera (AB)

a través del clip se encuentra en la parte delantera, esquina izquierda de la transmisión.

4.


Retire los tapones de transporte de la manguera (AC) y la manguera (AD). Conserve todos

los medio de bridas para la reinstalación en el paso 6 y paso 7. Deseche todos los pernos,arandelas y tuercas.

5.


Conecte la manguera (CA) a la transmisión. Utilice cuatro pernos (13), cuatro arandelas(15), y el medio bridas que se eliminaron en la Etapa 5 con el fin de asegurar la manguera(CA).

6.





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Conecte la manguera (AD) para la transmisión. Utilice cuatro pernos (14), cuatro arandelas(15), y el medio bridas que se eliminaron en la Etapa 5 con el fin de asegurar la manguera(dC).

7.

Install the Breather Assembly


Quitar respiradero (16) y el accesorio (17) desde el eje trasero. Retire el tapón de la tubería

de la caja del eje. Instalar respiradero (16) y el accesorio (17) a la caja del eje trasero.

1.

Install the Electrical Connection





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Retire los dos tornillos y dos arandelas (AE) de la transmisión y el soporte de montaje (FA).1.


Retire el soporte (AG) del soporte de montaje (FA) y la transmisión. Retire los dosarandelas (AH) de soporte de montaje (FA) y la transmisión. Deseche las dos arandelas(AH).

2.






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Instale el soporte (AG) en el soporte (AF) con el hardware que se retiró en el paso 1.3.

Instale el tapón (AJ) en el receptáculo y apriete el tornillo de montaje.4.

Retire la tuerca, el perno, arandelas de dos, y el clip (AK) del soporte (FA). Instale el clip para el arnés de la clavija (AJ) y volver a instalar el clip, el perno, dos arandelas y la tuercade fijación (AG).

5.

Install the 280-6920 Platform Gp and 280-6930 Platform Gp

Piezas necesarias para la instalación de la Plataforma Gp


1 1 280-6920 Plataforma Gp


Tabla 39


Retire los seis tornillos (A) y seis arandelas (B) de la estructura. El uso de herramientas(AA) con el fin de eliminar toda la pintura y el óxido de la superficie de contacto.

1.





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El uso de herramientas (AA) con el fin de eliminar toda la pintura o el óxido de la superficiede contacto.

2.


Instale un dispositivo de elevación adecuado y el grupo de posición de la plataforma (2) ensu posición. El peso de cada plataforma es de 112 kg (245 libras).

3.

Vuelva a instalar seis arandelas (B) y seis pernos (A) que se quitaron en el paso 1. Apretarlos tornillos.

4.

Repita los pasos del 1 al 4 para el otro lado.5.




1 2 241-2699 Escalera Gp

Tabla 40





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De la mano derecha del parachoques

Retire los cuatro tornillos (A) y cuatro arandelas (B).1.


Posición Escalera (1) a la estructura y volver a instalar cuatro arandelas (B) y cuatro pernos(A) que se quitaron en el paso 1. Apretar los tornillos. Repita este procedimiento para el otrolado.

2.

Install the Suspension Cylinders from the 264-5808 FrontSuspension (non-European part number) or from the 264-5809 Front Suspension (European part number) and Install

the Steering Arms from the 9D-3030 Steering Link



1 2290-7232 (uno)



2 2 9D-2498 Claves

Tabla 41





7/25/2019 ENSAMBLE 777F


3 28 7B-9215 Tornillos

4 28 3S-1356 Frutos de cáscara completa

5 56 3S-1349 Lavadoras duros


6 2 4J-8535 Abrazaderas

7 2 116-1949 Cubre

(1) Número Europea


Nota: Consulte la Instrucción Especial, REHS4445, "Mantenimiento de los Cilindros desuspensión para camiones fuera de carretera" para cualquier información referente a los cilindrosde suspensión. La Instrucción Especial incluye herramientas, las presiones y los procedimientos

correctos para purgar (aceite y nitrógeno) y de carga (de petróleo y nitrógeno).


Gastos de envío patín

Retire los soportes de transporte de los cilindros de suspensión delanteros.1.

AVISO

NO permita que el conjunto del brazo de dirección para pasar el ratosin apoyo, haciendo hincapié en la rótula. Apoyar el conjunto del brazo

de dirección con las herramientas adecuadas.





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Retire el soporte de transporte de la estructura. El uso de herramientas (AA) para quitar la pintura. El uso de herramientas (BB) con el fin de limpiar las superficies de contacto.

2.

Elimine las rebabas de las superficies de contacto. Asegúrese de que las superficies decontacto son lisas.

3.

AVISO

NO cuelgue la tapa que lleva por la línea de lubricación.


Retire los cuatro pernos de montaje (A), ocho arandelas (B), teniendo la tapa (D), y lascalzas (C).

4.

El uso de herramientas (BB) con el fin de limpiar la tapa del cojinete.5.





7/25/2019 ENSAMBLE 777F



Instale una llave (2). Alinear la tecla con el fin de permitir que los pernos a través de losorificios de los pernos.

6.


El uso de herramientas (CC) con el fin de posicionar grupo suspensión (1) sobre el bastidordel camión. Alinear la válvula de carga para el cilindro de suspensión hacia la parte frontalde la máquina. El peso de un conjunto de montante delantero es 1475 kg (3250 libras).

7.





7/25/2019 ENSAMBLE 777F



Utilice los siguientes elementos a fin de asegurar la suspensión del grupo (1) en el cuadro:

dieciséis tornillos (3), dieciséis nueces completas (4) y treinta y dos arandelas de disco duro(5).

8.

Apriete los pernos de 16 (3) con un par de 1175 ± 48 N · m (870 ± 35 lbs).9.


Instalar teniendo la tapa (D) para el grupo de suspensión (2). Ajustar el número requerido decuñas (C) por detrás de la tapa del cojinete con el fin de eliminar cualquier hueco. Instale losdos pernos (A) y ocho arandelas (B). Apriete los pernos (A) para la tapa del cojinete con un

par de 370 ± 50 N · m (275 ± 35 lb-pie). Repetir el procedimiento para el cilindro de otrasuspensión.

10.





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Conecte las líneas de grasa (E) a la suspensión del grupo (1). Repetir el procedimiento para

el cilindro de otra suspensión.

11.


De la mano derecha delante del cilindro de suspensión

Conecte el sensor (F) para el monitor de carga de la camioneta al conector (G).12.





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La mano izquierda delante del cilindro de suspensión

Conecte el sensor (F) para el monitor de carga de la camioneta al conector (H).13.


Retire los cuatro tornillos (J) y cuatro arandelas de disco duro (K). Limpie la superficie decontacto para el brazo de dirección en el eje. Elimine las rebabas de la superficie decontacto. Repetir el procedimiento para el cilindro de otra suspensión.

14.





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Nota: Antes de instalar el brazo de dirección, asegúrese de que las superficies de contactoestén limpias.

Vuelva a colocar los cuatro tornillos (J) y cuatro arandelas de disco duro (K), que se retiróen el paso 14. Tornillos (J) y arandelas (K) se utilizan para sujetar los brazos de dirección enel eje de cada uno de cilindros de suspensión delanteros (2). Apriete los cuatro tornillos (J)en un par de 1800 ± 200 N · m (1325 ± 150 lbs). Repetir el procedimiento para el otro lado.

15.

Nota: Si los espárragos de bolas se retiran, limpiar las velas y aplicar herramientas (EE). A

continuación, instale las tuercas del castillo. Apretar las tuercas de corona con un par de1.360 Nm (1.000 lb-pie). Inserte el pasador a través de la tuerca castillo. Si el agujero parael pasador no está alineado, apriete la tuerca castillo hasta el agujero para el pasador está enla alineación.

Nota: Con el fin de evitar daños a los montantes de bola, apoyar a los cilindros de direccióndurante el montaje. No permita que las barras se le caiga de los cilindros de dirección.


Instale la cubierta (7). Asegure la cubierta (7) con la abrazadera (6). Repetir el procedimiento para el cilindro de otra suspensión.

16.

Installation of the Hydraulic Oil Cooler Lines and the Front

Service Brake Lines

Nota: El 247-3752 del enfriador de aceite hidráulico Líneas Gp son parte de la 234-2647 Arreglo

de frenos. La 229-2093 Servicio de frenos Líneas Gp son también parte de la 234-2647 Arreglo defrenos. Las máquinas están equipadas con 243-5551 Freno de servicio médico de cabecera noestán equipadas con las líneas del frente del enfriador de aceite. 243-5551 Servicio de frenos Gpson los frenos de disco tipo. Las máquinas están equipadas con 243-5551 Freno de servicio

médico de cabecera también tienen 254-3356 Servicio de frenos Líneas Gp lugar de 229-2093Servicio de frenos Líneas Gp.

Tabla 42





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Piezas necesarias para la instalación de las líneas del enfriador de aceite delantero y líneas

delanteras del freno de servicio



1 4 103-5422 Como la manguera


2 8 4J-0522 O-ring


Quite los ocho tornillos (A), ocho arandelas duros (B), y cuatro bridas medio (C). Deseche

las cubiertas.

1.


Instalación de dos tubos (1) a la mampara con dos sellos (2), cuatro pestañas medio (C),

ocho arandelas de disco duro (B), y ocho tornillos (A), que se retiró en el paso 1. Apretar lostornillos.

2.





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Nota: Las mangueras de instalación (1) con el ángulo de 67,5 a la parte superior. Asegúrese

de que las mangueras se instalan con fuerza contra las barras de soporte.


Quite los ocho tornillos (A), ocho arandelas duros (B), y cuatro bridas medio (C). Desechelas cubiertas.

3.

Instalación de dos tubos (1) a los frenos con dos sellos (2). Utilice cuatro bridas medio (C),ocho arandelas de disco duro (B), y ocho tornillos (A), que se retiró en el paso 3. Apretar lostornillos.

4.


Quite los tornillos (F), arandelas (G), y el bloque (E). Retire la tapa de ajuste de los frenos y

quitar el tapón de la manguera (C). Instale la manguera (D).

5.

Vuelva a instalar el bloque (E), las arandelas (G), y los pernos (F) que se han eliminado enel Paso 5.

6.





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Repetir del Paso 1 al Paso 6 para el otro lado de la máquina.7.

Front Service Brake Lines (Dry Brakes)

Nota: El 247-3752 del enfriador de aceite hidráulico Líneas Gp son parte de la 234-2647 Arreglode frenos. La 229-2093 Servicio de frenos Líneas Gp son también parte de la 234-2647 Arreglo de

frenos. Las máquinas están equipadas con 243-5551 Freno de servicio médico de cabecera noestán equipadas con las líneas del frente del enfriador de aceite. 243-5551 Servicio de frenos Gpson los frenos de disco tipo. Las máquinas están equipadas con 243-5551 Freno de serviciomédico de cabecera también tienen 254-3356 Servicio de frenos Líneas Gp lugar de 229-2093Servicio de frenos Líneas Gp.


Retire todas las tapas y tapones. Instalar la manguera (A) para conjunto de freno. Repetir el procedimiento para el otro lado de la máquina.

1.

Install the Fuel Tank



1 1223-5868 Tanque de combustible Gp (1)


Tabla 43

(1) 1140 L (300 gal EE.UU.) Tanque(2)

1320 L (350 gal EE.UU.) Tanque





7/25/2019 ENSAMBLE 777F



El uso de herramientas (AA) para quitar la pintura de las superficies de contacto. El uso de

herramientas (BB) para limpiar las superficies de contacto. Elimine las rebabas que están presentes.

1.


Retire los cuatro tornillos (A), cuatro arandelas de disco duro (B), y dos tapones (C). El usode herramientas (AA) para quitar la pintura de las superficies de contacto. El uso de

herramientas (BB) con el fin de limpiar las superficies de contacto. Elimine las rebabas queestán presentes.

2.





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Retire los dos tornillos (E), dos arandelas de seguridad (F), dos arandelas de disco duro (G),dos arandelas (H), y cuatro soportes (D).

3.



Utilizar un dispositivo de elevación adecuado para posicionar el tanque de combustible (1).Posición depósito de combustible (1) en el lado derecho del camión.

4.





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Nota: 223-5868 del tanque de combustible Gp pesa 336 kilogramos (740 libras).

Nota: 219-9712 depósito de combustible pesa 448 kg (990 libras).


Nota: Asegúrese de que el tanque de combustible central (1) sobre los soportes antes de

asegurar.

Vuelva a colocar dos tapones (C), cuatro pernos (A) y cuatro arandelas de disco duro (B)que se quitaron en el paso 2 con el fin de asegurar el tanque de combustible. Apretar lostornillos.

5.


Posición dos montajes (D) en cada lado del soporte. Utilice los componentes que se quitaronen el paso 3 con el fin de asegurar el tanque de combustible (1). Apretar los tornillos.

6.





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Conecte la línea de combustible (J) y la línea de combustible (K) para las salidas en la parte posterior del tanque de combustible. Conecte la manguera (K) del filtro de combustible primario para la toma de corriente que tiene la válvula de cierre.

7.



Conecte el arnés (L) a través del clip en el conector (M).8.





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Install the 241-7779 Cab Mounting Gp , and the 240-2262

Cab Mounting Gp



1 1 250-5930 Como apoyo

2 1 241-7777 Como apoyo


3 8 173-9684 Tornillos

4 8 198-4782 Lavadoras duros

5 10 129-3175 Tornillos


7 1 240-2263 Manga

8 8 117-8131 Como Montar

9 1 8T-5397 Atornillar

10 4 252-0080 Arandelas

11 3 3E-4898 Mangas



14 4 7X-7729 Arandelas

15 4 240-2261 Como Pin

Tabla 44






7/25/2019 ENSAMBLE 777F


Quite los tornillos de fijación, arandelas, y los ojos de elevación de la superficie de apoyo de

montaje frontal. Deseche los pernos, arandelas, y el ojo de elevación. Estas partes no sevolverá a utilizar.

1.

El uso de herramientas (AA) para eliminar la pintura de las superficies de montaje de lacabina apoya y las superficies de contacto sobre el chasis. El uso de herramientas (BB) paralimpiar las superficies de montaje de la cabina y apoya las superficies de contacto en el

chasis. Elimine las rebabas que están presentes.

2.


Conecte un dispositivo de elevación adecuado para el apoyo (1). Posición soporte (1) alchasis. Utilice los ocho tornillos (3) y ocho arandelas (4) con el fin de asegurar el apoyo (1)en el chasis. Apriete los tornillos a una torsión de 800 ± 110 N · m (590 ± 80 lb-pie). El

peso del soporte (1) es de 148 kg (325 libras).

3.

Nota: Al instalar la cabina de apoyo, no use los tornillos que aseguraban el ojo de

elevación.


Conecte un dispositivo de elevación adecuado para apoyar (2). Posición soporte (2) alchasis. Utilice diez tornillos (5) y diez arandelas (6) con el fin de asegurar el apoyo (2) en el

4.





7/25/2019 ENSAMBLE 777F


chasis. Apriete los pernos con un par de 1600 ± 200 N · m (1180 ± 150 lb-pie). El peso de

soporte (2) es de 230 kg (500 libras).


Instale dos mangas (11) y cuatro soportes de la cabina (8) en el soporte (1), en el montajedelantero de la cabina y el chasis. Instale una manga (11) y dos para la cabina (8) El soporte(3).

5.


Instale una manga (7) y dos para la cabina (8) en el montaje posterior de la cabina delchasis.

6.





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Instale los dispositivos de elevación adecuados a la cabina. Utilice los puntos de elevaciónen la cabina con el fin de aumentar la cabina. Alinear la cabina en el bastidor y en losconjuntos de soporte. El peso de la cabina es 1320 kg (2910 libras).

7.

Nota: Una vez que la cabina se ha instalado, quite todos los dispositivos de elevación.Vuelva a colocar los pernos de montaje que se utilizaron para colocar los dispositivos deelevación de la cabina.


Utilizar dos arandelas (10) y dos pernos (12) con el fin de asegurar la cabina en los montajesde cabina delanteras. Aplique la herramienta (HH) a los tornillos. Apriete los tornillos a unatorsión de 800 ± 110 N · m (590 ± 80 lb-pie).

8.

Utilizar una arandela (10) y un perno (12) con el fin de asegurar la cabina a la cabina demontaje en el soporte trasero. Aplique la herramienta (HH) a los tornillos. Apriete el pernocon un par de 800 ± 110 N · m (590 ± 80 lb-pie).

9.





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Utilizar una arandela (10) y un tornillo (9) con el fin de asegurar la cabina en el montaje

posterior de la cabina en el chasis. Aplique la herramienta (HH) al perno. Apriete el pernocon un par de 800 ± 110 N · m (590 ± 80 lb-pie).

10.


Instale los pernos de la cabina (13), arandelas (14), y los pernos (15) en cuatro lugares.Apretar los tornillos.

11.

Installation of the Exhaust Arrangement



Tabla 45





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1 1 256-6757 Tubo de escape Gp


2 2 4N-9330 Abrazaderas

3 2 6V-3823 Tornillos


5 2 8T-4244 Nueces

6 1 256-9400 Como tubo

7 6 7X-2563 Tornillos

8 6 8T-4123 Arandelas


Retire los cuatro pernos, arandelas de cuatro, y una placa de cubierta. Deseche todas las partes.

1.

El uso de herramientas (AA) para quitar la pintura de las superficies de contacto. El uso deherramientas (BB) para limpiar las superficies de contacto. Elimine las rebabas que están

presentes.

2.





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Instalar la abrazadera (2), el perno (3), dos arandelas duras (4) y la tuerca (5) al final delconjunto del tubo (6). Instale el tubo (6) en el silenciador.

3.

Instale un dispositivo de elevación adecuado para el montaje. El peso del tubo de escapegrupo (2) es de 155 kg (340 libras).

4.







7/25/2019 ENSAMBLE 777F


Utilice seis tornillos (7) y seis arandelas (8) para asegurar el conjunto de la camioneta.

Instalar la abrazadera (2), el perno (3), dos arandelas duras (4) y la tuerca (5) para elextremo ranurado del tubo (6).

5.

Apriete los pernos (3) en dos abrazaderas (2).6.

Install the Right Hand Platform




Cuadro 46


Quite los ocho tornillos de montaje (A) y ocho arandelas de disco duro (B). El uso deherramientas (AA) para quitar la pintura de las superficies de contacto. El uso deherramientas (BB) para limpiar las superficies de contacto. Elimine las rebabas que están

presentes.

1.






7/25/2019 ENSAMBLE 777F


Instalar un dispositivo de elevación adecuado a mano derecha de la plataforma (1). El peso

de la mano derecha plataforma (1) es de 230 kg (510 libras).

2.

Instalar la plataforma de la derecha (1).3.


Secure derecha plataforma (1) con cuatro pernos (A) y cuatro arandelas duros (B) en la partetrasera de la plataforma.

4.


Secure derecha plataforma (1) con cuatro pernos (A) y cuatro arandelas duros (B) en la partedelantera de la plataforma.

5.





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Retire los cinco correas de cable (C).6.


Instale el tapón (D) en el receptáculo.7.





FF 10 7K-1181 Correas de cable

Tabla 47





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Retire los cuatro tornillos (A) y cuatro arandelas (B) que se utilizan para montar el grupo deescalera.

1.


Quite las dos tuercas (C), dos arandelas (D), y dos tornillos (E) que se utilizan para montargrupo de escaleras (1).

2.





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Instale un dispositivo de elevación adecuado al grupo de escaleras (1). El peso del grupo

escalera (1) es de 68 kg (150 libras).

3.


Posición grupo de escalera (1). Vuelva a instalar los dos pernos (A) y dos arandelas (B) quese retiró en el paso 1.

4.





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Vuelva a colocar dos tornillos (E), dos arandelas (D), y dos tuercas (C) que se retiró en el paso 2.

5.


Ruta mazo de cables (F) de la extensión del parachoques de la derecha en el interior delcompartimiento del motor de la derecha ya lo largo de la plataforma de la derecha de la

escalera.

6.





7/25/2019 ENSAMBLE 777F


Instale el conector del arnés (F) al conector de arnés (G). Mazo de cables de seguridad (F) a

la plataforma de la derecha de la escalera con dos correas de cable (FF).

7.

Install the 237-0288 Service Brake Control Gp Fittings

Piezas necesarias para la instalación de los accesorios para los grupos de control del freno

de servicio



1 2 148-8347 Como el codo


Cuadro 48


Parte inferior de la cabina

Quitar todos los tapones de la válvula de control de freno que se encuentra en la parte

inferior de la cabina. Deseche todos los enchufes.

1.





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Instale dos conjuntos de codo (1) y el montaje del codo (2) a la válvula de control de freno.2.

Install the 237-0288 Service Brake Control Gp


La mano izquierda frente a lado del chasis


Parte inferior de la cabina

Conectar la manguera (A) a la válvula de control de freno.1.

Conectar la manguera (B) a la válvula de control de freno.2.

Conectar la manguera (C) a la válvula de control de freno.3.





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Install the 267-4707 Steering Lines Gp Fittings




1 2 148-8324 Como conector

2 1 148-8326 Como conector


Cuadro 49


Delantera de la cabina

Quitar todos los tapones de la unidad dosificadora mano que se encuentra en la partedelantera de la cabina. Deseche todos los enchufes.

1.





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Instale dos conjuntos de codo (1), el montaje de codo (2), y dos conjuntos de codo (3) a launidad de medición de la mano (HMU).

2.

Install the 267-4707 Steering Lines Gp





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La mano izquierda frente a lado del chasis


Delantera de la cabina

Conectar la manguera (A) a la parte posterior de la unidad dosificadora mano (HMU).1.

Conectar la manguera (B) a la parte posterior de la unidad dosificadora mano (HMU).2.

Conectar la manguera (C) a la parte posterior de la unidad dosificadora mano (HMU).3.

Conectar la manguera (D) a la parte posterior de la unidad dosificadora mano (HMU).4.





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Conectar la manguera (E) a la parte posterior de la unidad dosificadora mano (HMU).5.

Install the 273-2359 Platform Gp

Piezas necesarias para la instalación de la Plataforma Gp



Cuadro 50


Retire los cuatro tornillos (A) y cuatro arandelas (B) con el fin de quitar la tapa (C). Guardetodo el hardware.

1.






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Retire los seis tornillos (D) y seis arandelas (E).2.


Instale un dispositivo de elevación adecuado a la plataforma (1). El peso de la plataforma(1) es 65 kg (140 libras).

3.

Posición de la plataforma (1) para la cabina. Vuelva a instalar seis arandelas (D) y seistornillos (E) que se quitaron en el paso 2.

4.





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Vuelva a instalar la cubierta (C) con cuatro tornillos (A) y cuatro arandelas (B) que se retiróen el paso 1.

5.


Retire los seis tornillos (F) y seis arandelas (G) de la extensión de parachoques. Retire la placa (H) de la extensión de parachoques.

6.






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Ponga la protección (J) y la placa (H) en la extensión de parachoques. Instalación de seis

arandelas (G) y los seis tornillos (F) que se retiró en el paso 6. Apriete los pernos con un parde 55 ± 10 N · m (40 ± 7 lb-pie).

7.


Desconecte el arnés (K) de la luz (L).8.


Instale el arnés (K) a través del ojal (M) que se encuentra en la plataforma (1).9.

Conecte el arnés (K) en la luz (L).10.

Install the 273-2325 Walkway Gp



1 1 273-2325 Paseo del Gp

Cuadro 51





7/25/2019 ENSAMBLE 777F


GG 3 3S-2093 Correas de cable



Quite los ocho tornillos (A) y ocho arandelas (B). Guarde todo el hardware.1.

El uso de herramientas (AA) para quitar la pintura de las superficies de contacto. Elimine

las rebabas que están presentes.

2.





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Instalar un dispositivo de elevación adecuado para pasarela grupo (1). El peso del grupocalzada (1) es de 190 kg (420 libras).

3.


Posición grupo de pasarela (1), La ilustración muestra el 126.4.






7/25/2019 ENSAMBLE 777F



Instalación de pasarela de grupo (1) con ocho pernos (A) y ocho arandelas (B) que se retiró

en el paso 1.

5.





FF 17 3S-2093 Correas de cable




5 1 169-5414 Recortar

6 1 130-5300 Recortar

Cuadro 52





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Retire los dos pernos (A) y dos arandelas (B) cuenta con el apoyo de la izquierda. Guardetodo el hardware.

1.


Retire los dos tornillos (C), dos arandelas (D), y dos tuercas (E) de la izquierda escalera (1).Guarde todo el hardware.

2.






7/25/2019 ENSAMBLE 777F


Instale un dispositivo de elevación adecuado para la izquierda escalera (1). El peso de la

izquierda escalera (1) es de 60 kg (130 libras).

3.



Instalación de escaleras (1) con dos pernos (A) y dos arandelas (B) que se retiró en el paso1. Vuelva a colocar dos tornillos (C), dos arandelas (D), y dos tuercas (E) que se quitaron enel paso 2. Apriete todos los tornillos.

4.





7/25/2019 ENSAMBLE 777F



Mazo de cables de seguridad (F) con 13 correas de cable (FF) a los clips de montaje en laizquierda escalera y la plataforma de la izquierda. Mazo de cables de seguridad (F) con

cuatro correas de cable (FF) a los clips de montaje en la plataforma (G).

5.





7/25/2019 ENSAMBLE 777F



Conecte las conexiones eléctricas en los siguientes componentes: los juegos de cables (F),

interruptor de apagado del motor (H), de la izquierda la luz de escalera (J), y dejó las lucesde conducción de la mano (K).

6.


Conecte las conexiones eléctricas en los siguientes componentes: los juegos de cables (F),luz lateral marcador (L), y la izquierda indicador luminoso (M).

7.

Install the 273-2387 Handhold Gp

Piezas necesarias para la instalación de la Agarradera Gp


1 1 273-8920 Como asidero







7 2 115-3580 Placas

Tabla 53





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8 4 5P-7468 Clips

9 4 5P-7469 Clips



12 4 8T-4244 Nueces

13 4 8T-7087 Ojales

Ilustración 137





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Vista de la zona (G)

Retire los pernos (A 12), 12 arandelas (B), 12 pernos (C) y 12 arandelas, D). Instale pasamanos (1) y volver a instalar 12 tornillos (A), 12 arandelas (B), 12 pernos (C) y 12

arandelas (D).

1.

Quite los ocho tornillos (E) y ocho arandelas (F). Instale pasamanos (2) y volver a instalarlos ocho tornillos (E) y ocho arandelas (F).

2.

Quite los tornillos (12 H) y 12 arandelas (J). Instale pasamanos (3) y volver a instalar 12

tornillos (H) y 12 arandelas (J).

3.

Quite los ocho tornillos (K) y ocho arandelas (L). Instale pasamanos (4) y vuelva a instalarocho tornillos (K) y ocho arandelas (L).

4.

Nota: placa de instalación (7) en el exterior de la barandilla. Orientar el hardware con el finde evitar el peligro de roce o el punto de captura de la ropa.

Instale los dos anillos (13), dos clips (8), dos clips (9), y la placa (7) con dos tornillos (10),cuatro arandelas (11), y dos tuercas (12).

5.





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139 Ilustración





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Vista de la zona (P)

Quite los tornillos (12 M) y 12 arandelas (N). Instale pasamanos (5) y vuelva a instalar lostornillos 12 (M) y 12 arandelas (N).

6.

Quite los ocho tornillos (R) y ocho arandelas (S). Instale dos pasamanos (6) y volver ainstalar los ocho tornillos (R) y ocho arandelas (S).

7.

Nota: placa de instalación (7) en el exterior de la barandilla. Orientar el hardware con el finde prevenir un riesgo o punto de pellizco.

Instale los dos anillos (13), dos clips (8), dos clips (9), y la placa (7) con dos tornillos (10),cuatro arandelas (11), y dos tuercas (12).

8.

Install 280-4416 Tube As , that is part of 256-9394 Muffler

Gp

Piezas necesarias para la instalación del tubo de escape



Cuadro 54





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1 1 280-4416 Como tubo





Retire los cuatro tornillos (A), cuatro arandelas (B), y una cubierta (C) de la caja (D).Deseche todas las partes.

1.





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Instale el conjunto del tubo (1) a la caja (D) con cuatro tornillos (2) y cuatro arandelas de

disco duro (3).

2.

Install the 276-4002 Mirror Gp (if equipped)

Piezas necesarias para la instalación de la Gp Espejo




1 1 7X-7468 Espejo convexo

2 1 279-0467 Espejo Gp

3 1 322-7277 Como Espejo



5 1 2G-1133 Ojal

6 1 284-5263 Mazo de cables

7 1 7G-7053 Ojal

Cuadro 55





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De la mano izquierda espejos

Quitar la tuerca (A) y la arandela (B) desde el espejo de montaje (1). Instalar espejoconvexo (1) para el apoyo y volver a instalar la arandela (B) y la tuerca (A).

1.





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Retire los seis tornillos (C) y arandelas de seis duros (D) del ensamblaje del soporte en elriel de la derecha. Instalar espejo de grupo (2) en el soporte y vuelva a instalar seis arandelas

de disco duro (D) y seis tornillos (C).

2.

Instalar ojal (5) para el grupo pasarela. Ruta cable eléctrico desde el espejo (2) por la barandilla y por el ojal en el grupo de paseo. Asegure el cable eléctrico con correas de cable(GG).

3.





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Conectar el cable eléctrico al conector (E). Asegure el arnés con tirantes de cable (GG).4.





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(A) de 30 ± 5 mm (1,2 ± 0,2 cm)

(B) 152 ± 5 mm (6,0 ± 0,2 pulgada)

Con el fin de instalar el grupo de espejo (3), asegúrese de que se cumplan los siguientesrequisitos:

5.

Temperatura de la superficie está entre 21 ° C (70 ° F) y 38 ° C (100 ° F).

La superficie está limpia y seca. Limpiar la superficie con una solución 50:50 dealcohol isopropílico y agua. Limpie la superficie con una toalla de papel hasta que la

superficie esté seca.

Retire la lámina del adhesivo en el espejo de montaje (3). Posición conjunto de espejo (3) ala dimensión (A) y dimensión (B) en el espejo (2).

6.





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Instale el conjunto del espejo (3) al espejo (2). Aplicar una presión mínima de 105 kPa (15 psi) en dos localidades con el fin de asegurar las piernas de espejo de montaje (3).

Asegurarse de que las patas de la nueva espejo totalmente en contacto con la superficie delespejo (2).

7.





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De la mano derecha-espejos

Retire los cuatro tornillos (F) y cuatro arandelas de disco duro (G) del espejo de soportes(H) en el conjunto de barandilla de la derecha. Instale dos conjuntos de espejo (4) al espejo

soportes (H) y volver a instalar cuatro arandelas de disco duro (G), y los cuatro tornillos (F).

8.

Instalar ojal (7) a la plataforma de la derecha. Dirija el arnés (6) por el soporte del espejo.Asegure el arnés con tirantes de cable (GG).

9.





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Red de cableado para el espejo que se encuentra en el grupo de pasarela de la izquierda

Dirija el arnés (6) a través del ojal (7). Asegure el arnés con tirantes de cable (GG). Conecteel cable (6) al arnés (J).

10.

Install the 328-9834 Mirror Group (if equipped)

Piezas necesarias para la instalación de 328-9834 Mirror Group (si está equipado)


1 1 330-5264 Como tubo

2 2 329-7328 Espejos convexos

3 10 7Y-5262 U-Bolts (M10X1.5)


5 20 8T-0389 Contratuerca

6 1 331-3268 Como tubo

7 4 8T-4182 Tornillos (M10X1.5)

Tabla 56





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9 2 334-1004 Conjuntos de tubos

10 2 144-2227 Conjuntos de espejo


12 4 7X-3391 Lavadora duro


14 4 7D-9969 Apoyar

15 11 3S-2093 (1) Correas de cable

16 1 324-6674 (1) Mazo de cables

17 1 2G-1133 (1) Ojal

18 1 298-7329 Como soporte de





23 2 134-0989 Bloques

24 4 8T-4133 Tuerca

25 1 7G-7053 (1) Ojal

(1) Parte del cableado 247-5666 Espejo Gp





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Vista de conjunto de pasarela junto a la cabina

(1) 330-5264 tubo como

(2) 329-7328 espejo convexo

(3) 7Y-5262 U-Bolt

(4) Lavadora 8T-4121 duro

(5) 8T-0389 Tuerca

Use las siguientes partes con el fin de instalar el tubo como (1): seis pernos en U (3), docearandelas de disco duro (4) y doce frutos secos (5).

1.

Instale la parte frontal izquierda espejo convexo (2) en el tubo como (1).2.





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Vista de la esquina frontal derecha del camión

(1) 330-5264 tubo como


(3) 7Y-5262 U-Bolt


(5) 8T-0389 Tuerca





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(6) 331-3268 tubo como

(7) 8T-4182 Perno

(8) 198-4777 Lavadora duro

Use las siguientes partes con el fin de instalar el tubo como (6): cuatro pernos, (3), ochoarandelas de disco duro (4), ocho tuercas (5), cuatro tornillos (7) y cuatro arandelas de disco

duro (8).

3.

Instale delantera derecha espejo convexo (2) en el tubo como (6).4.



(9) 334-1004 tubo como

(10) 144-2227 Espejo Gp

(11) 8T-4137 Perno

(12) 7X-3391 Lavadora duro

(13) 8T-6868 Perno

(14) 7D-9969 de Apoyo





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Utilice cuatro pernos (11) y cuatro arandelas duras (4) con el fin de ensamblar cada espejode la derecha como (10) a uno de los conjuntos de tubos (9).

5.



(9) 334-1004 tubo como

(10) 144-2227 Espejo Gp

(11) 8T-4137 Perno


(13) 8T-6868 Perno

(14) 7D-9969 de Apoyo

Utilice cuatro tornillos (13) y cuatro arandelas de disco duro (12) a fin de asegurar los dosconjuntos de tubo (9) y cuatro soportes (14) para el conjunto de carril.

6.





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(9) 334-1004 tubo como

(10) 144-2227 Espejo Gp

(15) 3S-2093 Cable Correa

(16) 324-6674 haz de cables

(17) 2G-1133 Ojal

Conecte los conectores de cada espejo (10) para el cableado (16). Utilice correas de cable(15) con el fin de asegurar el cable de alimentación a los lugares apropiados de la barandilla.

7.





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(18) 298-7329 Soporte Como

(19) 300-5512 Como Espejo

(20) 8T-4196 Perno

(21) 8T-4195 Perno

(22) 300-0560 retrovisor Gp

(23) 134-0989 Bloque

(24) 8T-4133 Tuerca

Montar espejo superior izquierda como (19) para el soporte como (18). Utilice dos tornillos(21), cuatro arandelas de disco duro (4), y dos tuercas (24).

9.

Ensamble inferior izquierda como espejo (22) para el soporte como (18). Utilice dostornillos (21), cuatro arandelas de disco duro (4), y dos tuercas (24).

10.

Instale el soporte como (18) para el conjunto de carril. Utilice cuatro tornillos (20) y cuatroarandelas de disco duro (4) con el fin de asegurar dos bloques (23) para el soporte como(18).

11.





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(22) 300-0560 retrovisor Gp

(25) 7G-7053 Ojal

Utilice correas de cable (15) con el fin de asegurar el cable de alimentación a los lugares

apropiados de la barandilla.

12.


Instalar ojal (25) en el lado izquierdo de la pasarela. Inserte el cableado para el espejo de laizquierda a través del ojal (25). Conecte el cableado del espejo para el conector adecuado enel arnés de la plataforma como (B) por debajo de la pasarela.

13.





2 1 338-9281 Placa

3 7 5P-1076 Lavadora duro

4 4 3K-6060 Contratuerca

5 1 338-9280 Placa


7 15 8T-4121 Lavadora duro

8 2 8T-4133 Tuerca

Cuadro 57





7/25/2019 ENSAMBLE 777F


9 1 311-7059 Espejo Gp




13 2 134-0989 Bloquear

14 1 8T-7087 Ojal

15 1 5P-7468 Recortar



18 1 129-3180 Contratuerca

19 1 295-8899 Placa

20 2 144-2227 Espejo Gp

21 2 323-5341 Como tubo


23 6 7D-9969 Apoyar




27 6 3S-2093 Cable Correa







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(1) 7X-7468 espejo convexo

(2) 338-9281 Placa

(3) 5P-1076 Lavadora duro

(4) 3K-6060 Tuerca

Asegure la placa (2) a convexo espejo (2) mediante el uso de una arandela duro (3) y unatuerca de seguridad (4). Apriete la tuerca (4) con un par de 25 ± 5 N · m (221 ± 44 lb pulg).

1.


(A) Barandilla de montaje

(2) 338-9281 Placa

(5) 338-9280 Placa

(6) 8T-4198 Perno


(8) 8T-4133 Tuerca

Asegure la placa (2) de barandilla de montaje (A) mediante el uso de una placa (5), dostornillos (6), cuatro arandelas (7), y dos tuercas (8).

2.





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(9) 311-7059 Espejo Gp


(11) 8T-4136 Perno

Secure Mirror Group (9) en el soporte de montaje (10) por medio de tres tornillos (11) y tresarandelas (7).

3.


Vista del conjunto de pasarela de la izquierda





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(12) 8T-4186 Perno

(13) 134-0989 Bloque

Asegure el soporte de montaje (10) a la barandilla de montaje (A) mediante el uso de dos bloques (13), cuatro pernos (12), y cuatro arandelas (7).

4.

Front Mirror Installation





(4) 3K-6060 Tuerca

(14) 8T-7087 Ojal

(15) 7468 5P-Clip

(16) 7469 5P-Clip

(17) 8T-4183 perno

(18) 129-3180 Tuerca

(19) 295-8899 Placa





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Secure espejo convexo (1) a barandilla de montaje (A) por medio de tres arandelas (3), una

tuerca de seguridad (4), una arandela (14), un clip (15), un clip (16), uno de los tornillos(17), una tuerca de seguridad (18), y una placa (19). Apriete la tuerca (4) con un par de 25 ±5 N · m (220 ± 44 lb pulg).

1.




(20) 144-2227 Espejo Gp

(21) 323-5341 tubo como

(22) 8T-4137 Perno

Asegure dos grupos de espejo (20) a dos conjuntos de tubos (21) por medio de cuatrotornillos (22) y cuatro arandelas (7).

1.





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(B) Barandilla de montaje

(21) 323-5341 tubo como

(23) 7D-9969 de Apoyo

(24) 8T-6868 Perno


Asegure dos conjuntos de tubos (21) para barandilla de montaje (B) mediante el uso de seissoportes (23), seis tornillos (24), y seis arandelas (25).

2.






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(20) 144-2227 Espejo Gp

(21) 323-5341 tubo como



Conecte dos mazos de cables (26) a los grupos de espejo (20) y el conjunto de cables delchasis del arnés.

3.

Arneses de cableado seguros (26) en la parte inferior de conjuntos de tubos (21) mediante eluso de seis correas de cable (27).

4.





2 1 338-9281 Placa

3 1 5P-1076 Lavadora duro

4 1 3K-6060 Contratuerca

5 1 338-9280 Placa



8 22 8T-0389 Contratuerca

9 1 311-7059 Espejo Gp




13 2 134-0989 Bloquear

14 2 329-7328 Espejo convexo

15 1 330-5264 Como tubo

16 10 7Y-5262 U-Bolt

17 1 350-7140 Como tubo


Tabla 58





7/25/2019 ENSAMBLE 777F


19 4 198-4777 Lavadora duro

20 2 144-2227 Espejo Gp

21 2 323-5341 Como tubo


23 6 7D-9969 Apoyar




27 6 3S-2093 Cable Correa




(2) 338-9281 Placa


(4) 3K-6060 Tuerca

Asegure la placa (2) a convexo espejo (2) mediante el uso de una arandela duro (3) y unatuerca de seguridad (4). Apriete la tuerca (4) con un par de 25 ± 5 N · m (221 ± 44 lb pulg).

1.





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(2) 338-9281 Placa

(5) 338-9280 Placa

(6) 8T-4198 Perno


(8) 8T-0389 Tuerca

Asegure la placa (2) de barandilla de montaje (A) mediante el uso de una placa (5), dostornillos (6), cuatro arandelas (7), y dos tuercas (8).

2.





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(9) 311-7059 Espejo Gp


(11) 8T-4136 Perno

Secure Mirror Group (9) en el soporte de montaje (10) por medio de tres tornillos (11) y tresarandelas (7).

3.


Vista del conjunto de pasarela de la izquierda




(12) 8T-4186 Perno

(13) 134-0989 Bloque

Asegure el soporte de montaje (10) a la barandilla de montaje (A) mediante el uso de dos bloques (13), cuatro pernos (12), y cuatro arandelas (7).

4.

Installation of the Front Mirrors





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(15) 330-5264 tubo como

Segura espejo convexo (14) para montaje de tubo (15) mediante el uso de los tornillos desujeción que son parte de espejo convexo (14). Apriete los tornillos de apriete a una torsiónde 2,25 ± 0,5 N · m (20 ± 4,4 lb in).

1.



(8) 8T-0389 Tuerca





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(15) 330-5264 tubo como

(16) 7Y-5262 U-Bolt

Conjunto de tubo de seguro (15) de barandilla de montaje (A) mediante el uso de seis

pernos en U (16), 12 arandelas de disco duro (7), y 12 tuercas de seguridad (8).

2.



(17) 350-7140 tubo como

Segura espejo convexo (14) para montaje de tubo (17) mediante el uso de los tornillos de

sujeción que son parte de espejo convexo (14). Apriete los tornillos de apriete a una torsiónde 2,25 ± 0,5 N · m (20 ± 4,4 lb in).

3.





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(8) 8T-0389 Tuerca

(16) 7Y-5262 U-Bolt

(17) 350-7140 tubo como

(18) 8T-4182 Perno

(19) 198-4777 Lavadora duro

Conjunto de tubo de seguro (17) para pasamanos montaje (B), pasamanos montaje (C), yconjunto de soporte (D). Utilice cuatro pernos en U (16), ocho arandelas de disco duro (7),ocho tuercas (8), cuatro pernos (18), y cuatro arandelas de disco duro (19).

4.




(20) 144-2227 Espejo Gp

(21) 323-5341 tubo como

(22) 8T-4137 Perno

Asegure dos grupos de espejo (20) a dos conjuntos de tubos (21) por medio de cuatrotornillos (22) y cuatro arandelas (7).

1.





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(B) Barandilla de montaje

(21) 323-5341 tubo como

(23) 7D-9969 de Apoyo

(24) 8T-6868 Perno


Asegure dos conjuntos de tubos (21) para barandilla de montaje (B) mediante el uso de seissoportes (23), seis tornillos (24), y seis arandelas (25).

2.






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(20) 144-2227 Espejo Gp

(21) 323-5341 tubo como



Conecte dos mazos de cables (26) a los grupos de espejo (20) y el conjunto de cables delchasis del arnés.

3.

Arneses de cableado seguros (26) en la parte inferior de conjuntos de tubos (21) mediante eluso de seis correas de cable (27).

4.

Install the 272-2552 Antenna Mounting Group that is a Partof the 268-7809 Communication Installation Group or the

313-5951 Communication Installation Group (if equipped)

Componentes necesarios para la instalación del Grupo de montaje de la antena


1 1 284-8533 Antena Asamblea

2 1 283-5837 Placa

3 17 3S-2093 Correas de cable


5 3 4P-8134 Clips

6 1 061-8844 Ojal

Tabla 59





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Instalar la placa (2) para el espejo con el hardware para el montaje del espejo.1.

Instalación de antena de montaje (1) a la placa (2).2.

Lleve el cable desde la antena de montaje (1) hacia abajo a través de la pasarela. Use lascorreas de cable (3) para asegurar el cable a la barandilla.

3.

Asegure el cable de la antena de montaje (1) para recortar (4) y los enlaces de soldadura por

debajo de la pasarela con correas de cable (3).

4.

Utilice abrazaderas de cable (3) con el fin de asegurar conjunto de antena (1) a los clips (5).5.

Ruta conjunto de antena (1) a través del agujero en el suelo de la cabina mediante ojal (6).6.

Conectar el conector TNC inverso al puerto más cercano a la producción de luz en la radio.7.

Conecte el conector TNC hasta el puerto restante en la radio.8.

Connect the 270-2660 Hydraulic Tank Gp

Piezas necesarias para la instalación del tanque hidráulico Gp


1 2 1P-3705 Los sellos rectangulares (1)

Tabla 60

(1) Sellos rectangulares están en la bolsa que está unida al tanque de dirección.





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Quite los ocho tornillos (A), ocho arandelas duros (B), ocho tuercas (C), y cuatro medios bridas (D) de la mampara. Retire todas las tapas y de la mampara. Deseche todas las tapas ycubiertas.

1.


Quite los ocho tornillos (E), ocho arandelas de disco duro (F), ocho tuercas (G), y cuatro bridas media (H) de las líneas de dirección. Retire todas las tapas y de las líneas dedirección. Deseche todas las piezas desmontadas.

2.





7/25/2019 ENSAMBLE 777F



Instale el sello rectangular (1) en el tubo de montaje (J). Conjunto de tubo de Segura (J) enel muro con dos bridas de media (D), cuatro pernos (A), cuatro arandelas de disco duro (B),y cuatro tuercas (C) que se retiró en el paso 1.

3.

Instale el sello rectangular (1) en el tubo de montaje (K). Conjunto de tubo de seguros (K)hasta el mamparo con dos bridas de media (D), cuatro pernos (A), cuatro arandelas de discoduro (B), y cuatro tuercas (C) que se retiró en el paso 1.

4.

Instale el tubo de montaje (L) al cierre.5.

Instale el tubo de montaje (M) para el mamparo.6.

Install the 241-2694 Fender Gp

Piezas necesarias para la instalación de la Gp Fender


1 1 273-2344 Como apoyo

2 1 282-3022 Guardia

3 1 275-9226 Guardia

4 1 273-8918 Guardia

5 1 282-9097 Guardia

6 1 256-0639 De goma de la Guardia

Tabla 61

Left Hand Fender Guards


Parte trasera de la pasarela de la izquierda





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Retire los seis tornillos (A) y seis arandelas (B).1.


Parte trasera de la pasarela de la izquierda

Coloque la unidad del soporte (1). Vuelva a instalar seis arandelas (B) y seis pernos (A) quese quitaron en el paso 1. Apriete los pernos con un par de 55 ± 10 N · m (40 ± 7 lb-pie).

2.


Trasera izquierda del cuadro principal

Retire los cuatro tornillos (C), cuatro arandelas (D), y la placa (E).3.





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Del depósito hidráulico

Retire los cuatro tornillos (F), cuatro arandelas (G), y la placa (H).4.


Trasera izquierda del cuadro principal

Posición de guardia (2). Vuelva a instalar la placa (E), cuatro arandelas (D), y los cuatrotornillos (C) que se retiró en el paso 3. Apriete los pernos con un par de 55 ± 10 N · m (40 ±7 lb-pie).

5.





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Del depósito hidráulico

Posición de guardia (2). Vuelva a instalar la placa (H), cuatro arandelas (G), y los pernos decuatro (F) que se retiró en el paso 4. Apriete los pernos con un par de 55 ± 10 N · m (40 ± 7lb-pie).

6.

Right Hand Fender Guards


De la mano derecha cubierta

Retire los dos tornillos (J), dos arandelas de disco duro (K), y la placa de soporte (L).1.





7/25/2019 ENSAMBLE 777F



Quite los tres tornillos (M), tres arandelas de disco duro (N), y la placa de soporte (P).2.

191 Ilustración g01378195

De la mano derecha cubierta

Posición de goma protector (3) y la placa de soporte (L) por detrás de la plataforma. Vuelvaa instalar dos arandelas de disco duro (K) y dos tornillos (J), que se retiró en el paso 1.Apriete los pernos con un par de 55 ± 10 N · m (40 ± 7 lb-pie).

3.





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Posición de caucho protector (1) y la placa de soporte (P) bajo el parachoques. Vuelva ainstalar tres arandelas de disco duro (N) y tres tornillos (M) que fueron retirados en el paso2. Apriete los pernos con un par de 55 ± 10 N · m (40 ± 7 lb-pie).

4.


De la mano derecha escalera

Retire los cuatro tornillos (Q), cuatro arandelas de disco duro (R), y la placa de soporte (S).5.


Retire los dos tornillos (T), dos arandelas de disco duro (U), y la placa de respaldo (V).6.





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Parte inferior de la plataforma de la derecha

Retire los dos tornillos (W), dos arandelas (X), y la placa (Y).7.


De la mano derecha escalera

Posición de caucho protector (4). Vuelva a instalar la placa (S), dos tornillos (Q), y dosarandelas (R) que se retiró en el paso 5. Apriete los pernos con un par de 55 ± 10 N · m (40± 7 lb-pie).

8.





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Posición de caucho protector (4). Vuelva a instalar la placa (V), dos arandelas (U), y dostornillos (T) que se retiró en el paso 6. Apriete los pernos con un par de 55 ± 10 N · m (40 ±7 lb-pie).

9.


Parte inferior de la plataforma de la derecha

Posición de guardia (4) y vuelva a instalar la placa (Y), dos arandelas (X), y dos tornillos

(W) que se retiró en el paso 7. Apriete los pernos con un par de 55 ± 10 N · m (40 ± 7 lb- pie).

10.





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Parte trasera de la mano derecha de la plataforma

Retire los cuatro pernos (Z), cuatro arandelas (HH), y la placa (JJ).11.


Retire los dos tornillos (KK) y dos arandelas (LL).12.





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Parte frontal del tanque de combustible

Retire los cuatro pernos (MM), cuatro arandelas (NN), y la placa (PP).13.


Parte trasera de la mano derecha de la plataforma

Posición de guardia (5) y vuelva a instalar la placa (JJ), cuatro arandelas (HH), y los cuatrotornillos (Z), que se retiró en el paso 11. Posición del conjunto del protector (5) a la

desviación de escape y volver a instalar dos arandelas (LL) y dos tornillos (KK) que fueronretirados en el Paso 12. Apriete los pernos con un par de 55 ± 10 N · m (40 ± 7 lb-pie).

14.


Parte frontal del tanque de combustible

Ponga la protección (5) y vuelva a instalar la placa (PP), cuatro arandelas (NN), y los cuatrotornillos (MM) que se han eliminado en el Paso 13. Apriete los pernos con un par de 55 ±10 N · m (40 ± 7 lb-pie).

15.





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De la mano derecha de plataforma

Retire los seis tornillos (QQ), seis arandelas (RR), y la placa (SS).16.


De la mano derecha de plataforma

Posición de caucho protector (6) y volver a instalar la placa (SS), seis arandelas (RR), y seistornillos (QQ) que fueron retirados en el paso 16. Apriete los pernos con un par de 55 ± 10

N · m (40 ± 7 lb-pie).

17.

Connect the 298-4577 Chassis Harness As and the 251-4169Coaxial Cable Assembly to the Right Side of the Cab





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Retire todas las tapas y tapones de la cabina. Deseche todas las tapas y tapones.1.


Conexiones en el lado derecho de la cabina

Instalar 298-4577 arnés del chasis como (A) a los receptáculos en la parte derecha de lacabina.

2.

Nota: Las aberturas para los enchufes eléctricos que no están marcados. Sin embargo, cadaconector sólo encaja en un enchufe.

Instale 251-4169 cable coaxial (B) en el receptáculo en el lado derecho de la cabina.3.





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Quite el perno (C) y la arandela (D). Posición cable de tierra (E) y volver a instalar laarandela (C) y el perno (C).

4.

Connect the Cable Harnesses for the Caterpillar IntegratedObject Detection System (CIODS) (If Equipped)


Vista de la parte derecha de la cabina





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Quitar seis pernos (A) y las arandelas seis (B) que fije la placa (C) al lado de la cabina.Mantener el hardware.

1.

Retire la placa (C). Conservar la placa (C).2.


Típica vista desde el lado derecho de la cabina

Introduzca los arneses de cable (D) para las cámaras a través del orificio inferior de la placa

(C).

3.





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Vista lateral de la placa (C)

Asegure los arneses de cable (D) a la placa (C) mediante el uso de arandela de montaje (E).Apriete ojal de montaje (E) con un par de 20 ± 2 N · m (175 ± 17,5 lb in).4.

Nota: Ojal de montaje (E) se envía adjunta a los mazos de cable (D).

Conecte los arneses de cable (D) a los mazos de cables que se encuentran en la cabina.Utilice la Tabla 62 para ayudar a conectar los arneses de cable.

5.

Cables de vídeo para mostrar Cables de vídeo a la cámara Cable Color

1 Frente Rojo

2 Derecho Azul

3 Parte trasera Verde

4 Izquierda Amarillo

Tabla 62





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Vista de la parte derecha de la cabina

Asegure la placa (C) al lado de la cabina mediante seis tornillos (A) y seis arandelas (B) quese han eliminado en el Paso 1.

6.

Install the 247-3754 Air Conditioner Lines Gp

Localizar las líneas del calentador y las líneas de aire acondicionado que están sujetados a laestructura.

1.


El lado derecho de la cabina bajo el capó

Retire todas las tapas de las conexiones de las mangueras de aire acondicionado. Desechetodas las tapas.

2.







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Instale la manguera (A) y la manguera (B) para los accesorios de la cabina.3.


El lado derecho del motor



Instalar la manguera del calentador (C) que es desde la salida de la bomba de agua. Instalarla manguera del calentador (D) desde el orificio de entrada en la bomba de agua. Manguera

del calentador Secure (C) y el calentador de la manguera (D) con abrazaderas (E).

4.

Use the 243-5549 Front Wheel Group to Install the Front

Tires

Piezas necesarias para la instalación de las ruedas delanteras

Tabla 63





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1 40 5D-0765 Frutos de cáscara completa

2 40 5D-0764 Lavadoras duros

Asegúrese de que toda la pintura, desperdicios y, grasa de envío azules han sido retirados delos pernos de la rueda y de las superficies de contacto.

1.

Nota: Uso de herramientas (AA) con el fin de eliminar la pintura. El uso de herramientas(BB) con el fin de limpiar las superficies de contacto.

Elevar la parte delantera del camión 1117 mm (44 pulgadas) por encima del suelo. Apoyarel camión con los bloques adecuados o soportes adecuados. Agregar el polipasto unido alcamión hasta que los neumáticos están instalados.

2.



Utilizar un controlador neumático con el fin de instalar un neumático y la llanta de la ruedaen cada lado del camión.

3.





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El uso de herramientas (AA) con el fin de eliminar la pintura y limpiar las superficies demontaje. Asegurarse de que toda la pintura, grasa de envío, y las rebabas se han eliminadode los pernos de la rueda y las superficies de contacto.

4.

Instalar llanta (A) con 20 arandelas duro (2) y 20 tuercas completo (1).5.

Si se aplica 4C-5592 compuesto antiadherente a las roscas de las tuercas completos,apriete las tuercas con un par completo de 1210 ± 100 N · m (890 ± 75 lb-pie).

a.

Si el anti-adherente compuesto no se usa, apriete las tuercas con un par completo de2100 ± 200 N · m (1550 ± 150 lb-pie).

b.

Nota: Deje el carro en los stands a fin de alinear las ruedas delanteras y cargar loscilindros de suspensión.

El uso de herramientas (DD) con el fin de inflar los neumáticos delanteros. Consulte laInstrucción Especial, SMHS7867, "El uso de 6V-4040 Grupo de neumáticos con nitrógeno

inflación ".

6.

Repita los pasos del 1 al 6 para la otra rueda delantera y la llanta.7.

Use the 243-5544 Rear Wheel Gp to Install the Rear Wheels

Piezas necesarias para la instalación de las ruedas traseras



1 2 272-7949 Tire de la válvula Gp

2 2 6G-8019 Tire de la válvula Gp


3 80 5D-0765 Frutos de cáscara completa

Tabla 64





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4 80 5D-0764 Lavadoras duros


1.

Elevar la parte trasera del camión mm 1118 (44 pulgadas). Apoyar el camión con los bloques adecuados o soportes adecuados. Agregar el polipasto unido al camión hasta que losneumáticos están instalados.

2.

Inner Rear Tires

Nota: Remueva la pintura y el uso de herramientas (BB) con el fin de limpiar las superficies decontacto.


Marque los mandos finales con el fin de colocar la cubierta de extensión para el vástago de

la válvula. Marque el neumático y la llanta interna con el fin de localizar el vástago de laválvula.

1.

Retire los dos pernos (A), dos arandelas de disco duro (B), y la placa (C).2.





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El uso de un controlador neumático con el fin de instalar un neumático y la llanta interna enel camión.

3.

Alinear las marcas con el fin de instalar el neumático y la llanta trasera interior en elcamión.

4.


El uso de herramientas (AA) con el fin de eliminar la pintura y limpiar las superficies demontaje. Asegurarse de que toda la pintura, grasa de envío, y las rebabas se han eliminado

de los pernos de la rueda y las superficies de contacto.

5.

Utilice arandelas de 20 duros (4) y 20 tuercas completos (3) con el fin de asegurar la ruedatrasera y el borde interior de la unidad final.

6.

Si se aplica 4C-5592 compuesto antiadherente a las roscas de las tuercas completos,apriete las tuercas con un par completo de 1210 ± 100 N · m (890 ± 75 lb-pie).

a.

Si el anti-adherente compuesto no se usa, apriete las tuercas con un par completo de2100 ± 200 N · m (1550 ± 150 lb-pie).

b.

Nota: El anillo debe estar mirando hacia afuera.





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Instale la válvula del neumático (1) en la llanta trasera interior. Vuelva a instalar la placa

(C), dos arandelas de disco duro (B), y dos tornillos (A) sobre la válvula del neumático (1).Apriete los dos pernos (A) a 100 ± 20 N · m (75 ± 15 lbs).

7.

El uso de herramientas (DD) con el fin de inflar el neumático trasero interno. Consulte la

Instrucción Especial, SMHS7867, "El uso de 6V-4040 Grupo de neumáticos con nitrógenoinflación ".

8.

Repita los pasos del 1 al 8 para la rueda trasera interior de otra.9.

Outer Rear Tires

Nota: Uso de herramientas (AA) con el fin de eliminar la pintura. El uso de herramientas (BB)con el fin de limpiar las superficies de contacto.


Marque el neumático y la llanta externa con el fin de localizar el vástago de la válvula.1.

Instale una válvula de neumático (2) en el borde trasero exterior.2.





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El uso de un controlador neumático con el fin de instalar un neumático y la llanta externa enel camión.

3.


Alinear las marcas con el fin de instalar el neumático y la llanta trasera interior en elcamión.

4.


5.

Utilice arandelas de 20 duros (4) y 20 tuercas completos (3) para asegurar que el neumáticotrasero exterior y el borde de la asamblea de la rueda trasera.

6.

Si se aplica 4C-5592 compuesto antiadherente a las roscas de las tuercas completos,apriete las tuercas con un par completo de 1210 ± 100 N · m (890 ± 75 lb-pie).a.





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Si el anti-adherente compuesto no se usa, apriete las tuercas con un par completo de

2100 ± 200 N · m (1550 ± 150 lb-pie).

b.

Nota: El anillo debe estar mirando hacia el interior. Inward anillos enfrenta hará quelos bordes de uno frente a otro entre los neumáticos.

El uso de herramientas (DD) con el fin de inflar el neumático trasero exterior. Consulte la

Instrucción Especial, SMHS7867, "El uso de 6V-4040 Grupo de neumáticos con nitrógenoinflación ".

7.

Repita los pasos del 1 al 7 para el neumático trasero exterior y otra llanta.8.

Front Wheel Alignment

Nota: Las ruedas delanteras deben estar fuera de la tierra. Asegúrese de que los cilindros de

suspensión estén completamente extendidos.

AVISO

Los tirantes deben ser apretados con un par de 285 N · m (210 lb-pie).Los tirantes deben ser apretados, independientemente de si el ajuste se

ha hecho.

Mover las ruedas hasta que las ruedas apunten hacia delante.1.


Mida la distancia (D) entre los neumáticos delanteros.2.





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Marque la ubicación (D) en cada rueda delantera. Rote las llantas hasta que las marcas son

de 180 grados desde el punto (D).

3.

Mida la distancia (E) entre las marcas de los neumáticos.4.

Reste la distancia (E) de la distancia (D). Este valor será 64,3 mm (2,53 pulgadas) cuando eldedo de salida es correcta.

5.

Si es necesario, ajustar los tirantes con el fin de establecer el toe-out. Afloje las abrazaderas

(F) en el lado izquierdo. Afloje las abrazaderas (G) en el lado derecho. Gire cada tirante porla misma cantidad. Asegúrese de que los tirantes son de la misma longitud.

6.

Cuando el dedo del pie de espera se establece, apriete las abrazaderas (C) y las abrazaderas(G) con un par de 285 N · m (210 lb-pie).

7.

Nota: Asegúrese de que existe una brecha de al menos 3,18 mm (0,125 pulgadas) antes de

apretar las pinzas de los tirantes.

Bajar la parte delantera del camión al suelo.8.

Use the 308-0618 Truck Body Mounting Gp to Install theTruck Body

Install the Truck Body

Piezas necesarias para la instalación del Acuerdo de Consejo de camiones ( 308-0618Truck Body montaje Gp)


1 2 8W-8454 Como Pin

2 1 8W-2897 (1) Arandela de empuje

3 2 9D-3432 (1) Las arandelas de empuje

4 2 8W-8456 Placas



7 2 3B-8489 Engrasadores

8 2 322-5067 Lodo de la Guardia

9 2 322-5068 Placa

10 2 331-5956 Placa

11 20 9B-7237 Atornillar

12 20 6V-8801 Tuerca


Tabla 65





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15 8 8T-4244 Tuerca

(1) Utilice la arandela de empuje 8W-2897 cuando la arandela de empuje 9D-3432 no se ajusta.

Quitar la pintura de las superficies de acoplamiento de la carrocería del camión y elarmazón. Retire todos los cáncamos y terminales de antes de la instalación.

1.


Vista de la parte inferior de la carrocería del camión

(1) 8W-8454 Pin Como

Insertar un pasador (1) en el pivote pasador exterior llevó a cada lado de la carrocería delcamión.

2.





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Ilustración 229

Utilizar un dispositivo de elevación adecuado con el fin de posicionar el cuerpo del vehículo

sobre el bastidor del camión.

3.

Alinear los orificios eje de giro del cuerpo del vehículo y los taladros eje de giro del bastidor del camión.

4.


En cada lado de la máquina, inserte una arandela de empuje (3) entre el oído externo delcuerpo del vehículo y el bastidor del camión.

5.

Nota: Si la arandela de empuje (3) no se ajusta, inserte una arandela de empuje (2).

Arandela de empuje (2) es de 2,0 mm (0,079 pulgadas) más delgada que la arandela deempuje (3).





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Pasadores de arrastre (1) a través del pasador de pivote aburre de la carrocería del camión ydel bastidor del camión.

6.

Utilice los componentes que siguen con el fin de asegurar los pasadores (1) en el lugar: dos placas (4), cuatro pernos (5) y cuatro arandelas de disco duro (6).

7.

Instale dos puntos de engrase (7).8.






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(8) 322-5067 guardabarros

(9) 322-5068 Placa

(10) 331-5956 Placa

(11) 9B-7237 Perno

(12) 6V-8801 Tuerca

Asegure dos guardabarros (8) a dos placas (9) y dos placas (10) mediante el uso de pernosde 20 (11) y 20 arandelas (12).

9.


Vista de la parte inferior del cuerpo

(9) 322-5068 Placa

(13) 8T-4183 perno

(14) 8T-4223 Lavadora duro

(15) 8T-4244 Tuerca





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Fijar dos placas (9) a la parte inferior del cuerpo mediante el uso de ocho pernos (13), ocho

arandelas duros (14), y ocho tuercas (15).

10.

Nota: Apriete los ocho tornillos a una torsión de 100 ± 20 N · m (74 ± 15 lb-pie).

Use the 9D-2725 Hoist Cylinder and Mounting Gp to Install

the Hoist Cylinders

Piezas necesarias para la instalación de los cilindros de elevación de la


1 2 5T-9266 Como Pin

2 4 9D-2316 Espaciadores

3 2 5T-5528 Placas



Tabla 66

Retire las tapas protectoras de los agujeros de los tornillos en el cuerpo cerca de los orificiosde pasador. Quitar la pintura de las superficies de contacto alrededor de los taladros clavijasen el cuerpo. Quitar la pintura de las superficies de contacto de los cilindros del polipasto.

1.

Antes de quitar los soportes de transporte de los cilindros de montacargas, utilice una

cadena y un extractor de la palanca a fin de estabilizar los cilindros de elevación.

2.

Use un dispositivo de elevación adecuado con el fin de alinear los orificios de pasador de lacaja del camión y los cilindros de elevación.

3.





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Colocar un separador (2) en cada lado del polipasto cojinete cilindro. En cada lado de la

máquina, insertar un perno (1) a través del cuerpo del vehículo a través del cojinete y polipasto cilindro.

4.

Nota: Antes de instalar Pins (1), se aplican herramientas (EE) a los pines.

Utilizar los componentes que siguen con el fin de asegurar cada pasador (1): una placa (3),dos pernos (4) y dos arandelas duros (5).

5.

Use the 308-0618 Truck Body Mounting Gp to Install theTruck Body

Install the Body Retaining Pins

Piezas necesarias para la instalación de la clavija de retención


1 4 5D-3887 Varillas

2 4 6F-8499 Springs,

3 4 054-3788 Orificios

4 8 3B-4615 Chavetas

5 2 270-7034 Como Pin

Cuadro 67


Utilizar los componentes que siguen con el fin de instalar las barras (1) en el lado derecho yel lado izquierdo de la carrocería del camión: muelles (2), los orificios (3) y ocho chavetas

(4).

1.

Instalar dos pasadores (5) a la carrocería del camión. Bloquear las espigas por las barras (1).2.





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Install the Rock Ejectors

Piezas necesarias para la instalación de los eyectores de Rock ( 308-0618 Truck Bodymontaje Gp)


1 2 253-7490 Eyectores

2 2 6G-7773 Pines

3 4 3B-4647 Chavetas

4 16 1D-0503 Arandelas

Tabla 68



Utilice los componentes que siguen con el fin de instalar una roca de expulsión (1) en cada

conjunto de la placa: un pasador (2), dos chavetas (3) y ocho arandelas (4).

1.

Nota: arandelas uso (4) con el fin de centro eyectores Rock (1) entre las dos ruedas traserasen cada lado de la máquina.





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Install the Visual Body Down Indicator

Piezas necesarias para la instalación del Consejo de Visual Indicador de Down


1 1113-1218

326-3097 (1)

Como bafle bafle Como

2 2 031-9831 Tornillos

Tabla 69

(1) Parte de la 341-5471 retrovisor médico de cabecera o al 328-9834 retrovisor Gp

Nota: la máquina equipada con el 341-5471 retrovisor médico de cabecera o al 328-9834retrovisor Gp debe utilizar el 326-3097 Como deflector. La 326-3097 deflector Como se usa en loscuerpos de carbón. Las máquinas sin cuerpo de carbón debe utilizar el 113-1218 deflector como.


Vista típica

(1) 113-1218 o 326-3097 Como Deflector Deflector Como

(2) 031-9831 Perno

Utilice dos tornillos (2) con el fin de instalar el conjunto del deflector (1) en la copa.1.

Install the Pad Assembly (Dump Body)

Las piezas requeridas para la instalación de la Asamblea Pad (Caja volcadora)Cuadro 70





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1 4 229-6177 Como Pad

2 20 106-8227 Cuñas



AVISO

Un nivel inadecuado de aceite hidráulico puede resultar en daños a lamáquina.

Levante y asegurar el cuerpo volcado.1.


(A) ensamblaje de la almohadilla

(B) Placa





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Retire los dos conjuntos de pastillas (A) y dos placas (B) de los dos zapatos en el marco.Conserve las asambleas almohadilla (A), placas (B), y el hardware.

2.

Nota: las asambleas Pad (A) y las placas (B) se envían unido a los dos zapatos.


(1) 229-6177 Como Pad

(2) 106-8227 Cuña

Pila de una plataforma de montaje (1) y una cuña (2) en cada ubicación de montaje de laalmohadilla en los largueros del bastidor.

3.





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(1) 229-6177 Como Pad

(2) 106-8227 Cuña

Retire los dispositivos de seguridad y baje lentamente el cuerpo volcado hasta que el cuerpo

toca la almohadilla de las asambleas y las calzas.

4.





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Agregue separadores (2) de uno en uno, hasta que no queden espacios entre conjuntos de

pastillas (1) y el cuerpo de volcado.

5.

Levante el cuerpo de volcado. Asegure el cuerpo del vertedero.6.

Ilustración 242

(1) 229-6177 Como Pad

(2) 106-8227 Cuña

(3) 5P-2566 Perno


Asambleas Secure pad (1) y cuñas (2) en el cuerpo volcado mediante 20 pernos (3) y 20arandelas (4). Apriete los pernos (3) con un par de 100 ± 20 N · m (74 ± 15 lb-pie).

7.





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(A) ensamblaje de la almohadilla

(B) Placa

Volver dos conjuntos de pastillas (A) y las placas de dos (B) a los zapatos.8.

Retire los dispositivos de seguridad y baje lentamente el cuerpo volcado hasta que lasasambleas almohadilla en contacto con los largueros del bastidor.

9.

Agregue separadores (2) de uno en uno, hasta que no queden espacios entre conjuntos de pastillas (A) y el cuerpo de volcado.

10.

Nota: Cada cuña (2) es de 2 mm (0,079 pulgadas) de espesor.

Levante el cuerpo de volcado. Asegure el cuerpo del vertedero.11.

Añadir una cuña adicional (2) debajo de cada conjunto de almohadilla (A).12.

Asambleas Secure almohadilla (A) a los zapatos con el hardware que se ha quitado en el

paso 2. Apriete los tornillos a una torsión de 100 ± 20 N · m (74 ± 15 lb-pie).

13.

Retire los dispositivos de seguridad y bajar el cuerpo con el fin de asegurarse de que todoslos conjuntos de pastillas montadas incluso ponerse en contacto con el marco. Agregueseparadores (4), según sea necesario.

14.





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Adjust the Position Sensor for the Dump Body (Lever Switch)

Levante el cuerpo volcado e instalar el cuerpo de los pasadores de retención con el fin deasegurar el cuerpo volcado en la posición UP.

1.


(A) 45 grados

(1) cuerpo hacia arriba o abajo cambia

(2) Palanca

(3) Placa

Ajuste la palanca (2) inicialmente a un ángulo de 45 grados desde la horizontal.2.

Nota: Asegúrese de que la placa (3) se ajusta todo el camino hacia la parte trasera del

camión.

Retire el cuerpo de los pasadores de retención y baje el cuerpo volcado en la posicióninferior.

3.

Con el fin de ajustar la posición desaire del cuerpo volcado a aproximadamente 200 a 300

mm (8 a 12 pulgadas) entre la parte frontal de las pastillas del cuerpo y el larguero del bastidor, el ciclo del cuerpo de volcado y observar la posición desaire. Si el cuerpo llega a la posición de descarga SNUB demasiado pronto, mueva la palanca (2) la baja en un escalón.Si el cuerpo llega a la posición de descarga SNUB demasiado tarde, mueva la palanca (2)hacia arriba por una muesca.

4.

Repita el paso 4 hasta la posición deseada SNUB del cuerpo volcado se obtiene.5.





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Adjust the Position Sensor for the Dump Body (Magnetic

Switch)

Levante el cuerpo volcado e instalar el cuerpo de los pasadores de retención con el fin de

asegurar el cuerpo volcado en la posición UP.

1.


(1) Cuerpo del interruptor hacia arriba

(2) Imán

(3) Placa





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(A) 10 mm (0,394 pulgadas)

(1) Cuerpo del interruptor hacia arriba

(2) Imán

Ajuste la placa (3) por lo que la brecha entre el interruptor (1) y el imán (2) es de 10 mm(0,394 pulgadas).

2.

Retire el cuerpo de los pasadores de retención y baje el cuerpo volcado en la posicióninferior.

3.

Con el fin de ajustar la posición desaire del cuerpo volcado a aproximadamente 200 a 300mm (8 a 12 pulgadas) entre la parte frontal de las pastillas del cuerpo y el larguero del

bastidor, el ciclo del cuerpo de volcado y observar la posición desaire. Si el cuerpo llega a la posición de descarga SNUB demasiado pronto, mover imán (2) hacia arriba. Si el cuerpollega a la posición de descarga SNUB demasiado tarde, movimiento del imán (2) haciaabajo.

4.

Repita el paso 4 hasta la posición deseada SNUB del cuerpo volcado se obtiene.5.

Install the 237-4151 Central Lubrication Lines Gp (If Equipped)

Piezas necesarias para la instalación de la Central de Lubricación Grupo de Líneas




1 12 5P-9085 Clips

2 10 5M-3062 Tornillos




Tabla 71





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Dentro del marco en la parte trasera

Retire los dos pernos (A) y dos arandelas (B). Gire bloque de grasa (C) en el marco.1.


Vista trasera

Posición bloque grasa (C) a los patrones de montaje en la caja del eje trasero. Vuelva ainstalar dos arandelas (B) y dos pernos (A).

2.





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Ilustración 249

Vista trasera

Retire los dos tornillos (E), dos arandelas (F) y dos clips (G) de la estructura.3.

Coloque dos clips (G) a la manguera (H) y la manguera (J). Coloque dos clips (G), dosarandelas (F) y dos tornillos (E) en el bastidor trasero. Consulte la ilustración 247.

4.

Ruta dos mangueras (J) a los pines del cuerpo de pivote. Conecte las mangueras (J) a los puntos de engrase.

5.

Ruta dos mangueras (H) para el extremo del vástago de los cilindros de suspensión. Conectelas mangueras (H) a los puntos de engrase.

6.

Ruta dos mangueras (K) en el extremo de la cabeza de los cilindros de suspensión. Conectelas mangueras (K) para los puntos de engrase.

7.





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Coloque dos clips (1) a dos tubos (K). Coloque dos clips (1), dos arandelas de disco duro (3)

y dos (2) pernos de la carcasa del eje trasero.

8.

Ilustración 250

Vista lateral derecha

Las mangueras de ruta (D) a la cabeza de los extremos de los cilindros de elevación.Conecte las mangueras (D) a los puntos de engrase. Consulte la ilustración 247 y 250ilustraciones.

9.

Por el lado derecho, una posición pinza (1) a la manguera (D). Instalar un clip de (1), unaarandela duro (5) y un perno (4) al marco. Consulte la ilustración 250.

10.

Para el lado derecho, la posición cuatro clips (1) a la manguera (D). Instale los cuatro clips(1), cuatro arandelas de disco duro (3) y cuatro tornillos (2) a la caja de volteo. Consulte lailustración 250.

11.

Repetir el paso 10 y el paso 11 para el lado izquierdo.12.

Utilice correas de cable (GG) para fijar la manguera (H) a la manguera (D). Consulte lailustración 247.

13.





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Manguera de Ruta (L) a la barra hacia el interior influencia. Conecte la manguera (L) al

puerto de grasa.

14.


Ruta de la manguera (M) para la barra estabilizadora motor fuera de borda. Conectar la

manguera (M) para el puerto de grasa.

15.

Install the 273-1141 Automatic Lubrication Gp (If Equipped)

Piezas necesarias para la instalación de la lubricación automática Gp


Tabla 72





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2 10 5M-3062 Bolts


4 12 5P-9085 Clips

5 2 8T-4137 Bolts


Illustration 253

Rear view





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Remove two bolts (D), two washers (E) and two clips (F) from the frame.1.

Position two clips (F) to hoses (A), hoses (B) and hoses (C). Install two clips (F), twowashers (E) and two bolts (D) to the rear frame. Refer to Illustration 252.

2.

Route two hoses (B) to the body pivot pins. Connect the hoses (B) to the grease ports.3.

Route two hoses (C) to the rod end of the suspension cylinders. Connect the hoses (C) to thegrease ports.

4.

Route two hoses (J) to the head end of the suspension cylinders. Connect the hoses (J) to thegrease ports.

5.

Position two clips (4) to two hoses (J). Install two clips (4), two hard washers (3) and two

bolts (2) to the rear axle housing.

6.

Route hose (G) to the inboard sway bar. Connect hose (G) to the grease port.7.


Route hose (H) to the outboard sway bar. Connect hose (H) to the grease port.8.





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Illustration 255

Right side view

Route hoses (A) to the head ends of the hoist cylinders. Connect hoses (A) to the grease ports. Refer to Illustration 252 and Illustration 255.

9.

For the right-hand side, position one clip (4) to hose (A). Install one clip (4), one hardwasher (6) and one bolt (5) to the frame. Refer to Illustration 255.

10.

For the right-hand side, position four clips (4) to hose (A). Install four clips (4), four hardwashers (3) and four bolts (2) to the dump body. Refer to Illustration 255.

11.


Use cable straps (1) to secure hose (C) to hose (A). Refer to Illustration 252.13.





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Remove plugs from the end of tube assembly and the hose assembly. Connect the tubeassembly (L) with O-ring Seal (M) to the hose assembly (K). The hose assembly (K) isattached to the fuel tank. Tighten the hose assembly to 65 to 72 N·m (48 to 53 lb ft). Refer

to Illustration 256.

14.

Note: If a machine is shipped from the factory with the 273-1141 Automatic Lubrication Gp , the278-7067 Hose As (K) that is used in the automatic lubrication group is assembled to the fueltank. If the machine is equipped with 273-1141 Automatic Lubrication Gp only, leave the hoseassembly in the same location. If the machine is equipped with both the 273-1141 Automatic

Lubrication Gp and the 258-0673 Service Center Gp , install the hose assembly (K) and thecoupler that is connected to the hose assembly to the 258-0673 Service Center Gp by using theunused hole in the service center box.

Install Lubrication Hose to the 258-0673 Service Center Gp (If Equipped)

Use the following procedure to install the hose assembly (K) to the 258-0673 Service Center Gp :






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Detail N

Remove one bolt (V), one hard washer (U), one clip (P), one clip (R), and grommet (T) thatare used to attach the hose assembly (K) to the fuel tank. Discard the parts.

1.

Disconnect the hose assembly (K) from the adapter (X). Remove the O-ring seal (M) fromthe adapter. Remove the bulkhead nut (W). Disassemble the coupler (S) from the adapter(X). Retain the parts.

2.


Service center





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Assemble the box (AA) to the fuel tank by using four bolts (Y) and four hard washers (Z).

Tighten bolts to 47 ± 9 N·m (35 ± 7 lb ft).

3.

Insert the adapter (X) through the unused hole (BB) in the box (AA). Assemble the adapterto the box with the bulkhead nut (W). Assemble the coupler (S) to the adapter (X) .

4.

If 5P-3413 Pipe Sealant is used, tighten the coupler to 45 to 50 N·m (33 to 37 lb ft). Ifsealant is not used, tighten the coupler to 60 to 66 N·m (44 to 48 lb ft).

5.

Install O-ring seal (M) to the adapter (X). Connect the hose assembly (K) to the adapter.Tighten the hose assembly to 65 to 72 N·m (48 to 53 lb ft).

6.

Install the 289-2182 Film Gp



1 1 289-8453 Film

2 1 289-8455 Film

3 1 289-8454 Film

Table 73

The following conditions must be met in order to install the films.

Surface temperature is between 15 °C (60 °F) and 27 °C (80 °F).•

The painted surface is fully dried.•

The surface is clean and dry.•





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Preparation for Installing the Films

Clean the surfaces with a 50:50 solution of isopropyl alcohol and water.1.

Use a cleaning agent in order to clean any oily surface or any surface that is covered with

grease.

2.

Note: Use water in order to remove the cleaning agent.

Wipe the surface with a clean paper towel until the surface is dry.3.

Procedure for Installing the Films

Apply an application fluid.1.

Note: Use only a pure soap and clean water that is mixed in a low concentration. Therecommended mixture for the solution is 1 to 3 drops of Ivory Soap per 1 L (1 qt).Additional information about Ivory Soap is available at the following address.

The Procter & Gamble Company

1 Proctor & Gamble PlazaCincinnati, OH 45201USA

Expose the adhesive by removing the liner from the back of the film. Align that end of the

film and position and lightly press onto the sprayed surface.

2.

Remove the rest of the liner paper and press the other end into position.3.

Use a squeegee in order to apply pressure to the film. By using firm, overlapping strokeswith the squeegee, start from the middle and work toward the edges of the film.

4.

Note: The adhesive needs between three and five minutes to set up.

Peel back the backing of the film, starting in a top corner and pulling at a 45 degree angle.5.

Continue to apply the squeegee to the film after the backing has been removed. Make surethat the film is securely applied to the proper location on the truck.

6.

Wipe the film and the surrounding area in order to remove the excess application fluid.7.

Locations for the Installation of the Films





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Install film (1) on the front of the canopy.1.

Note: Center the films in the available space.

Install film (2) on the right side of the truck body.2.


Install film (3) on the left side of the truck body.3.






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Purge the Air from the Hydraulic Brake System

In order to purge the brake system of air, refer to the Testing and Adjusting, RENR8315, " 777FOff-Highway Truck Hydraulic System Testing and Adjusting".

Suspension Cylinder Charging ProcedureRefer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-HighwayTrucks" for any information concerning suspension cylinders. The Special Instruction,REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" Service Manual

includes tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging(oil and nitrogen), that is used on the 777F off-highway truck suspension cylinders.

Brake Accumulator Test and Charge

Refer to Systems Operation, Testing and Adjusting, RENR8315, "Brake Accumulator - Test andCharge" for any information concerning brake accumulator charge. The Systems Operation,Testing and Adjusting includes Tooling, pressures, and the correct procedures for testing andcharging (oil and nitrogen), that are used on 777F Off-Highway Truck brake accumulators.

Installation of the Caterpillar Integrated Object Detection

System (CIODS)

The information that is contained in this Special Instruction guides the user in the installation ofthe Caterpillar Integrated Object Detection System for Off-Highway Trucks.

The following Special Instruction will cover the installation of the following arrangements:

365-8470 Monitor Display Ar •

365-8471 Monitor Display Ar•

365-8472 Object Detection Installation Ar•

Do not perform any of the procedures until you have read the information in this publication.

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures" for additional welding

instructions.





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Illustration 263

View of the object detection locations


Safety Information

Do not perform any procedure in this Special Instruction until you have read this SpecialInstruction and you understand this information. Use only proper tools and observe all precautionsthat pertain to the use of those tools. Failure to follow these procedures can result in personalinjury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused byfailure to observe basic safety rules or precautions. An accident can often be avoided byrecognizing potentially hazardous situations before an accident occurs.





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A person must be alert to potential hazards. This person should also have the necessary training,

skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If thesehazard warnings are not heeded, bodily injury or death could occur to you or to other persons.Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not allinclusive. Ensure that any tool, procedure, work method, or operating technique you use that is notrecommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by theoperation, lubrication, maintenance, or repair procedures used.

Prepare the Machine

Raise the truck body and install the body retaining pin for the truck body.1.

Set the parking brake.2.

Turn the key start switch and the disconnect switch to the OFF position.3.

Required Parts



4 347-1668 Camera Gp

3 305-3748 Plate As

8 n/a (1) Bolt

8 n/a (1) Washer

1 271-6768 Plate

1 305-3747 Plate As

6 8T-6466 Bolt


6 8T-4133 Nut


Table 74




Table 75





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4 365-8490 Object Detection Box Gp

4 348-8760 Bracket

32 8T-4137 Bolt

32 7X-7729 Washer

4 347-7917 Object Detection Box Gp (RADAR)

4 348-8759 Bracket




4 7X-0818 Bolt




4 8T-4956 Bolt


2 8T-4195 Bolt


3 8T-5005 Bolt


3 8T-4133 Nut

1 067-2551 Clip

Table 76




6 (1) 8T-4194 Bolt

6 (1) 198-4778 Hard Washer

6(1)

8T-4223 Hard Washer

6 (1) 8T-4244 Nut

Table 77





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4 7X-0818 Bolt



4 8T-4195 Bolt



4 8T-4195 Bolt

1 8T-4136 Bolt

1 8M-2773 Clip





4 7X-0818 Bolt




10 8T-4195 Bolt


1 8T-4136 Bolt

1 8M-2773 Clip

Table 78




4 7X-0818 Bolt



Table 79





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2 8T-4195 Bolt


2 8T-4136 Bolt

1 4P-8134 Clip


Assemble the Camera Groups



1 4 347-1668 Camera Gp

2 3 305-3748 Plate As

3 8 n/a (1) Bolt

4 8 n/a (1) Washer

5 1 271-6768 Plate

6 1 305-3747 Plate As

7 6 8T-6466 Bolt


9 6 8T-4133 Nut

10 1 365-8501 Bracket As

Table 80


Note: An arrow is located at the top of the camera lens which indicates the up direction of thecamera. The camera that is going to be installed on the rear of the truck needs to have this arrowinstalled facing up.





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(1) 347-1668 Camera Gp

(2) 305-3748 Plate As

(A) Camera harness

Route camera harness (A) and the connector through the hole that is in plate assembly (2).Place the grommet that is provided on camera harness (A) through the hole. Repeat this

procedure for all the cameras.

1.






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(1) 347-1668 Camera Gp

(2) 305-3748 Plate As

(3) Bolt

(4) Washer

Use six bolts (3) and six washers (4) to secure three camera groups (1) to three plateassemblies (2) .

2.

Note: The three camera groups in Step 2 are for the front and the side camera locations.


Typical view of the rear camera

(1) 347-1668 Camera Gp

(3) Bolt

(4) Washer

(5) 271-6768 Plate

Use two bolts (3) and two washers (4) to secure one camera group (1) to one plate (5) .3.





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(2) 305-3748 Plate As

(6) 305-3747 Plate As

(7) 8T-6466 Bolts


(9) 8T-4133 Nuts

For the left-hand side camera, mount plate assembly (2) to plate assembly (6) by using three bolts (7), six washers (8), and three nuts (9) .

4.





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(2) 305-3748 Plate As

(7) 8T-6466 Bolts


(9) 8T-4133 Nuts

(10) 365-8501 Bracket As

Secure one plate assembly (2) to bracket assembly (10) by using three bolts (7), six washers(8), and three nuts (9) .

5.

Secure the Object Detection Box Groups to the Brackets

Note: The following section only applies to machines with the 365-8472 .



1 4 365-8490 Object Detection Box Gp

2 4 348-8760 Bracket

3 32 8T-4137 Bolt

4 32 7X-7729 Washer

5 4 347-7917 Object Detection Box Gp (RADAR)

6 4 348-8759 Bracket

Table 81





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Note: Mounting location is important. Each radar box must be mounted in the designated location

that is labeled on the harness connector for each box.

The sensors for the Caterpillar Object Detection System are assembled before shipping. Use thefollowing procedure in order to assemble the mounting brackets to the radar boxes.

Note: Inspect the grommet on the bottom of the radar box to ensure that the sealant has not been

disturbed during shipment. If the seal is not intact, use silicone sealant in order to seal thegrommet.


View of the front and rear object detection box group


(2) 359-7444 Bracket As

(3) 6V-7357 Bolt



1.





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View of the side object detection box group


(3) 6V-7357 Bolt


(5) 364-5738 Bracket As


2.

Installation of the Front Hardware



1 1 360-3915 Bracket As

2 4 7X-0818 Bolt



5 1 361-6088 Bracket As

6 4 8T-4956 Bolt


8 2 8T-4195 Bolt

Table 82





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10 3 8T-5005 Bolt


12 3 8T-4133 Nut

13 1 067-2551 Clip


Each radar box has a specific mounting location. The radar sensors have individual part numberslocated on the harnesses at the bottom of the box.

Installation of the Box Group for the Object Detection (Front)


(A) 359-7444 Bracket As

(1) 360-3915 Bracket As

(2) 7X-0818 Bolt



Secure bracket assembly (A) to bracket assembly (1) by using four bolts (2), four washers


1.





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(5) 361-6088 Bracket As

(6) 8T-4956 Bolt


Secure bracket assembly (5) to the front of the bumper assembly by using four bolts (6) andfour washers (7) .

2.





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(1) 360-3915 Bracket As

(5) 361-6088 Bracket As

(8) 8T-4195 Bolt



3.





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(B) Harness assembly

Connect harness assembly (B) to the sensor that is inside the object detection box group.4.

Installation of Camera Group (Front)





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View of the top of the cowling group

(C) Camera group


(10) 8T-5005 Bolt


(12) 8T-4133 Nut

(13) 067-2551 Clip

Secure the front camera that was previously assembled to the front of the cowling group byusing three bolts (10), six washers (9), three washers (11), and three nuts (12) .

1.

Secure the harness assembly for the camera by using one clip (13), and existing bolt (10) .2.

Connect existing cable assembly to the harness assembly for the camera assembly.3.

Installation of the Left Side Hardware


Table 83





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1 1 361-4972 Bracket As

2 6 (1) 8T-4194 Bolt

3 6 (1) 198-4778 Hard Washer

4 6 (1) 8T-4223 Hard Washer

5 6 (1) 8T-4244 Nut

6 1 359-7850 Bracket As

7 4 7X-0818 Bolt



10 4 8T-4195 Bolt



13 4 8T-4195 Bolt

14 1 8T-4136 Bolt

15 1 8M-2773 Clip



Installation of the Box Group for the Object Detection (Left Hand Side)





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Note: If the machine is equipped with lamp (A) for the Truck Payload Measurement System(TPMS), complete Step 1 that follows.

If equipped, remove lamp (A) for the Truck Payload Measurement System (TPMS). Retain

lamp (A) and the hardware that secures lamp (A) to the catwalk assembly.

1.







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(1) 361-4972 Bracket As

(2) 8T-4194 Bolt



(5) 8T-4244 Nut

Secure one bracket assembly (1) to the left side of the catwalk assembly by using six bolts(2), six washers (3), six washers (4), and six nuts (5) .

2.

Note: If the machine is equipped with TPMS, refer to Step 2.a.




(1) 361-4972 Bracket As

(2) 8T-4194 Bolt



(5) 8T-4244 Nut

If the machine is equipped with TPMS, secure one bracket assembly (1) and one lamp

assembly (A) to the left side of the catwalk assembly by using two bolts (2), twowashers (3), two washers (4), two nuts (5) and the hardware that was removed in Step1.

a.





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Note: Two bolts (2) go through the two lowest holes on bracket assembly (1). The

upper four holes are for the bolts that were removed in Step 1.




(1) 361-4972 Bracket As

(6) 359-7850 Bracket As

(7) 7X-0818 Bolt



(10) 8T-4195 Bolt


Secure radar box assembly (B), that was previously assembled, to one bracket assembly (6) by using four bolts (7), four washers (8), and eight isolation mounts (9) .

3.

Secure bracket assembly (6) to bracket assembly (1) by using four bolts (10) and fourwashers (11) .

4.





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(C) Harness assembly


Connect the existing harness assembly (C) to the harness assembly from radar box assembly(B) .

5.

Secure harness assembly (C) to the side of bracket assembly (1) by using two cable straps(12) .

6.

Installation of Camera Group (Left Hand Side)





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(D) Camera and plate assembly

(E) Camera harness assembly

(F) Chassis harness assembly


(13) 8T-4195 Bolt

(14) 8T-4136 Bolt

(15) 8M-2773 Clip

Secure camera and plate assembly (D) to the catwalk assembly by using four bolts (13) andfour washers (11) .

1.

Note: Camera and plate assembly (D) was previously assembled.

Connect camera harness assembly (E) to chassis harness assembly (F) .2.

Secure chassis harness assembly (F) and camera harness assembly (E) to the side of cameraand plate assembly (D) by using one bolt (14), one washer (11), and one clip (15) .

3.

Installation of the Right Side Hardware



1 1 359-7850 Bracket As

2 4 7X-0818 Bolt



5 1 360-3919 Bracket As

6 10 8T-4195 Bolt


8 1 8T-4136 Bolt

9 1 8M-2773 Clip

Table 84






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Installation of the Box Group for the Object Detection (Right Hand Side)



(1) 359-7850 Bracket As

(2) 7X-0818 Bolt



Secure radar box assembly (A) to bracket assembly (1) by using four bolts (2), four washers


1.






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View of the right-hand support assembly

(5) 360-3919 Bracket As

(6) 8T-4195 Bolt


Secure bracket assembly (5) to the right-hand support assembly by using four bolts (6) andfour washers (7) .

2.


(1) 359-7850 Bracket As





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(5) 360-3919 Bracket As

(6) 8T-4195 Bolt



3.



(B) Chassis harness assembly

Connect the wiring harness from radar box assembly (A) to existing chassis wiring harnessassembly (B) .

4.

Installation of the Camera Group (Right Hand Side)





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(C) Camera and bracket assembly

(D) Wiring harness assembly

(6) 8T-4195 Bolt


(8) 8T-4136 Bolt

(9) 8M-2773 Clip

Secure camera and bracket assembly (C) to the right side of the support assembly by usingfour bolts (6) and four washers (7) .

1.

Connect the wiring harness for the camera to wiring harness assembly (D) .2.

Secure the wiring harness assemblies to camera and bracket assembly (C) by using one bolt(8), one washer (7), and one clip (9) .

3.

Installation of the Rear Hardware



1 1 359-7850 Bracket As

2 4 7X-0818 Bolt



Table 85





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5 2 8T-4195 Bolt


7 2 8T-4136 Bolt

8 1 4P-8134 Clip


Install the Box Groups for the Object Detection (Rear)

ReferenceRefer to Special Instruction, KENR8668 for the orientation of the radar. The radarorientation is critical for the operation of the object detection system.



(1) 359-7850 Bracket As

(2) 7X-0818 Bolt




Secure radar box assembly (A) to bracket assembly (1) by using four bolts (2), four washers(3), and eight isolation mounts (4) .

1.





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View of the rear of the truck

(B) Wiring harness assembly

(1) 359-7850 Bracket As

(5) 8T-4195 Bolt


Secure bracket assembly (1) to the rear of the frame by using two bolts (5) and two washers(6) .

2.

Connect the wiring harness for the camera assembly to existing wiring harness assembly(B) .

3.

Installation of the Camera Group (Rear)





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(C) Plate and camera assembly

(D) Bracket assembly

(E) Wiring harness assembly


(7) 8T-4136 Bolt

(8) 4P-8134 Clip


Secure plate and camera assembly (C) to the top of bracket assembly (D) by using two bolts(7) and two washers (6) .

1.

Note: Plate and camera assembly (C) was previously assembled.

Connect the wiring harness for the camera assembly to wiring harness assembly (E) .2.

Secure wiring harness assembly (E) to the top of bracket assembly (D). Use one clip (8),one cable strap (9), existing bolt (7), and existing washer (6) .3.

Flash the Caterpillar Integrated Object Detection System

(CIODS) Software onto the Display

The display is shipped with the application software installed. Use the following procedure inorder to flash the application software into the display.

Note: Flashing the software may be required.

Required Material

Caterpillar Electronic Technician CAT (ET)•





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Communication Adapter •

345-7489 Monitor Harness As•

Software

Part NumberSystem Notes

361-8176 Caterpillar Integrated Object Detection SystemRadar and Camera

362-3942Caterpillar Integrated Object Detection System (VisionOnly)

Cameras only

Table 86

Perform the following procedure in order to flash program the ECM. The ECM is flashed in order

to upgrade the software. Flash programming of the ECM must be done if the ECM has beenreplaced. Caterpillar Electronic Technician (Cat ET) contains the program WinFlash. WinFlash isused in order to load the software into the ECM. The following procedure is used in order to flashthe software into the display.

Procedure

Ensure that the key start switch and the disconnect switch are in the OFF position.1.

Disconnect the center 12-pin connector from the display.2.

Connect the 345-7489 Monitor Harness As between the system harness for the display andthe center connector on the display.

3.

Connect the 7X-1425 Data Link Cable As between the 7X-1700 Communication Adapter

Gp and Cat ET.

4.

Connect the 139-4166 Data Link Cable As between the 7X-1700 Communication AdapterGp and the diagnostic connector of the 345-7489 Monitor Harness As .

5.

Turn power back on to the display.6.

Use WinFlash in order to load the software.7.

Disconnect the 345-7489 Monitor Harness As from the system harness for the display andthe center connector on the display.

8.

Connect the 12-pin connector of the system harness to the center connector of the display.9.

Turn the disconnect switch and the key start switch to the ON position.10.

Verify that the display turns on and the Caterpillar Integrated Object Detection systemstarts.

11.

Note: Refer to Special Instruction, REHS5191 regarding information for the CIODS.





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Perform the Commissioning Procedure for the Machine

This section contains assembly checks and functional checks of systems. Perform the checks before you deliver the machine to a customer.

Prepare the Machine Before the Machine Is Started

NOTICE




Connect a laptop computer to the Caterpillar Diagnostic Connector (1) on the fuse panel behind the operator seat. The laptop computer should have JERD2142 or JERD2129 datasubscription. Use a 139-4166 Data Link Cable As , 171-4400 Communication Adapter Gp ,

NEXG4523 Service Program Module, and a 7X-1425 Data Link Cable As in order to

connect the laptop computer.

1.






Start the Electronic Technician (ET). ET will list all of the electronic control modules forthe machine. There will be at least an "ENGINE CONTROL" and a "TRANSMISSION

3.





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CONTROL". If the truck has the Automatic Retarder Control (ARC) or the Automatic

Electronic Traction Aid (AETA), the ET screen should show the features.

ET should also display the truck model for each control. Make sure that the model is correctfor each control.

4.

Choose the "ENGINE CONTROL". Next, choose "CONFIGURATION".5.



6.

Perform the steps under the Section ""Test Product Link (if equipped)" " if the machine isequipped.

7.

Choose "ACTIVE CODES" from the ET menu. Click on the button on the bottom of thescreen. The button reads "INCLUDE ALL ECMS". If "NO ACTIVE CODES" appears, then

continue. If active fault codes are present, resolve the active faults.

8.

Choose "LOGGED CODES" from the ET menu. Click on the button at the bottom of thescreen that reads "INCLUDE ALL ECM's". Clear all logged codes.9.

Choose "DIAGNOSTICS" and choose "EVENTS" from the ET menu. Click on the button

that reads "INCLUDE ALL ECM's". Clear all logged events.

10.

Choose "DIAGNOSTICS" and choose "DIAGNOSTIC TESTS" from the ET menu. Next,choose "OVERRIDE PARAMETERS".

11.

If the truck has a starting aid or an ether aid, choose "STARTING AID" or choose "ETHERAID". Choose "CHANGE" and turn on the feature. You should hear the click of the ether aid or the starting aid solenoid on the chassis. Choose "CHANGE" again and turn off the

feature.

12.

From the ET menu, select" DATA LINK". Next, select "SELECT ECM". Next, select"TRANSMISSION CONTROL". Next, select "CONFIGURATION".

13.



a.

Check the "BODY UP GEAR LIMIT" parameter. The parameter should be set to 1. b.

If the truck has the AUTOMATIC RETARDER system, select "DATA LINK" from the ET

menu. Next, select "CHOOSE ECM". Next, select "AUTOMATIC RETARDER". Finallyselect "CONFIGURATION".

14.

Activation of the Hoist Controls for the Truck Body

The truck might appear to have a problem with the body hoist controls. The 247-7746 PowerTrain Software will set the parameters for the hoist system.

Note: The software for the Electronic Technician (ET) must be used to set these parameters. Usethe latest version of the ET software.

Enable the Hoist System (An Adjustable Parameter)

The Hoist Enable Parameter is set at a value of "2" for all trucks that are shipped from the factorywith the 247-7746 Power Train Software and with a body that is not installed. Parameter Value 2





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will prevent the hoist cylinders from being activated by accident. After the body is installed,

change the Parameter Value to "1". The hoist system should function properly. When the hoistsystem does not work, check the items below.

Settings for the Hoist Enable Parameter

ParameterValue

Description

0

This value is used when the hoist system is not installed. The hoist lever will

not function, and no diagnostics will be logged on the hoist lever or on thesolenoids.

1This value is used for normal operation when the hoist system is installed and

enabled.

2

This value is the default value that is set in the factory when the hoist system is

installed but disabled. The solenoids and the hoist lever have diagnostics, butthe hoist lever is ignored. The solenoids are kept in the HOLD position.

Table 87

Verify that the hoist system is enabled in the Configurable Parameters Screen through the pull-down service menu in the Electronic Technician (ET).

1.

Disconnect ET and then reconnect the line if the Hoist Enable Status does not appear on theconfiguration screen. The hoist enable parameter flexes with the 3.0 ET Software when the

parameter connects. Occasionally, ET misses the flexed parameters at the time of theconnection.

2.

Note: The hoist enable parameter is standard on the configuration screen of the 3.1 ETSoftware.

If the Hoist Enable Status does not change, check the following potential causes:3.

The engine should not be running. When the engine is running, the engine may causethe signal from the Transmission Output Speed (TOS) to fluctuate. The TOS must bezero in order to change the Hoist Enable Status.

The truck should not be moving.

Note: Press the "F5" key on the laptop computer in order to access the configuration screen

on ET.

Adjustment for Hoist Lower Valve

The command for the hoist lower valve is adjustable. An adjustable command can compensate forthe differences between the valves. The adjustment range is -5 to +5 with zero as the default. A

positive adjustment factor will increase the lower valve command. This causes the body to comedown harder. A negative adjustment factor will decrease the lower valve command. This causesthe body to come down softer.

The Adjustment for the Hoist Lower Valve may not be available on earlier ECM systems. The

adjustment range may be from 0 to 10 with 5 as the default on some early ECM systems.





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Note: When the Adjustment for the Hoist Lower Valve is set too high, too much oil can be

diverted to the hoist system while the hoist system is in float mode. This causes the brake oil toheat up faster. Retarding capability is also decreased. To set the Adjustment for the Hoist LowerValve, follow the procedure below.

Raise the body of the truck and install the body retaining pins.1.

Place a 6V-7830 Tetragauge or place a 3.45 MPa (500 psi) gauge with a hose extension onthe outlet port of the hoist pump.

2.

Note: Remove the body pins and lower the body to the frame.

While the body is down, place the hoist lever in the HOLD position.3.

Enter the configure parameter screen through the pull-down service menu in the ElectronicTechnician (ET).

4.

Change the Adjustment for the Hoist Lower Valve to a setting that is desired from -5 to 5.

The procedure begins at 0. Adjust the settings in increments of 1 in the positive position orin the negative position.

5.

Note: If you are using a 3.45 MPa (500 psi) gauge, remove the gauge from the extension.

Raise the body to the middle position.6.

Lower the body to the frame.7.

If a 6V-7830 Tetragauge is not installed, shut off the engine and install a 3.45 MPa (500 psi)gauge. Start the engine and run the engine to high idle. Cycle the hoist lever to the FLOAT

position and to the HOLD position. Do not power down or raise the bed if you are using a

3.45 MPa (500 psi) gauge. Damage may occur to the gauge.

8.

While the engine is running, place the hoist lever in the FLOAT position.9.

Run the engine to high idle. Verify that the pressure at the hoist outlet port is less than 1724kPa (250 psi).

10.

Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. Thiscauses too much oil to be diverted to the hoist valve. This causes the brake oil to overheat whenthe body is in the FLOAT position. Lower the adjustment setting and repeat Step 4 through Step10. This lowers the pressure below 1724 kPa (250 psi).

Note: If you change the adjustment setting and there is no corresponding change in pressure, cyclethe hoist lever again. A change will occur in the settings between 2 and 5.

Body Down Snub Function (A Parameter That Is Not Adjustable)

The body down snub function cushions the shock when the body hits the bed of the truck. Whenthe body is lowered, the body up switch detects the position of the body when the body is close tothe rail of the truck. This causes the ECM to go into snub mode.

When the operator's request is less than the snub mode, the ECM will use the operators request.This ensures that the snub function will never cause the body to go down faster than the hoist levermodulation (operator's request).





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The body down snub function will be Canceled as the operator moves the hoist lever out of the

FLOAT position or out of the LOWER position. The body down snub function will not start untilthe body goes above the body up switch activation level.

Check the Suspension Cylinders

Note: Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" for any information concerning suspension cylinders. The Special Instructionincludes Tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging(oil and nitrogen).

Transmission and Torque Converter Filters

The transmission system uses 343-4465 Oil Filter Elements , which have to be replaced by aservice filter element after 8 hours of machine operation. Failure to change to a serviceelement may result in clogging of the filter.

Replace the 343-4465 Oil Filter Element with a 343-4465 Oil Filter Element or a 1R-0741 OilFilter Element Assembly .

Note: The 343-4465 Oil Filter Element is recommended for replacement, however the 1R-0741

Oil Filter Element Assembly is also an acceptable replacement.

Note: The 343-4465 Oil Filter Element is for power train use only and not approved forhydraulic applications.

Contamination is one of the major causes of transmission control system failure. Some power train

oil systems were cleaned with fine cleanout filters, which frequently caused oil to bypass the filter.The use of cleanout filters in power train oil systems is no longer recommended. A new line of

advanced efficiency Caterpillar transmission filters have been introduced for use in power trainapplication.

Replacing the Cleanout Filters

Cleanout filters are installed on some of the 777F hydraulic systems at the factory. Replace allcleanout filters with the standard filters that have been provided with the truck after the truck has

been continuously operated for 8 hours. Failure to replace cleanout filters can cause a pluggedfilter condition causing oil to enter the transmission, torque converter, steering, hoist, or brake

hydraulic systems.

Use the following chart for replacing the filters.

Hydraulic System Cleanout Filter Standard Filter Qty

Parking Brake Release 132-8875 (6µ max.) 1R-0773 (20µ) 1

Steering Case Drain 126-1813 (5µ max.) 4I-3948 (25µ max.) 1

Steering Return Line 144-0832 (5µ max.) 4T-6788 (27µ max.) 1

Torque Converter Charge 343-4465 343-4465

(1)

1R-0778 (2) 2

Table 88





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Transmission Charge 343-4465343-4465 (1)

1R-0778 (2) 2

( 1 ) Recommended( 2 ) Acceptable

Calibrate the Transmission

In order to calibrate the transmission refer to the Testing and Adjusting, RENR8342, " 773F,775F, and 777F Trucks/Tractor and Quarry Truck Chassis Electronic Control System".

Duo-Cone Break-In Procedure

The Break-In procedure must be run as a continuous section. Time that is required to carry out theBreak-In procedure is 25 minutes. This procedure should be performed when the wheels turn forthe first time. This procedure may also be done after you purge the air from the brake system aslong as the wheels are not turned before you purge the air from the brake system. Follow the break

-in procedure in the sequence that is mentioned below:

Note: If testing is performed on stands instead of tires, do not exceed SECOND GEAR.

Operate the machine at low idle rpm in the FIRST GEAR for 5 minutes.1.

Operate the machine at high idle rpm in the FIRST GEAR for 5 minutes.2.

Operate the machine at high idle rpm in the SECOND GEAR for 5 minutes.3.

Operate the machine at high idle rpm in the THIRD GEAR for 5 minutes.4.

Operate the machine at high idle rpm in the FOURTH GEAR for 5 minutes.5.

Test Product Link (if equipped)







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Connect a laptop computer to the Caterpillar Diagnostic Connector (1) on the fuse panel

behind the operator seat. The laptop computer should have JERD2142 or JERD2129 datasubscription. Use a 139-4166 Data Link Cable As , 171-4400 Communication Adapter Gp ,

NEXG4523 Service Program Module, and a 7X-1425 Data Link Cable As in order toconnect the laptop computer.

1.






Start the Electronic Technician (ET). ET will list all of the electronic control modules for

the machine. There will be at least an "ENGINE CONTROL" and a "TRANSMISSION

CONTROL". If the truck has the Automatic Retarder Control (ARC) or the AutomaticElectronic Traction Aid (AETA), the ET screen should show the features.

3.

ET should also display the truck model for each control. Make sure that the model is correct

for each control.

4.

Illustration 292

Choose the "Product Link" ECM.5.





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Illustration 293

Note: The communication status of product link needs tested. Since there can be up to a 15

minute delay in satellite coverage, the wiggle test in ET can be used to save time bydetecting the changes in status while other activities in the commissioning procedure are performed. Leave the wiggle test running and check the status during the ""Final Check" "

at the end of this Special Instruction. The wires do not need to be wiggled.

Choose "Diagnostics" from the ET menu. Choose "Diagnostic Tests" from the menu. Thenchoose the "Wiggle Test" from the test menu.

6.

Illustration 294

Read the warning and select the "OK" button.7.





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Illustration 295

From the "Wiggle Test" screen, select the "Groups" button.8.





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Illustration 296

Choose the "New" button in order to create a group for the product link.9.

Note: The product link group needs to be created one time.

Illustration 297

Type "Product Link" and select the "OK" button.10.





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Illustration 298

In the left-hand column of available parameters, select the "Number of GPS Satellites"

under "Product Link" and then select the right arrow. In the left-hand column, select"Satellite Communications Status" that is under the "Product Link" title and then select theright arrow.

11.






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Illustration 299






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Illustration 300

Note: In order to confirm the two types of the satellite communication, the "Numberof GPS Satellites" should be greater than "0" and the "Satellite CommunicationStatus" should be "Established". The screen shows that the GPS communication is

established. The screen shows that the satellite communication is established.

If the "Number of GPS Satellites" is greater than "0" and the " SatelliteCommunication Status" is "Established", then the communication status of productlink is confirmed. Record this information in the ""Final Check" " at the back of thisSpecial Instruction.

a.





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Illustration 301

Note: If the "Number of GPS Satellites" is greater than "0" and the "SatelliteCommunication Status" is "Not Established", the wiggle test can be run in order tomonitor the communication status.

Select "Start" in order to start the wiggle test if the parameters do not confirm thecommunication status.

b.

Note: Leave ET running and do not navigate to a different screen in ET while thewiggle test is running. These actions will end the wiggle test.





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Illustration 302

When a parameter changes during a wiggle test the parameter will be highlighted in red. A 2 second bee





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Illustration 303

The parameter will stay red even if "the parameter" changes back to the original value. The "Satellite Codisplayed in red text. This means that communication was established during the wiggle test.

Note: Satellite communication may have a 15 minute gap in communication. Make

sure that you leave the wiggle test running longer than 15 minutes before failing the product link.

Note: In order to establish communication, the antenna for the product link must havea clear view of the sky. Objects that obstruct the antennas view of the sky may resultin a failure. If the antenna was obstructed during the test, retest the product link withan unobstructed view of the sky. Satellites can be seen from the horizon to 15 degrees

above the horizon. Check the following web address for satellite coverage in yourarea: http://corneroftheuniverse.net/orbcomm/sats/sat_coverage.html

Check the parameters later during the commissioning procedure. Record this

information in the""Final Check" " at the back of this Special Instruction. Allow thetest to run for a minimum of 15 minutes or allow the test to run until thecommunication is established. The parameters will be highlighted in red if the statuschanged during the test.

c.

If no communication is established and the test has been running longer than 15minutes, check the antenna for damage and check the connection from the antenna to

the radio. If the cable did not have a good connection to the radio, establish a goodconnection and repeat the test.

d.

If there is a good connection from the antenna to the radio but no communication isestablished, Refer to Troubleshooting, RENR7911, "Product Link 121/321".

e.

Final Check

Use the Service Manual and use the Operation and Maintenance Manual in order to correct anysystem problems before you deliver the truck.

Note: After eight hours of continuous operation, replace the cleanout filter elements with standardfilter elements for the systems that follow: the parking brake filter, the transmission filter, the

steering system filter and the torque converter charging oil filter.

After you complete the final check, sign your name and the name of the dealer.

Make copies of the check procedure. Mail the copies to the following address:

Caterpillar Inc. Attention: CMT Product Support

777F Truck N. 27th and Pershing Road Decatur, IL 62525

Dealer:____________________

Customer:____________________

Product Identification Number:____________________







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Before you start the engine, make sure that all hydraulic systems are full. Also, make sure

that all pump case drains are full.

1.

Establish a satellite communication (if equipped).2.

YES ____ NO ____

Establish a GPS communication (if equipped).3.

Number of GPS Satellites ____

Check that the system pressures are set correctly.4.

Pump

YES ____ NO ____

Brake

YES ____ NO ____

Steering Pressure

YES ____ NO ____

Transmission

YES ____ NO ____

Torque Converter

YES ____ NO ____

Differential

YES ____ NO ____

Check that the brake accumulators are correctly charged.5.

YES ____ NO ____

Check the machine lights.6.

Operational

YES ____ NO ____

Cab and Dash

YES ____ NO ____

Check the controls in the cab.7.

Check if the cab door opens. Check if the cab door closes.

YES ____ NO ____





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Check if the Operation and Maintenance Manual is in the literature pouch on the back

of the operator seat.

YES ____ NO ____

Check if the horn functions.

YES ____ NO ____

Check if the front window wipers and front window washers function.

YES ____ NO ____

Check if the seat belts operate.

YES ____ NO ____

Check if the fan switch operates.

YES ____ NO ____

Check if the heater functions.

YES ____ NO ____

Check if the air conditioner functions.

YES ____ NO ____

Check the test light. The test light is for the EMS.

YES ____ NO____

Check if the hour meter operates.

YES ____ NO ____

Check if the implements operate:

Hoist

YES ____ NO ____

Steering Action

YES ____ NO ____

Check if the steering column functions.

YES ____ NO ____

Check if the parking brake functions.

YES ____ NO ____

Check if all fluid levels are full.8.





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YES ____ NO ____

Correct any unusual noises or unusual leaks.9.

YES ____ NO ____

Check if all lubrication lines are filled with grease.10.

YES ____ NO ____

Check if all clean-out filters have been replaced as specified by assembly procedure.11.

YES ____ NO ____

Check if all quality requirements are fulfilled. Check if all variances have been corrected.12.

YES ____ NO ____

Check if the backup alarms function.13.

YES ____ NO ____

Check if the machine is repainted to the factory specifications.14.

YES ____ NO ____

Check if there was damage to the machine from shipment.15.

YES ____ NO ____

Check if all required parts were shipped with the machine.16.

YES ____ NO ____

Sign your name in the space below.17.

Hydraulic

____________________

Electrical

____________________

Structural

____________________

Other

____________________

Comments18.

________________________________________

________________________________________





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________________________________________

________________________________________

________________________________________

________________________________________

________________________________________

________________________________________

________________________________________

________________________________________

Specifications for the Commissioning Procedure

Description Specifications Actual Comments

Engine Low Idle rpm 700 +30 -10 rpm

Engine High Idle 1935 ± 30 rpm

Pressure of Brake Retract Pump at High

Idle 4690 ± 200 kPa (680 ± 30 psi)

Relief Pressure of Hoist Pump 18950 ± 520 kPa (2750 ±75 psi)

Steering High Pressure Cutoff21200 ± 350 kPa (3075 ±

50 psi)

Steering Cycle Time 6.5 seconds at66 °C (150 °F)

Relief Pressure of Transmission Pressure

at High Idle 3200 kPa (465 psi)Maximum

Pressure of Transmission Lubrication at

High Idle110 ± 30 kPa (16 ± 4 psi)

Pressure of Transmission Lubrication atLow Idle 22.4 ± 19 kPa (3.25 ±

2.75 psi)

Torque Converter Outlet Pressure at Stall(Wet Front Brakes) 760 ± 69 kPa (110 ± 10 psi)

Table 89





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Torque Converter Outlet Pressure at Stall

(Dry Front Brakes) 550 ± 69 kPa (80 ± 10 psi)

Predelivery Worksheet

Date Employee I.D. Model Serial Number Hours Inspector Name

Table 90

Note: All safety product improvement programs (PIP) must be completed.

VisualInspection

Service Points

and FluidLevels

Operation AfterOperation

Engine (1) (2)

_ Paint _ Outside

Damage

_ Oil _ Coolant _ Fuel

_ Batteries OVC> (12.45) _VDC1 _ VDC2

_ Air Filters _ Drain Water

from Fuel Tank _ Drain WaterSeparator

_ Open Coolant

conditionerValves

_ GreaseFittings

_ Priming Pump _ Governor Control _ Air Compressor

_ Smoke Color _ Unusual Noise

_ Air CleanerIndicator

_ V-Belt

Tension _ Leaks (Oil,Air, Fuel,Coolant)

_ Friction on

Hoses _ Friction onWires

_ Loose Wire

Connections _ Loose orLost Fasteners

Power Train


_ Tires -Cuts, gouges

_ Transmission _ Differential _ Final Drives

_ Tire Pressure _ GreaseFittings

_ Front & Rear

Axle BoltTorques

_ Front & RearUniversalTorques

_ Wheel to RimTorques

_ Transmission - EachGear

_ Neutral Start _ Transmission Lever

Lock _ Back - Up Alarm _ Neutralizer Valve _ Unusual Noise

_ Leaks (Oil) _ Loose or lost

Fasteners _ Tires - Cuts,Gouges

Table 91





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Steering andBrakes


_ Brake Fluid

_ Drain Waterfrom Air Tank

_ GreaseFittings

_ Steering

_ Retarder _ Service Brakes _ Parking Brakes _ Air Dryer _ Unusual Noise

_ Leaks - Oil,

Air _ Loose orLost Fasteners

Chassis _ Sheet Metal _ Paint _ Damage

_ Grease

Fittings

_ Enclosure Doors -

Locks and Latches


_ Welds

Hydraulic _ CylinderRods

_ HydraulicTank

_ GreaseFittings

_ Controls _ Too much Drift _ Unusual Noise

_ Leaks - Oil _ Friction orLost Fasteners

Truck Body

_ Paint

_ Damage _ Liners

_ Grease

Fittings

_ Body Pads _ RetentionCable

_ Body Positions

_ Welds

_ Loose orLost Fasteners _ Damage

_ Front Window

W h

_ Disconnect Switch _ VIMS _ Hoist Control _ Horn _Seat Belts _ Seat Adjustments _ All Switches &

C t l

_ OperationGuide

_ Maintenance

Guide

P t B k


Documents

ENSAMBLE 777F