777G Off-Highway Truck Engine Supplement Caterpillar

Engine and Torque Converter - Remove and Install

Usage:

777G GT7

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	4C-6486	Stand	1
	8S-7611	Tube	1
	8S-8048	Saddle	1
	8S-7615	Pin	1
C⁽¹⁾	9U-7536	Lift Stand	1
	447-0910	Electric Hydraulic Pump Gp (115V)	1
	447-0911	Electric Hydraulic Pump Gp (230V)	1
C1	OR
	504-9826	Lift Gp (60Hz)⁽²⁾	1
	504-9827	Lift Gp (50Hz)⁽³⁾	1

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⁽¹⁾	Use Tooling (C) or (C1) based on requirements.
⁽²⁾	Operating-Voltage (380-500V)
⁽³⁾	Operating-Voltage (180-300V)

Start By:

Remove the radiator.

Turn the battery disconnect switch into the OFF position.
Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" for the correct draining and filling procedures.
Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.
Refer to Operation and Maintenance Manual, "Engine Oil and Filter - Change" for the correct draining and filling procedures.
Refer to Operation and Maintenance Manual, "Power Train Oil - Change" for the correct draining and filling procedures.
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Illustration 1 g00461867
Raise the bed. Install Tooling (A) under the frame of the bed, as shown. This will help balance the machine when the engine is removed.
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Illustration 2 g02958056
Disconnect hose assemblies (1). Remove cover (3), and hose (4) from engine and torque converter (2).
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Illustration 3 g02958120
Remove belt (5). Refer to Operation and Maintenance Manual, "Belts - Inspect/Adjust/Replace".
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Illustration 4 g02958141
Disconnect cable assembly (6), and harness assemblies (7). Remove air conditioning compressor (9).
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Illustration 5 g02958257
Remove hose assemblies (9).
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Illustration 6 g02958338
Disconnect cable (10). Remove drain hose (10a)
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Illustration 7 g02958356
Disconnect hose assembly (11).
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Illustration 8 g02958436
Disconnect hose assemblies (12).
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Illustration 9 g02958474
Disconnect hose assemblies (13).
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Illustration 10 g02963703
Disconnect hose assembly (14).
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Illustration 11 g02958560
Disconnect hose assembly (15).
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Illustration 12 g02958576
Remove clip (16).
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Illustration 13 g02958583
Disconnect hose assemblies (17).
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Illustration 14 g02958497
Attach a suitable lifting device to drive shaft (18). The weight of drive shaft (18) is approximately 82 kg (180 lb). Remove drive shaft (18).
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Illustration 15 g02959558
Disconnect tubes (19), hose assemblies (20), and hose assemblies (21).
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Illustration 16 g02959643
Disconnect hose assemblies (22).
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Illustration 17 g02959763
Disconnect hose assemblies (23).
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Illustration 18 g02959816
Remove clip (24). Disconnect hose assemblies (25).
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Illustration 19 g02960160
Remove tube (27), and mounting cap (29). Disconnect cable (28).
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Illustration 20 g02960318

For Tooling (C)
Position Tooling (C) under the front frame of the machine, as shown. Tooling (C) is necessary to support the machine when cross member (31) is removed.
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Illustration 21 g06406524

For Tooling (C1)
Position Tooling (C1) under the front frame of the machine, as shown. Tooling (C1) is necessary to support the machine when cross member (31) is removed. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (C1).
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Illustration 22 g02960356
Attach a suitable lifting device to cross member (31). The weight of cross member (31) is approximately 68 kg (150 lb). Disconnect hose assembly (29) and harness assembly (30). Remove cross member (31).
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Illustration 23 g02960599
Remove clips (32).
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Illustration 24 g02960622
Disconnect hose assembly (33).
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Illustration 25 g02960628
Remove clips (34). Disconnect harness assembly (35).
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Illustration 26 g02960723
Disconnect harness assemblies (36). Remove clips (37).
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Illustration 27 g02960918

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Illustration 28 g02961057
Attach Tooling (C) to engine and torque converter (2). The weight of engine and torque converter (2) is approximately 4445 kg (9800 lb). Remove bolts (38) from engine and torque converter (2).