777G Off-Highway Truck Machine Systems Caterpillar

Removal Procedure

Start By:

1. Install the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: The following procedure is identical for both sides of the machine. If necessary, repeat the procedure for the remaining side of the machine.

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Illustration 1	g06202924

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Illustration 2	g06202949

1. Raise the truck body to install suitable blocking between the bed rail and the frame.
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   Illustration 3	g01347987

2. Attach Tooling (A) to hoist cylinder (3). Remove bolts (1) and plate (2). The weight of hoist cylinder (3) is approximately 286 kg (630 lb)
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   Illustration 4	g06266736

   Note: Attach a suitable lifting device to Tooling (B).

3. Use Tooling (B) and a suitable lifting device to remove pin assembly (4) from cylinder (3).

4. Retract hoist cylinder (3). Use Tooling (A) to rest hoist cylinder (3) against the wheel assembly. Ensure that hoist cylinder (3) is secure before proceeding to the nest step.

5. Release the system pressure. Refer to Operation and Maintenance Manual, "System Pressure - Release"

6. Drain the hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Hoist and Brake Tank Oil - Change".
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   Illustration 5	g01347985

7. Place a suitable container below hose assemblies (5) to contain the hydraulic oil for storage or disposal. Disconnect hose assemblies (5) from hoist cylinder (3).
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   Illustration 6	g01347994

8. Remove bolts (6) and cover (7) from hoist cylinder (3).
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   Illustration 7	g06202421

9. Position a suitable lifting device around hoist cylinder (3) and remove Tooling (A). The weight of hoist cylinder (3) is approximately 286 kg (630 lb).
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   Illustration 8	g06202323

10. Remove bolts (8).
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    Illustration 9	g06202332

11. Use Tooling (C) to disconnect hoist cylinder (3) and the self-aligning bearing from the hoist cylinder spindle. Use the suitable lifting device to remove cylinder (3). The weight of hoist cylinder (3) is approximately 286 kg (630 lb).

12. Remove the retainer from the frame assembly.

Disassembly and Assembly Information

Illustration 10	g06202518

Illustration 11	g06202981
Detail A

• (1) Lubricate the bolts with the lubricant that is being sealed. Tighten the bolts to a torque of 475 ± 50 N·m (350 ± 37 lb ft).

• (2) Apply Tooling (F) to the last three threads of head. Tighten head to a torque of 1000 N·m (738 lb ft) MAX.

• (3) Tighten the head bolts to a torque of 475 ± 50 N·m (350 ± 37 lb ft) with the rod fully extended.

• (4) ( 5) (6) Lubricate the sealing lips with the lubricant that is being sealed.

• (7) Apply Tooling (G) to the internal threads before assembly.

• For self-aligning bearing installation, do not freeze the bearing races below −55° C (−67° F). Freezing should not exceed 48 hours.

Installation Procedure

Note: The following procedure is identical for both sides of the machine. If necessary, repeat the procedure for the remaining side of the machine.

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Illustration 12	g06202421

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Illustration 13	g06202405

1. Apply Tooling (H) to the inner diameter of the self-aligning bearing. Install the retailer. Use a suitable lifting device to install hoist cylinder (3) onto the machine. The weight of hoist cylinder (3) is approximately 286 kg (630 lb). Use the suitable lifting device to lower hoist cylinder (3) onto the rear wheel.
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   Illustration 14	g06202323

2. Install bolts (8) to seat hoist cylinder (3) and the self-aligning bearing to the frame assembly. Tighten bolts (8) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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   Illustration 15	g01347994

3. Position the retainer onto hoist cylinder (3) then install cover (7) and bolts (6). Tighten bolts (6) to a torque of 215 ± 40 N·m (159± 30 lb ft)
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   Illustration 16	g01347985

4. Connect hose assemblies (5) to hoist cylinder (3).
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   Illustration 17	g01347992

5. Attach Tooling (A) and a suitable lifting device to hoist cylinder (3). Apply Tooling (J) to pin assembly (4).

6. Fill the hydraulic tank. Refer to Operation and Maintenance Manual, "Hoist and Brake Tank Oil - Change".

7. Use the machine hydraulics and Tooling (A) to position cylinder (3) to align the upper bore of the hoist cylinder with the bores of the truck body. Install pin assembly (4). Install plate (2) and bolts (1). Remove Tooling (A) and the suitable lifting device.
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   Illustration 18	g06202949

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   Illustration 19	g06202358

8. Raise the truck body to remove the suitable blocking.

End By:

1. Remove the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".