Procedure to Improve the Steering Oil Lines Group on Certain 777G Off-Highway Trucks {4304, 5057}
- Off-Highway Truck/Tractor
- 777G (S/N: GT71-UP; T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)
Reference: Operation and Maintenance Manual , "777G Off-Highway Truck" , System Pressure Release and Steering System Oil Level - Check
Introduction
This Special Instruction contains information to improve the steering oil lines Group on the machines listed above.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Important Safety Information
Show/hide table
 |
|
Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. |
Show/hide table
|
|
Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. |
Show/hide table
| NOTICE |
|---|
|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
Show/hide table
| NOTICE |
|---|
|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Machine Preparation
- Move the machine to a hard level surface.
- Avoid sudden steering inputs when you are parking the machine.
- Apply the service brakes to stop the machine.
- Move the transmission control lever to the PARK position.
- If needed, raise the body and install the retaining pins. Refer to Operation and Maintenance Manual for instructions on securing the truck body. Place the hoist control lever in the FLOAT position for at least 10 seconds.
- Turn the engine start switch to the OFF position to stop the engine.
- Turn the battery disconnect switch to the OFF position.
- Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable - Inspect/Replace" for additional information.
- Chock the front wheels and the rear wheels. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".
- Ensure that the pressure is released from any closed system that will be opened during the maintenance procedure. Refer to Operation and Maintenance Manual , "777G Off-Highway Truck" , System Pressure Release for more information.
Serial Numbers S/N:RDR1-499, ; S/N:TNM1-999, ; S/N:GT71-UP, ; S/N:T4Y1-499 and ; S/N:T5A1-299
Required Parts
Show/hide table
| Serial Numbers S/N:RDR1-499, ; S/N:TNM1-999, ; S/N:GT71-UP and ; S/N:T5A1-299 | ||||
|---|---|---|---|---|
| Equipped with Variable Speed Fan | ||||
| Item | Qty | New Part Number | Description | Former Part Number |
| 1 | 1 | Hose As | ||
| 3 | 2 | O-Ring Seal | - | |
| 4 | 2 | Clip | - | |
| 5 | 2 | Clip | - | |
| 6 | 2 | Grommet | - | |
| 7 | 3 | Hard Washer | - | |
| 8 | 1 | Bolt | - | |
| 9 | 1 | Bracket As | - | |
| 10 | 1 | Bolt | - | |
| 11 | 1 | Elbow | ||
| 12 | 1 | O-Ring Seal | - | |
| 13 | 1 | Hose and Tube As | ||
| 14 | 2 | O-Ring Seal | - | |
| 15 | 1 | Plate | ||
| 16 | 1 | Clip | - | |
| 17 | 1 | Clip | - | |
| 18 | 1 | Grommet | - | |
| 19 | 1 | Clip | - | |
| 20 | 1 | Bolt | - | |
| 21 | 2 | Washer | - | |
| 22 | 2 | Nut | - | |
Show/hide table
| Serial Numbers S/N:TNM1-999, ; S/N:GT71-UP and ; S/N:T4Y1-499 | ||||
|---|---|---|---|---|
| Not equipped with Variable Speed Fan | ||||
| Item | Qty | New Part Number | Description | Former Part Number |
| 1 | 1 | Hose As | ||
| 3 | 2 | O-Ring Seal | - | |
| 4 | 2 | Clip | - | |
| 5 | 2 | Clip | - | |
| 6 | 2 | Grommet | - | |
| 7 | 3 | Hard Washer | - | |
| 8 | 1 | Bolt | - | |
| 9 | 1 | Bracket As | - | |
| 10 | 1 | Bolt | - | |
| 11 | 1 | Elbow | ||
| 12 | 1 | SEAL-O-RING-STOR | - | |
| 13 | 1 | Hose and Tube As | ||
| 14 | 2 | O-Ring Seal | - | |
| 15 | 1 | Plate | ||
| 22 | 1 | Nut | - | |
Removal Procedure
- Remove and discard plate (B) from the top of the secondary steering valve (D). Retain the associated hardware for reuse.
- Remove and discard tube assembly (C) and hose assembly (E) as shown in Illustration 2.
Show/hide table
Illustration 3 g06246798 (F) Elbow
(G) Hose and tube assembly
(H) Clip
(J) Spacer
(K) Hard washer
(L) Nut - Remove and retain clip (H), spacer (J), hard washer (K), and nut (L) as shown in Illustration 3.
- Remove and discard elbow (F), and hose and tube assembly (G).
Show/hide table
| |
| Illustration 1 | g06228527 |
Show/hide table
| |
| Illustration 2 | g06228528 |
|
View of area A (B) Plate (C) Tube assembly (D) Secondary steering valve (E) Hose assembly | |
Installation Procedure
- Install hose assembly (1) with hose sleeve (2) along with O-Ring seal (3) at both ends.
Note: For the top clamp, reposition the harness clip (M) to prevent contact with the hose (1) as shown in Illustration 4.
- Secure hose (1) using two clips (4), two clips (5), two grommets (6), two hard washers (7), one bolt (8), one bracket assembly (9), and one bolt (10) as shown in Illustration 4.
Show/hide table
Illustration 5 g06228534 (D) Secondary steering valve
(H) Clip
(J) Spacer
(K) Hard washer
(L) Nut
(N) Pump control valve group
(P) Steering Pump
(11)8T-7546 Elbow
(12)214-7566 O-Ring Seal
(13)523-6444 Hose and Tube As
(14)228-7089 O-Ring Seal
(15)524-9090 Plate - Install elbow (11) to the pump control valve group (N) along with O-Ring seal (12).
- Connect hose and tube assembly (13) to elbow (11) along with O-Ring seal (14) at both ends as shown in Illustration 5.
- Secure hose and tube assembly (13) using clip (H), spacer (J), hard washer (K), and nut (L) that were saved in Step 4 of "Removal Procedure".
Note: Ensure that hose and tube assembly (13) does not interfere with steering pump (P) as shown in Illustration 5.
- Install plate (15) on top of the secondary steering valve (D) as shown in Illustration 5. Secure plate (15) using hardware that were saved in Step 1 of "Removal Procedure".
Show/hide table
Illustration 6 g06228536 (R) Hose
(16)6V-1867 Clip
(17)6V-1868 Clip
(18)6V-1869 Grommet
(19)1S-1015 Clip
(20)8T-4186 Bolt
(21)7X-7729 Washer
(22)344-5675 Nut - If trucks are equipped with variable speed fan. To prevent hose (R) rub, secure hose (R) using one clip (16), one clip (17), one grommet (18), one clip (19), one bolt (20), two washers (21), and one nut (22) .
Note: Refer to Operation and Maintenance Manual , "777G Off-Highway Truck" , Steering System Oil Level - Check for more information.
- Top off steering oil as needed.
- Make sure that all machine systems are functioning correctly. Check for leaks and repair as needed. Return the machine to service.
Show/hide table
| |
| Illustration 4 | g06228532 |
|
(M) Harness Clip
(1) (2) Hose sleeve (Part of (3) (4) (5) (6) (7) (8) (9) (10) | |
Serial Numbers S/N:RDR500-UP, ; S/N:TNM1000-UP, ; S/N:T4Y500-UP and ; S/N:T5A300-UP
Required Parts
Show/hide table
| Serial Numbers S/N:RDR500-UP, ; S/N:TNM1000-UP, ; S/N:T4Y500-UP and ; S/N:T5A300-UP | ||||
|---|---|---|---|---|
| Equipped with Variable Speed Fan | ||||
| Item | Qty | New Part Number | Description | Former Part Number |
| 1 | 1 | Hose As | ||
| 3 | 2 | O-Ring Seal | - | |
| 4 | 2 | Clip | - | |
| 5 | 2 | Clip | - | |
| 6 | 2 | Grommet | - | |
| 7 | 2 | Hard Washer | - | |
| 8 | 1 | Bolt | - | |
| 9 | 1 | Stud | - | |
| 10 | 1 | Hard Washer | - | |
| 11 | 2 | Nut | - | |
| 12 | 1 | Elbow | ||
| 13 | 1 | O-Ring Seal | - | |
| 14 | 1 | Hose and Tube As | ||
| 15 | 2 | O-Ring Seal | - | |
| 16 | 1 | Plate | ||
| 17 | 1 | Clip | - | |
| 18 | 1 | Clip | - | |
| 19 | 1 | Grommet | - | |
| 20 | 1 | Clip | - | |
| 21 | 1 | Bolt | - | |
| 22 | 2 | Washer | - | |
Show/hide table
| Serial Numbers S/N:TNM1000-UP and ; S/N:T4Y500-UP | ||||
|---|---|---|---|---|
| Not equipped with Variable Speed Fan | ||||
| Qty | Qty | New Part Number | Description | Former Part Number |
| 1 | 1 | Hose As | ||
| 3 | 2 | O-Ring Seal | - | |
| 4 | 2 | Clip | - | |
| 5 | 2 | Clip | - | |
| 6 | 2 | Grommet | - | |
| 7 | 2 | Hard Washer | - | |
| 8 | 1 | Bolt | - | |
| 9 | 1 | Stud | - | |
| 10 | 1 | Hard Washer | - | |
| 11 | 1 | Nut | - | |
| 12 | 1 | Elbow | ||
| 13 | 1 | O-Ring Seal | - | |
| 14 | 1 | Hose and Tube As | ||
| 15 | 2 | O-Ring Seal | - | |
| 16 | 1 | Plate | ||
Removal Procedure
- Remove and discard plate (B) from the top of the secondary steering valve (E). Retain the associated hardware for reuse.
- Remove and discard tube assembly (C) and hose assembly (F) as shown in Illustration 2.
Show/hide table
Illustration 9 g06228546 View of area D
(G) Bolt
(H) Washer - Remove and discard bolt (G) and washer (H).
Show/hide table
Illustration 10 g06228533 (J) Elbow
(K) Hose and tube assembly
(L) Clip
(M) Spacer
(N) Hard washer
(P) Nut - Remove and retain clip (L), spacer (M), hard washer (N), and nut (P) as shown in Illustration 3.
- Remove and discard elbow (J), and hose and tube assembly (K).
Show/hide table
|
| |
| Illustration 7 | g06228527 |
Show/hide table
| |
| Illustration 8 | g06228538 |
|
View of area A (B) Plate (C) Tube assembly (E) Secondary steering valve (F) Hose assembly | |
Installation Procedure
- Install hose assembly (1) with hose sleeve (2) along with O-Ring seal (3) at both ends.
Note: For the top clamp, reposition the harness clip (R) to prevent contact with the hose (1) as shown in Illustration 11.
- Secure the hose (1) using two clips (4), two clips (5), two grommets (6), two washers (7), one bolt (8) one stud (9), one washer (10), and one nut (11). Refer to Illustration 11.
Show/hide table
Illustration 12 g06228769 (E) Secondary steering valve
(L) Clip
(M) Spacer
(N) Hard washer
(P) Nut
(S) Pump control valve group
(T) Steering Pump
(12)8T-7546 Elbow
(13)214-7566 O-Ring Seal
(14)523-6444 Hose and Tube As
(15)228-7089 O-Ring Seal
(16)524-9090 Plate - Install elbow (12) to the pump control valve group (S) along with O-Ring seal (13).
- Connect hose and tube assembly (14) to elbow (12) along with O-Ring seal (15) at both ends as shown in Illustration 12.
- Secure hose and tube assembly (14) using clip (L), spacer (M), hard washer (N), and nut (P) that were saved in Step 5 of "Removal Procedure".
Note: Ensure that hose and tube assembly (14) does not interfere with steering pump (T) as shown in Illustration 12.
- Install plate (16) on top of the secondary steering valve (E). Secure plate (16) using hardware that were saved in Step 1 of "Removal Procedure".
Show/hide table
Illustration 13 g06228544 (U) Hose
(11)344-5675 Nut
(17)6V-1867 Clip
(18)6V-1868 Clip
(19)6V-1869 Grommet
(20)1S-1015 Clip
(21)8T-4186 Bolt
(22)7X-7729 Washer - If trucks are equipped with variable speed fan. To prevent hose (U) rub, secure hose (U) using one clip (17), one clip (18), one grommet (19), one clip (20), one bolt (21), two washers (22), and one nut (11).
Note: Refer to Operation and Maintenance Manual , Steering System Oil Level - Check for more information.
- Top off steering oil as needed.
- Make sure that all machine systems are functioning correctly. Check for leaks and repair as needed. Return the machine to service.
Show/hide table
| |
| Illustration 11 | g06228541 |
|
(R) Harness Clip
(1) (2) Hose sleeve (Part of (3) (4) (5) (6) (7) (8) (9) (10) (11) | |
Caterpillar Information System:
Injection Timing Correction Procedure on Certain C3.3B Engines {0781, 0782, 1000, 1920} Injection Timing Correction Procedure on Certain C3.3B Engines {0781, 0782, 1000, 1920}
Injection Timing Correction Procedure on Certain C3.8 Engines {0781, 0782, 1000, 1920} Injection Timing Correction Procedure on Certain C3.8 Engines {0781, 0782, 1000, 1920}
Procedure to Install New Alternator Group and Support Bracket on Certain 770G and 772G Off-Highway Trucks {1405, 1802, 5917} Procedure to Install New Alternator Group and Support Bracket on Certain 770G and 772G Off-Highway Trucks {1405, 1802, 5917}
Process for Optimizing or Extending Oil Drain Intervals on Off Highway Trucks Equipped with a Centrifugal Oil Filter {1000, 1328, 1348} Process for Optimizing or Extending Oil Drain Intervals on Off Highway Trucks Equipped with a Centrifugal Oil Filter {1000, 1328, 1348}
MD6310 Rotary Drill Monitoring System
Improvements Have Been Made to Simplify Brake Hose Routing on Certain 700 C-Series Articulated Trucks {4257, 4258, 4263, 4291, 429B} Improvements Have Been Made to Simplify Brake Hose Routing on Certain 700 C-Series Articulated Trucks {4257, 4258, 4263, 4291, 429B}
735C and 745C Articulated Trucks Machine Systems General Information (HVAC System)
New Engine Software Is Now Used on Certain Material Handlers and Wheeled Excavators {7610, 7620} New Engine Software Is Now Used on Certain Material Handlers and Wheeled Excavators {7610, 7620}
994K Large Wheel Loader Field Assembly Manual Battery and Wiring - Install - Located Behind the Radiator
C27 and C32 Engines for Caterpillar Built Machines Fuel Filter Base
740 GC, 740 Ejector, 745 Articulated Truck Machine System Seat Suspension - Remove and Install
990K Wheel Loader Systems Air Conditioner
777D and 777E Off-Highway Truck Steering System Piston Pump (Steering)
Release Notes for Cat® Product Link Back-Office 2017A.2 {7490, 7606, 7610, 7620} Release Notes for Cat® Product Link Back-Office 2017A.2 {7490, 7606, 7610, 7620}
548 Forest Machine Machine System Upper Frame
777D and 777E Off-Highway Truck Steering System Steering Gear
548 Forest Machine Machine System Travel Motor Lines
992K Wheel Loader Systems Pressure Switch (Air Conditioner) - Compressor Clutch Refrigerant
548 Forest Machine Machine System Stick Lines
777D and 777E Off-Highway Truck Suspension Cylinder Suspension Cylinder (Front)
The Steering Oil Lines Group has been Improved on Certain 777G Off-Highway Trucks {4304, 5057} The Steering Oil Lines Group has been Improved on Certain 777G Off-Highway Trucks {4304, 5057}
424B2 Backhoe Loader Towing the Machine
The Hydraulic Lines Routing for the Torque Converter Lock Up Clutch (LUC) is Improved for Certain 797F Off-Highway Trucks {3016, 3154} The Hydraulic Lines Routing for the Torque Converter Lock Up Clutch (LUC) is Improved for Certain 797F Off-Highway Trucks {3016, 3154}
An Improved Hose Assembly in the Return Lines Group Is Now Used on Certain 424B Backhoe Loaders {5057} An Improved Hose Assembly in the Return Lines Group Is Now Used on Certain 424B Backhoe Loaders {5057}