776D, 777D and 777D HAA Off-Highway Trucks Machine Systems Caterpillar

Removal Procedure

Start By:

1. Install the body retaining pins. Refer to Disassembly and Assembly, "Pin (Body Retaining) - Remove and Install".
2. Purge the air from the air tanks. Refer to Disassembly and Assembly, "Air Tanks (Brake) - Purge".

Note: Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will prevent dirt from entering the internal mechanism.

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Illustration 1	g00692398

1. Attach Tool (A) to cover (1). Position a suitable lifting sling on Tool (A). Secure the suitable lifting sling to a hoist. Remove four bolts (2) and the hard washers. Remove cover (1). The weight of cover (1) is 18 kg (40 lb).

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Illustration 2	g00692400

2. Label all of the hose assemblies for installation purposes. Disconnect hose assembly (3) from reservoir (4) .

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Illustration 3	g00692403

3. Disconnect hose assembly (6) from air dryer (5) .

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Illustration 4	g00692405

4. Remove three bolts (7) and the clips that hold hose assembly (6) to the frame.

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Illustration 5	g00692401

5. Remove five tie straps (10) and remove tie strap (13). Disconnect hose assembly (9) from reservoir (8). Disconnect hose assembly (11) and hose assembly (12) from reservoir (4) .

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Illustration 6	g00692408

6. Position a suitable lifting sling around reservoir (8). Secure the suitable lifting sling to a hoist. Remove four bolts (14) and the hard washers. Remove reservoir (8). The weight of the reservoir is 14 kg (30 lb).

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Illustration 7	g00692409

7. Position a suitable lifting sling around reservoir (4). Secure the suitable lifting sling to a hoist. Remove four bolts (15) and the hard washers. Remove reservoir (4). The weight of the reservoir is 14 kg (30 lb).

Installation Procedure

Note: Check all of the O-ring seals and the components for wear or for damage. Replace the components, if necessary. Clean all of the components with a cloth that is free of loose material (lint).

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Illustration 8	g00692409

1. Position a suitable lifting sling around reservoir (4). Secure the suitable lifting sling to a hoist. Lift reservoir (4) into position, as shown. The weight of the reservoir is 14 kg (30 lb). Install four bolts (15) and the hard washers.

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Illustration 9	g00692408

2. Position a suitable lifting sling around reservoir (8). Secure the suitable lifting sling to a hoist. Lift reservoir (8) into position, as shown. The weight of the reservoir is 14 kg (30 lb). Install four bolts (14) and the hard washers.

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Illustration 10	g00692401

3. Connect hose assembly (11) and hose assembly (12) to reservoir (4). Connect hose assembly (9) to reservoir (8). Install five tie straps (10) and install tie strap (13) .

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Illustration 11	g00692405

4. Install three bolts (7) and the clips that hold hose assembly (6) to the frame.

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Illustration 12	g00692403

5. Connect hose assembly (6) to air dryer (5) .

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Illustration 13	g00692400

6. Connect hose assembly (3) to reservoir (4) .

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Illustration 14	g00692398

7. Attach Tool (A) to cover (1). Position a suitable lifting sling on Tool (A). Secure the suitable lifting sling to a hoist. Lift cover (1) into position, as shown. The weight of cover (1) is 18 kg (40 lb). Install four bolts (2) and the hard washers.

End By: Remove the body retaining pins. Refer to Disassembly and Assembly, "Pin (Body Retaining) - Remove and Install".