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

Assembly Procedure

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

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Illustration 1	g00648549

1. Install O-ring seal (16) and seal (17) on ring (3). Install four O-ring seals (18) on ring (3) .

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Illustration 2	g00648545

2. Attach Tooling (D) and a suitable lifting device to brake anchor (13). Position brake anchor (13) on ring (3), as shown. The weight of the brake anchor is approximately 58 kg (128 lb). Install bolts (15) and the washers that hold brake anchor (13) to ring (3) .

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Illustration 3	g00648553

3. Attach Tool (C) and a suitable lifting device to brake anchor (13). Turn over brake anchor (13) and ring (3) as an assembly. The weight of the assembly is approximately 120 kg (265 lb).

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Illustration 4	g00648556

4. Install spacers (12) and O-ring seal (14) in ring (3) .

5. Lubricate each friction disc (10) with a light coat of the oil that is used in the service brake. Install plate (11) in ring (3). Install friction discs (10) and the remaining 11 plates (11) in alternating order.

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Illustration 5	g00648557

6. Install damper (9) in ring (3) with the friction material upward, as shown.

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Illustration 6	g00648540

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Illustration 7	g00713619
View of an incorrectly installed seal ring (7)

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Illustration 8	g00713620
View of a correctly installed seal ring (7)

Note: Be sure that yellow side (X) of seal ring (7) is facing outward.

7. Install ring seals (7) and (8) on piston (4) .

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Illustration 9	g01034152

8. Install Tooling (A) and a suitable lifting device in plate (2). Install plate (2) on piston (4), as shown. The weight of plate (2) is approximately 44 kg (96 lb).

9. Install springs (6) and guides (5) on plate (2), as shown. Use Tooling (B) in order to compress spring (6) until the spring pin (not shown) can be installed. Repeat this procedure for the remaining nine springs, guides, and spring pins.

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Illustration 10	g01034155

10. Use Tooling (A) in order to position plate (2) and piston (4) on ring (3) as an assembly. The weight of the assembly is approximately 59 kg (130 lb).

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Illustration 11	g00648535

11. Install bolts (1) and the washers that hold plate (2) to ring (3). Tighten the bolts to a torque of 300 ± 15 N·m (221 ± 11 lb ft).

End By: Install the front oil cooled service brake. Refer to Disassembly and Assembly, "Service Brake (Front Oil Cooled) - Install".