Assembly Procedures for the 776D Tractors and for the 777D Off-Highway Trucks{7000, 7960} Caterpillar

Off-Highway Truck/Tractor:

776D (S/N: AFS79-81)

777D (S/N: AGC454-1428)

777D HAA (S/N: AGY78-81)

Introduction

This special instruction contains information and procedures that are required in order to assemble 776DOff-Highway Tractors and 777DOff-Highway Trucks.

The suggested tools should be available. Without proper tools and equipment, more time will be consumed when you assemble the machine.

Check for parts and for information in the following locations:

• Operator Station

• Truck Body

• Shipping Containers

Inspect all areas for parts and for information. Do not discard any material until the machine is completely assembled.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

Read the entire special instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Note: In this publication, some photos are for illustrative purposes. Photos for illustrative purposes may not be in sequence with the assembly procedure.

After the machine is assembled, refer to the Operation and Maintenance Manual, SEBU7261, "776D Tractors and 777D Off-Highway Trucks" or Operation and Maintenance Manual, SEBU7268, "777D HAA Off-Highway Trucks" in order to prepare the machine for operation. Use the Parts Manual and use the Service Manual in addition to this special instruction.

This special instruction also contains information for the high altitude arrangement. Refer to the index in order to find specific assembly procedures for that machine.

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NOTICE
Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

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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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Parts List

Table 1

Required Parts for the Installation of the Rear Axle Housing
Quantity	Part Number	Description
1	172-5232	Slip Joint
4	8B-5144	Bolt (5/8-18)
16	3R-2300	Bolt (1 1/4-7)
16	4K-0684	Hard Washer
4	4J-0528	O-Ring Seal
1	119-6708	Tube As
8	8T-4835	Bolt (1/2-13)
8	8T-8919	Bolt (1/2-13)
40	8T-4223	Hard Washer
1	119-6709	Tube As
1	119-6706	Tube As
1	119-6707	Tube As
5	4J-0527	O-Ring Seal
10	1P-4582	Half Flange
20	5P-2566	Bolt (1/2-13)
1	3J-1907	O-Ring Seal
1	118-7226	Temperature Sensor Gp
1	4J-0524	O-Ring Seal
2	1P-4579	Half Flange
4	7X-0325	Bolt (3/4-10)

Table 2

Required Parts for Installation of the Steps
Quantity	Part Number	Description
2	7I-5383	Step
4	7X-0365	Bolt (3/4-10)

Table 3

Required Parts for Installation of Front Suspension Cylinders
Quantity	Part Number	Description
2	9D-2498	Key
2	4T-4756	Front Suspension Cylinder
32	7B-9215	Bolt (1 1/8-12)
32	3S-1356	Full Nut
64	3S-1349	Washer
8	2H-3758	Bolt (1 1/4-7)
8	5D-0764	Hard Washer
24	116-2673	Shim

Table 4

Required Parts for Installation of Front Oil Cooler Lines and Front Service Brake Lines
Quantity	Part Number	Description
10	4J-0522	O-Ring Seal
16	1P-4578	Half Flange
32	8T-5360	Washer
24	8T-8916	Bolt (1/2-13)
4	103-5422	Hose Assembly
2	8X-7949	Plate
2	8X-5150	Block
2	5T-0967	Block
4	8T-9101	Bolt (3/8-16)
4	8T-4896	Hard Washer
2	6V-8398	O-Ring Seal
2	6V-9873	Connector
2	3J-1907	O-Ring Seal
2	8X-7920	Hose Assembly
8	8C-6877	Bolt (7/16-14)

Table 5

Required Parts for Installation of Fuel Tank
Quantity	Part Number	Description
1	114-0937	Fuel Tank
4	5D-5654	Mounting
2	0S-1627	Bolt (3/4-10)
2	9D-9438	Washer
2	5P-8248	Hard Washer
2	1K-6870	Locknut
1	6G-7803	Vent Assembly
1	5P-2230	Hose Clamp
1	139-0156	Hose Assembly

Table 6

Required Parts for Installation of Platform
Quantity	Part Number	Description
1	175-0183	Support
16	0S-1585	Bolt (1/2-13)
16	8T-4223	Hard Washer
4	4L-6454	Bolt (3/8-16)
12	5P-1075	Hard Washer
4	6V-8801	Nut
4	8T-2502	Bolt (3/8-16)

Table 7

Required Parts for Installation of Air Lines Group
Quantity	Part Number	Description
4	127-7455	Bracket
8	5S-7379	Bolt (3/8-16)
24	5P-1075	Hard Washer
1	127-7452	Tube
8	8T-2501	Bolt (3/8-16)
8	2K-4973	Locknut
12	8T-4988 (1)	Hose Clamp
2	127-7450	Air Inlet Hose
2	4P-5104 (1)	Elbow
1	127-7451	Tube
4	127-7453	Strap
1	161-9926	Pressure Sensor
1	172-0195	Adapter
2	6V-5048	O-Ring Seal
7	7X-1181	Strap
2	4P-7581	Clip
1	118-7952	Turbocharger Sensor Harness Assembly

( 1 )

Install the part when the air cleaner is installed.

Table 8

Required Parts for Installation of Catwalk
Quantity	Part Number	Description
1	191-7929	Catwalk
38	4L-6454	Bolt (3/8-16)
24	8T-4896	Hard Washer
1	116-4690	Catwalk
12	5S-7379	Bolt (3/8-16)
1	8W-4484	Pipe
26	5P-1075	Hard Washer
1	191-7927	Rail
1	6G-0115	Brace
1	7F-5462	Lug (1)
2	8T-8917	Bolt (1/2-13)
4	8T-4223	Hard Washer
4	6V-8801	Nut
1	161-2606	Handle
2	8T-9383	Bolt (1/2-13)
1	161-2605	Handle

( 1 )

The lug is welded on the catwalk.

Table 9

Required Parts for Installation of Cab Mounts and Cab
Quantity	Part Number	Description
1	106-6310	Support
8	9S-1367	Bolt (1-14)
8	5P-8250	Washer
32	163-0042	Cab Mount
12	163-3127	Sleeve
1	106-1840	Support
10	8F-3895	Bolt (1 1/8-12)
10	3S-1349	Washer
4	183-7800	Sleeve
4	6H-1628	Bolt (1 1/4-7)
8	5T-5807	Retainer
4	1K-9420	Bolt (1 1/4-7)
8	8W-7879	Washer
8	5B-5473	Bolt (1-8)

Table 10

Required Parts for Installation of Air Lines
Quantity	Part Number	Description
2	160-9821	Air Cleaner
4	119-8361	Support
12	4L-6454	Bolt (3/8-16)
32	5P-1075	Hard Washer
12	6V-8801	Nut
2	4P-5104 (1)	Elbow
4	8T-4989 (1)	Hose Clamp
2	7W-7417	Service Indicator
2	5K-5068	Nipple
2	5P-4400	Air Brake Connector
1	126-6603	Bracket
2	5P-4428	Elbow
2	5P-0756	Tube
2	8M-2772	Clip
8	8T-2502	Bolt (3/8-16)
4	8T-4988 (1)	Hose Clamp

( 1 )

The part is from the air lines.

Table 11

Required Parts for Installation of Fenders and Guards
Quantity	Part Number	Description
1	173-0585	Fender
64	5P-1075	Hard Washer
22	5S-7379	Bolt (3/8-16)
1	120-9726	Guard
34	6V-8801	Nut
4	5P-8167	Bolt (3/8-16)
2	6G-3361	Mud Flap
5	5S-7382	Bolt (3/8-16)
2	2G-6916	Strip
20	8T-2502	Bolt (3/8-16)
1	113-9960	Guard
12	5M-3062 (1)	Bolt (3/8-16)
1	8W-6062	Deflector
1	8W-6063	Strip
9	4L-6454	Bolt (3/8-16)
1	8W-9781	Baffle
1	8X-9699	Guard
1	5T-6553	Plate
4	8T-2561	Washer
1	2G-2258	Strip

( 1 )

Six bolts may already be installed in the 113-9960 Guard .

Table 12

Required Parts for installation of Heater and Air Conditioner Lines
Quantity	Part Number	Description
2	5D-1026	Hose Clamp
7	6D-1641	Clip
6	8T-4896	Hard Washer
1	5P-1075	Hard Washer
7	5S-7379	Bolt (3/8-16)
1	3S-2093	Cable Strap

Table 13

Required Parts for Installation of Steering Lines
Quantity	Part Number	Description
2	5K-9090	O-Ring Seal
2	6V-9746	O-Ring Seal
1	174-6583	Guard
3	7X-0772	Hard Washer
4	5M-3062	Bolt (3/8-16)
1	174-6565	Bracket
4	8T-4896	Hard Washer

Table 14

Required Parts for Installation of the Hoses for the Windshield Washer
Quantity	Part Number	Description
5 m (16.4 ft)	5P-0715	Hose
6	4D-7794	Clip
6	5M-3062	Bolt (3/8-16)
6	8T-4896	Hard Washer

Table 15

Required Parts for Installation of Handholds
Quantity	Part Number	Description
1	9D-4721	Rail
34	4L-6454	Bolt (3/8-16)
14	8T-4896	Hard Washer
1	113-1520	Rail (1)
1	116-0012	Rail (2)
20	5P-1075	Hard Washer
1	5T-4228	Rail
4	8T-8919	Bolt (1/2-13)
4	8T-4223	Hard Washer

( 1 )	Part of the 115-5706 Platform Group
( 2 )	Part of the 114-0936 Platform Group

Table 16

Required Parts for Installation of 5T-6547 Rear View Mirror
Quantity	Part Number	Description
1	2G-0266	Bracket
6	4M-5283	Bolt (1/4-20)
8	8T-4205	Hard Washer
1	2G-1255	Brace
2	5S-7349	Bolt (1/4-20)
1	6V-6962	Mirror
2	6V-6961	Knob
2	5P-9865	Mirror Spacer
1	153-9136	Bracket
2	5S-7379	Bolt (3/8-16)
3	2K-4973	Locknut
2	8T-2502	Bolt (3/8-16)
2	6V-8801	Nut
4	8T-4896	Hard Washer
1	5P-6872	Mirror
2	8D-8011	Plate

Table 17

Required Parts for Installation of 8X-9966 Rear View Mirror
Quantity	Part Number	Description
2	7D-9969	Support
2	7X-0326	Bolt (1/2-13)
2	8T-4223	Hard Washer
1	8W-7904	Tube
1	8T-2287	Mirror
2	5S-7379	Bolt (3/8-16)
2	5P-1075	Hard Washer

Table 18

Required Parts for Installation of Headlamps and Signal Lamps
Quantity	Part Number	Description
2	135-0427	Signal Lamp
2	157-0305	Headlight (Low Beam)
2	161-0908	Headlight (High Beam)
4	8T-4205	Hard Washer
6	8T-4134	Nut
2	130-5300	Clip
2	5P-4115	Washer
4	161-8044	Bracket
4	5M-3062	Bolt (3/8-16)
4	8T-4896	Hard Washer
4	5P-2955	Bolt (5/16-18)
8	8T-4224	Hard Washer
4	3E-9860	Locknut

Table 19

Required Parts for Installation of Front Wheels
Quantity	Part Number	Description
40	5D-0764	Hard Washer
40	5D-0765	Full Nut

Table 20

Required Parts for Installation of Rear Wheels
Quantity	Part Number	Description
80	5D-0764	Hard Washer
80	5D-0765	Full Nut
1	6G-8018	Tire Valve
2	6G-0333	Clamp
8	9B-7237	Bolt (3/8-16)
8	5P-1075	Hard Washer
1	6G-8019	Tire Valve

Table 21

Required Parts for Installation of Body
Quantity	Part Number	Description
2	8W-8454	Pin
2	8W-2897 (1)	Thrust Washer
2	9D-3432 (1)	Thrust Washer
2	8W-8456	Plate
12	5P-2566	Bolt (1/2-13)
12	8T-4223	Hard Washer
2	3B-8489	Grease Fitting
2	9D-5004	Plate
8	6V-8188	Nut
2	9D-5006	Baffle
2	9D-5005	Plate
16	9B-7237	Bolt (3/8-16)
16	6V-8801	Nut

( 1 )

Use the 8W-2897 Thrust Washer only when the 9D-3432 Thrust Washer will not fit.

Table 22

Required Parts for Installation of Hoist Cylinders
Quantity	Part Number	Description
2	5T-9266	Pin As
4	9D-2316	Spacer
2	5T-5528	Plate
4	5P-2566	Bolt (1/2-13)
4	8T-4223	Hard Washer
2	4S-7606	Elbow
2	4K-3026	Extension
2	4D-2560	Pipe Connector
2	3B-8489	Grease Fitting
2	7D-3973	Hose Assembly

Table 23

Required Parts for Installation of Retaining Pins
Quantity	Part Number	Description
2	5D-3887	Rod
2	6F-8499	Spring
4	054-3788	Orifice
4	3B-4615	Cotter Pin
2	6G-8161	Pin As

Table 24

Required Parts for Installation of Shims for the Body
Quantity	Part Number	Description
2	8W-4931	Shoe
2	5T-2031	Pin As
2	5T-2029	Plate
14	8T-8919	Bolt (1/2-13)
34	8T-4223	Hard Washer
6	106-8225	Pad
18	106-8227	Shim
20	5P-2566	Bolt (1/2-13)

Table 25

Required Parts for Installation of Rock Ejectors
Quantity	Part Number	Description
2	8W-1155	Rock Ejector Assembly
2	6G-7773	Pin As
4	3B-4647	Cotter Pin
16	1D-0503	Washer
2	153-7448 (1)	Plate
1	5T-9442 (2)	Plate
1	5T-9443 (3)	Plate

( 1 )	The 153-7448 Plate is used on bodies with flat floors.
( 2 )	The 5T-9442 Plate is used on dual slope bodies.
( 3 )	The 5T-9443 Plate is used on dual slope bodies.

Table 26

Required Parts for Installation Of Visual Body Down Indicator
Quantity	Part Number	Description
1	113-1218	Baffle
2	031-9831	Bolt (3/8-16)

Table 27

Required Parts For Installation of Magnetic Assembly
Quantity	Part Number	Description
1	3E-0461	Electronic Control
1	180-0468	Bracket
4	4M-6425	Bolt (5/16-18)
4	5P-4116	Washer
4	5S-7379	Bolt (3/8-16)
2	5P-1075	Hard Washer
1	5G-7820	Magnet Assembly
1	109-5286	Bracket
2	6V-8189	Nut
2	8T-4896	Hard Washer
1	8T-4896 (1)	Hard Washer
1	5S-7379 (1)	Bolt (3/8-16)
1	9G-9152 (1)	Clip

( 1 )

The part is from the 169-3770 Wiring and Lighting Group .

Table 28

Required Parts for Installation of Payload Lamps
Quantity	Part Number	Description
1	8K-1433	Grommet
1	8W-4812	Bracket
8	5M-3062	Bolt (3/8-16)
4	8T-4896	Hard Washer
2	9G-9150	Clip

Table 29

Required Parts for Installation of 8W-9078 Exhaust Pipe and 7C-4013 Muffler
Quantity	Part Number	Description
4	8T-4122	Washer
1	111-4368	Tube
2	8W-5558	Angle
2	4L-6454	Bolt (3/8-16)
4	8T-2561	Washer
2	7K-3215	Boss
2	8T-2501	Bolt (3/8-16)
1	186-4178	Bracket
4	5S-7379	Bolt (3/8-16)
20	8T-4896	Hard Washer
2	8W-4261	Strap
2	8T-8917	Bolt (1/2-13)
6	8T-4223	Hard Washer
4	6V-8188	Nut
1	111-4352	Muffler Assembly
1	4N-9330	Clamp
1	5P-2424	Bolt (1/2-13)
2	8W-4260	Strap
8	8T-2501	Bolt
8	6V-8801	Nut
1	129-9477	Exhaust Extension
1	6N-9298	Clamp
1	8T-4835	Bolt (1/2-13)

Table 30

Required Parts for Installation of 6G-7856 Exhaust Pipe
Quantity	Part Number	Description
1	5T-3492	Plate As
4	4L-6454	Bolt (3/8-16)
10	5P-1075	Hard Washer
1	6G-7031	Elbow
1	6G-7038	Seal Ring
1	5T-3369	Piston
1	5T-2762	Spring
1	5T-3367	Elbow
3	9D-2836	Lock
6	0L-1351	Bolt (3/8-16)
4	2D-9345	Stud
8	5P-8247	Hard Washer
8	7K-1270	Washer
4	4K-0367	Nut

Table 31

Required Parts for Installation of Exhaust Diverter Valve
Quantity	Part Number	Description
4	0S-1589	Bolt (5/8-11)
4	5P-8247	Hard Washer
4	7K-1270	Washer
2	4B-3586	Setscrew
2	1D-5117	Jam Nut
1	1B-4430	Jam Nut
1	2G-2477	Hose Assembly
1	2G-6523	Hose Assembly
1	3N-7235	Hose Assembly
1	3T-3048	Clip Assembly
1	4D-4065	Rod End
7	7K-1181	Cable Strap
2	7W-3447	Spacer
1	8M-8489	Dowel
1	125-4122	Cylinder
1	136-6964	Plate
1	170-1004	Exhaust Diverter Harness Assembly
1	3S-6115	Tee
2	0S-1595	Bolt (1/2-13)
1	0T-0573	Bolt (3/8-16)
2	4K-8302	Clip
2	4L-6454	Bolt (3/8-16)
2	4P-7429	Clip
4	5H-4778	Elbow
3	5K-8451	Clip
3	5P-1075	Hard Washer
1	5S-7383	Bolt (3/8-16)
3	6V-8801	Nut
3	8T-4896	Hard Washer

Table 32

Required Parts for Installation of Film
Quantity	Part Number	Description
1	100-5615	Film
2	131-5415	Film
1	125-4163	Film
1	125-4164	Film
1	125-4162	Film
1	125-4160	Film
1	8C-5563	Film
1	8C-5353	Film

Table 33

Required Parts for Installation of 136-0894 Air Cleaner Gp
Quantity	Part Number	Description
2	135-5285	Air Cleaner
2	119-8361	Support
12	4L-6454	Bolt (3/8-16)
32	5P-1075	Hard Washer
12	6V-8801	Nut
2	135-5294 (1)	Elbow
4	8T-4990 (1)	Hose Clamp
2	7W-7417	Service Indicator
2	5K-5068	Nipple
2	5P-4400	Air Brake Connector
1	135-5288	Bracket
2	5P-4428	Elbow
2	5P-0756	Tube
2	8M-2772	Clip
8	8T-2502	Bolt (3/8-16)
4	8T-4988 (1)	Hose Clamp
1	135-5290	Support
1	135-5293	Support
2	7W-0629	Filter Adapter

( 1 )

This part is from the air lines.

Table 34

Required Parts for Installation of 136-0895 Air Lines
Quantity	Part Number	Description
4	127-7455	Bracket
8	5S-7379	Bolt (3/8-16)
24	5P-1075	Hard Washer
1	136-5692	Tube
8	8T-2501	Bolt (3/8-16)
8	2K-4973	Locknut
12	8T-4988 (1)	Hose Clamp
2	127-7450	Air Inlet Hose
2	135-5294 (1)	Elbow
1	136-5691	Tube
4	127-7453	Strap
1	161-9926	Pressure Sensor
1	172-0195	Adapter
2	6V-5048	O-Ring Seal
7	7X-1181	Strap
2	4P-7581	Clip
1	118-7952	Turbocharger Sensor Harness Assembly

( 1 )

Install this part when the air cleaner is installed.

Weights and Specifications

Machine Weights

• The chassis weighs 21315 kg (47000 lb).

• The cab assembly weighs 1440 kg (3175 lb).

• The front suspension cylinder, the wheel, and the brake assembly weighs 2070 kg (4565 lb).

• The rear axle assembly weighs 9389 kg (20700 lb).

• The tire and rim assembly weighs 1960 kg (4320 lb).

• The standard body and canopy assembly weighs 15780 kg (34900 lb).

• A body weighs 21180 kg (46700 lb).

• The air tank weighs 160 kg (353 lb).

Machine Specifications

• The height dimension of the chassis assembly is 1676 mm (66 inches).

• When the tires are installed, the height dimension at the top of the hood is 3150 mm (124 inches).

• The distance from the center of the body to the outside wall is 2438 mm (96 inches).

• When the tires are installed, the height to the top edge of the body is 4288 mm (169 inches).

• When the tires are installed, the height to the top edge of the canopy is 5028 mm (198 inches).

• The length of the truck is 9780 mm (385 inches).

• The width of the truck is 6105 mm (240 inches).

Torque Specifications

• Tighten the bolts that mount the rear axle assembly to the suspension a-frame to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

• Tighten the bolts that mount the rear axle assembly to the rear suspension cylinders to 620 ± 80 N·m (460 ± 60 lb ft).

• Tighten the bolts that secure the control rod to the frame and to the rear axle assembly to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

• Tighten the bolts that secure the drive shaft to the transmission to a torque of 270 ± 15 N·m (200 ± 11 lb ft).

• Tighten the nuts that mount the front wheel rim to a torque of 1210 ± 55 N·m (890 ± 40 lb ft).

• Tighten the nuts that mount the rear wheel rim to a torque of 1200 ± 50 N·m (885 ± 37).

• Tighten the bolts that mount the front suspension cylinder to a torque of 1180 ± 48 N·m (870 ± 35 lb ft).

• Tighten the front suspension cylinder cap mounting bolts to a torque of 370 ± 50 N·m (270 ± 35 lb ft).

• Tighten the bolts that mount the front steering arm to a torque of 1800 ± 163 N·m (1325 ± 120 lb ft).

• Tighten the ballstud nuts to a torque of 1360 N·m (1000 lb ft).

• Tighten the cab mounting bolts at the front of the cab to a torque of 1050 ± 150 N·m (775 ± 110 lb ft).

• Tighten the cab mounting bolts at the rear of the cab to a torque of 2100 ± 250 N·m (1550 ± 185 lb ft).

• Tighten the cab support mounting bolts at the front support to a torque of 1050 ± 150 N·m (775 ± 110 lb ft).

• Tighten the cab support mounting bolts at the rear support to a torque of 1450 ± 150 N·m (1070 ± 110 lb ft).

Chains and Cables

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's literature in order to determine the application when you select the items that follow: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.

Illustration 1	g00629745
Lift angles for lifting slings. (A) The load capacity is 100% of the working load limit for the sling. (B) The load capacity is 86% of the working load limit for the sling. (C) The load capacity is 70% of the working load limit for the sling. (D) The load capacity is 50% of the working load limit for the sling.

Hoist Capability Assembly Tips

Chassis Assembly

When the differential housing is on supports, a hoist with a capacity of 10000 kg (22000 lb) is necessary in order to lift the chassis at the front lifting point.

When the front frame crossmember is on supports, a hoist with a capacity of 8600 kg (19000 lb) is necessary in order to lift the chassis at the rear lifting point.

Assembled Machine Without the Body

When the rear tires are on the ground, a hoist with a capacity of 17000 kg (38000 lb) is necessary in order to lift the truck at the front lifting point.

When the front tires are on the ground, a hoist with a capacity of 16000 kg (35000 lb) is necessary in order to lift the truck at the rear lifting points.

Necessary Equipment and Supplies

General Tools

• Use a 5P-7373 Axle Installation Tool in order to install the axles.

• When you are instructed, apply 4C-5593 Anti-Seize Compound to threads.

• When you are instructed, apply 5P-3931 Anti-Seize Compound to threads.

• Use a 6V-6080 Torque Multiplier in order to tighten the components that follow: the steering arm mounting nuts, the ballstud nuts and the wheel rim mounting nuts.

• Use a 6V-8720 Torque Multiplier in order to tighten the rear axle housing nuts.

• Use a 6V-7915 Torque Wrench with the torque multipliers.

• Use a 194-7586 Pneumatic Wrench Gp with a 194-7886 Drive Extension on the bolts that hold the front suspension cylinder to the frame assembly.

• Use an 8H-8548 Extension on the wheel rim mounting nuts.

• Use an 8H-8541 Socket on the steering arm mounting nuts.

• Use an 8H-8504 Socket on the ballstud nuts.

• Use an 8H-8540 Socket on the wheel rim mounting nuts.

• Use a 2P-2334 Socket on the bolts that hold the front suspension cylinder to the frame assembly.

• Use an 8H-8537 Socket on the cab mounting bolts.

• Use a 7H-1680 Compressor Assembly in order to pump oil in the suspension cylinders.

• Use a 6V-4040 Inflation Group in order to inflate the tires with nitrogen.

• Use an 8H-8536 Socket .

• Use an FT-1680 Pressure Gauge on the front suspension cylinders.

• Use a 7S-5437 Nitrogen Charging Group in order to charge the tires and the suspension cylinders.

• Use a 8T-5230 Torque Wrench that is regulated by air pressure in order to obtain a maximum torque of 300 N·m (220 lb ft).

• When you are instructed, apply 4C-4079 Brake and Electrical Cleaner in order to clean components.

Required Supplies

Refer to the information that follows in order to gather supplies and equipment.

• Obtain two barrels of final drive oil. Each barrel should have a capacity of 208 L (55 US gal). Final drive and axle oil (FDAO) is the oil that is recommended for the final drives, the differential, and the front wheels. SAE viscosity grade 60 is recommended. Refer to the Operation and Maintenance Manual.

• Have one 208 L (55 US gal) barrel of hydraulic oil (HYDO).

• Obtain five barrels of transmission/drive train oil (TDTO). Each barrel should have a capacity of 208 L (55 US gal). Three barrels should contain SAE 10W oil. Two barrels should contain SAE 30 oil. Ambient temperatures that are extreme may require a different oil viscosity. Refer to Service Manual, SEBU6250, "Caterpillar Machine Lubricant Recommendations".

• Have 20 nitrogen bottles that are T-size in order to inflate the tires and charge the suspension cylinders.

• Have one portable air compressor. The air compressor should have enough capacity in order to operate two 25.4 mm (1 inch) impact air guns. The air compressor should have a minimum capacity of 3 CM (100 CFM).

• Have one ladder that is 1.8 m (6 ft) tall. Have another ladder that is 3.6 m (12 ft) tall.

• Have one lift truck that can lift 4082 kg (9000 lb).

• Have another lift truck that can lift 13608 kg (30000 lb).

• Have one crane that can lift 36320 kg (80000 lb).

• Have at least 12 hardwood blocks that are 101 mm (4.0 inches) tall. The blocks should be 203 mm (8.0 inches) wide. The blocks should be 406 mm (16.0 inches) long.

• Have at least 40 hardwood blocks that are 203 mm (8.0 inches) tall. The blocks should be 203 mm (8.0 inches) wide. The blocks should be 914 mm (36.0 inches) long.

• Have at least 30.5 m (100 ft) of rope that is 12.7 mm (0.50 inch) in diameter. When you install the body on the chassis, use the rope in order to guide the body into position.

• Have several shackles. The shackles should have a working load limit of 27240 kg (60050 lb).

• Have cables, chains, and lifting devices that have adequate capacity.

Prepare to Assemble the Machine

Before you unload the chassis and related components, read the information that follows in order to make the job easier.

• In order to assemble the machine, select an area that is smooth and flat. The area should be 25 m (82 ft) wide and 30 m (98 ft) long. The area should drain well. Place the chassis in the center of the area.

• When you unload components, place the components near the chassis. However, keep an area around the chassis clear in order to position the cranes for lifting the components.

• Open all boxes and inspect the contents.

• Organize components and hardware in order to help reduce lost hardware and speed assembly.

• Do not open plastic bags of hardware. The plastic bags are marked with yellow labels that are printed with the group part number. Individual components are marked with yellow labels that are printed with the component part number and with the group part number. Move each plastic bag of hardware to the chassis when the corresponding component is installed.

Illustration 2	g00638037

Tire Inflation Pressure and Mounting

Note: When you mount the tire, install the valve stem connections and the extensions.

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Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures.

Table 35

Tire Inflation Pressure
Size	Ply Rating or Strength Index	Operating Pressure
27.00 - R49	Michellin Two Star	586 kPa (85 psi)
27.00 - R49	Bridgestone/Firestone Two Star	620 kPa (90 psi)
27.00 - R49	Goodyear Two Star	655 kPa (95 psi)

Chassis Lifting Points

Illustration 3	g00785292
Lifting points on the 776D Tractors

Illustration 4	g00785293
Lifting points on the 777D Off-Highway Trucks

Illustration 5	g00785303
Lifting points on the chassis

Illustration 6	g00785304
Lifting points on the chassis

Position the Chassis for Assembly

Illustration 7	g00528399
Wooden supports under the front frame

1. When you remove the chassis from the truck, place supports under the chassis. Place supports at the front of the chassis and place supports at the rear of the chassis.

2. When you place the supports at the front of the chassis, provide 1117 mm (44 inch) of ground clearance in order to install the tires.

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Illustration 8	g00785311

3. When you place the supports at the rear of the chassis, provide 1092 mm (43 inch) of ground clearance in order to install the tires.

Install the Rear Axle Group and the Transmission

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NOTICE
This procedure is for tractors and for trucks that are shipped with the new rear axle configuration. The rear axle configuration includes the axle housing, the transmission, and the final drives that are attached.

Table 36

Required Parts for the Installation of the Rear Axle Housing
Item	Quantity	Part Number	Description
1	1	172-5232	Slip Joint
2	4	8B-5144	Bolt (5/8-18)
3	16	3R-2300	Bolt (1 1/4-7)
4	16	4K-0684	Hard Washer
5	4	4J-0528	O-Ring Seal
6	1	119-6708	Tube As
7	8	8T-4835	Bolt (1/2-13)
8	8	8T-8919	Bolt (1/2-13)
9	40	8T-4223	Hard Washer
10	1	119-6709	Tube As
11	1	119-6706	Tube As
12	1	119-6707	Tube As
13	5	4J-0527	O-Ring Seal
14	10	1P-4582	Half Flange
15	20	5P-2566	Bolt (1/2-13)
16	1	3J-1907	O-Ring Seal
17	1	118-7226	Temperature Sensor Gp
18	1	4J-0524	O-Ring Seal
19	2	1P-4579	Half Flange
20	4	7X-0325	Bolt (3/4-10)

Note: In order to obtain the proper torque values, apply 4C-4188 Paint Remover on all mating surfaces. Remove any burrs, nicks, or rust before assembly.

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Illustration 9	g00787521

1. Remove nine bolts (A) and nine washers (B) that secure guard (C) to the frame. Remove guard (C) from the frame.

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Illustration 10	g00787522

2. Remove the bolt, the clip, and hose (D) from guard (E) .

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Illustration 11	g00787523

3. Remove nine bolts (F) and nine washers (G) that secure guard (E) to the frame. Remove guard (E) from the frame.

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Illustration 12	g00787524

4. Clean the mounting areas on the transmission drive shaft and on the torque converter yoke.

5. Install slip joint (1) to the torque converter yoke. Use four bolts (2) to secure slip joint (1) to the torque converter yoke. Tighten bolts (2) to a torque of 270 ± 15 N·m (200 ± 11 lb ft).

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Illustration 13	g00787523

6. Install guard (E) to the frame. Use nine bolts (F) and nine washers (G) to secure guard (E) to the frame.

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Illustration 14	g00787522

7. Install the bolt, the clip, and hose (D) to guard (E) .

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Illustration 15	g00785329

8. Remove the two bolts, the washers, and the nuts that secure the plate to the suspension A-frame. Remove the bolt, the washers, and the nut that secures the plate to the rear suspension cylinder. Repeat the procedure for the other plate.

9. Remove the shipping covers from the suspension A-frame. Repeat the procedure for the other side of the suspension A-frame.

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Illustration 16	g00785332

10. Use 4C-4188 Paint Remover to remove the paint from the rear axle assembly. Use 4C-4079 Brake and Electrical Cleaner to clean the mounting areas on the rear axle assembly.

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Illustration 17	g00785334

11. Use 4C-4188 Paint Remover to remove the paint from the suspension a-frame. Use 4C-4079 Brake and Electrical Cleaner to clean the mounting areas on the suspension A-frame.

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Illustration 18	g00787526

12. Remove the following components from the rear axle assembly: two 1A-5666 Full Nuts , four 8X-8414 Washers , two 5P-8249 Hard Washers , two 4B-7572 Bolts and two 9D-2278 Pins (H) .

13. Use 4C-4188 Paint Remover to remove the paint from two 9D-2278 Pins .

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Illustration 19	g00787528

14. Remove the following components from the rear of the chassis: 2J-3505 Full Nut , 5P-8249 Hard Washer , two 8X-8414 Washers , 2B-2391 Bolt and 7D-3009 Pin (J) .

15. Use 4C-4188 Paint Remover to remove the paint from 7D-3009 Pin .

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Illustration 20	g00785475

16. Place a suitable lift truck under the rear axle assembly. Lift the rear axle assembly to the frame.

    Note: Do not crush the hoses or do not pinch the hoses that are located in the rear of the chassis.

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Illustration 21	g00787529

17. Install 16 bolts (3) and 16 washers (4). This will secure the rear axle assembly to the suspension A-frame.

    Note: Tighten bolts (3) with an impact wrench. Do not torque bolts (3) at this time.

18. Align the rear suspension cylinders with the rear axle housing.

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Illustration 22	g00787530

19. Install 9D-2278 Pins to the rear axle housing and to the rear axle housing.

    Note: Lubricate 9D-2278 Pins with 4C-5593 Anti-Seize Compound before installation.

20. Install the following components to the rear suspension cylinder and to the rear axle housing: two 1A-5666 Full Nuts , four 8X-8414 Washers , two 5P-8249 Hard Washers and two 4B-7572 Bolts (H). Tighten the bolts to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

21. Repeat Step 18 through Step 20 for the other rear suspension cylinder.

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Illustration 23	g00787529

22. Torque bolts (3) that secure the rear axle assembly to the suspension a-frame. Tighten bolts (3) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

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Illustration 24	g00787532

23. Align control rod (K) with the frame. Install 7D-3009 Pin to the end of the control rod and to the frame.

24. Install the following components to control rod (K) and to the frame: 2J-3505 Full Nut , 5P-8249 Hard Washer , two 8X-8414 Washers and 2B-2391 Bolt (J). Tighten the bolt to a torque of 620 ± 80 N·m (460 ± 60 lb ft).

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Illustration 25	g00787533

25. Align the drive shaft to the transmission. Install four bolts (2) in order to secure the drive shaft to the transmission. Tighten bolts (2) to a torque of 270 ± 15 N·m (200 ± 11 lb ft).

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Illustration 26	g00787521

26. Install guard (C) to the frame. Install nine bolts (A) and nine washers (B) to secure guard (C) to the frame.

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Illustration 27	g00785895

27. Remove the link from the chain that secured the suspension A-frame to the chassis. Remove the chain from the chassis.

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Illustration 28	g00792418
(A) 11 mm (0.43 inch)

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NOTICE
Do not grind through the weld or through the parent material of the frame.

28. Carefully remove the two eyes from the side of the suspension a-frame and of the frame.

29. Slowly lower the rear axle assembly. Remove the lift truck from the rear axle assembly.

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Illustration 29	g00787410

30. Remove the four nuts and the washers that secure the plate to the wheel. Remove the plate from the wheel. Repeat the procedure for the other wheel.

Connect the Brake Lines

Note: The following steps are for 776D Tractor and for 777D Off-Highway Trucks that are equipped with the Traction Control System.

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Illustration 30	g00785749

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Illustration 31	g00785752

1. Remove the tie straps from the brake hoses. Remove the shipping caps from the brake hoses, the slack adjuster, and the traction control valve.

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Illustration 32	g00787536

2. Connect hose (L) to the traction control valve. Connect hose (M) to the traction control valve.

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Illustration 33	g00787538

3. Remove the bolt, the washer, and clip (N) from the differential housing. Connect the end of hose (P) to the slack adjuster. Reinstall the bolt, the washer, and clip (N) in order to secure hose assembly (P) to the differential housing.

Install the Brake Oil Cooler Lines

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Illustration 34	g00785853

1. Remove the shipping caps from the final drives.

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Illustration 35	g00787539

2. Install O-ring seal (5) in the end of tube (6) .

3. Use the following components to secure tube (6) to the bottom port of the final drive: two bolts (7), two bolts (8) and four washers (9) .

   Note: The two bolts (8) go in the top two holes of tube (6) .

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Illustration 36	g00787540

4. Install O-ring seal (5) in the end of tube (10) .

5. Use the following components to secure tube (10) to the top port of the final drive: two bolts (7), two bolts (8) and four washers (9) .

   Note: The two bolts (8) go in the back two holes of tube (10) .

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Illustration 37	g00787541

6. Remove the bolt, the washer, and clips (Q) from the suspension A-frame. Secure tube (6) and tube (10) with bolt, washers, and clips (Q) .

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Illustration 38	g00787542

7. Install O-ring seal (5) in the end of tube (11) .

8. Use the following components to secure tube (11) to the bottom port of the final drive: two bolts (7), two bolts (8) and four washers (9) .

   Note: The two bolts (8) go in the top two holes of tube (11) .

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Illustration 39	g00787543

9. Install O-ring seal (5) in the end of tube (12) .

10. Use the following components to secure tube (12) to the top port of the final drive: two bolts (7), two bolts (8) and four washers (9) .

    Note: The two bolts (8) go in the back two holes of tube (12) .

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Illustration 40	g00787586

11. Remove the bolt, the washer, and clips (R) from the suspension A-frame. Secure tube (11) and tube (12) with bolt, washers, and clips (R) .

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Illustration 41	g00787587

12. Remove the wire ties and the shipping caps from the hoses for the brake oil cooler.

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Illustration 42	g00787544

13. Connect the following tube assemblies to the following hose assemblies on the right side of the chassis: tube (6) to 8W-0958 Hose As and tube (10) to 8W-2278 Hose As .

14. Use the following components to secure the tube assemblies to the hose assemblies: two O-ring seals (13), four half flanges (14), eight bolts (15) and eight washers (9) .

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Illustration 43	g00787545

15. Connect the following tube assemblies to the following hose assemblies on the left side of the chassis: tube (11) to 8W-0958 Hose As and tube (12) to 183-5386 Hose As .

16. Use the following components to secure the tube assemblies to the hose assemblies: two O-ring seals (13), four half flanges (14), eight bolts (15) and eight washers (9) .

17. Install O-ring seal (16) and temperature sensor (17) to tube (11) .

    Note: Lubricate O-ring seal (16) with the lubricant that is being sealed.

    Note: Tighten temperature sensor (17) to a torque of 20 ± 3 N·m (177 ± 26 lb in).

Install the Transmission Lines

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Illustration 44	g00787547

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Illustration 45	g00787549

1. Remove all shipping caps from the transmission and from the hoses.

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Illustration 46	g00787550

2. Connect hose (T) to the lube port of the transmission.

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Illustration 47	g00787551

3. Use the following components to install hose (U) to the suction port of the transmission: O-ring seal (13), two half flanges (14), four washers (9) and four bolts (15) .

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Illustration 48	g00787553

4. Use the following components to install hose (V) to the supply port of the transmission: O-ring seal (18), two half flanges (19), four washers (9) and four bolts (20) .

Install the Electrical Connections

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Illustration 49	g00787554

1. Connect the electrical connection on the following components: brake oil temperature sensor (W), transmission speed sensor (X), transmission gear switch (Y), down shift solenoid for the transmission (Z) and up shift solenoid for the transmission (AA) .

Install the 126-7468 Ladder

Table 37

Required Parts for Installation of the Steps
Item	Quantity	Part Number	Description
1	2	7I-5383	Step
2	4	7X-0365	Bolt (3/4-10)

Illustration 50	g00528443

Use two bolts (2) in order to install one step (1) on each side of the bumper assembly.

Note: The bolts will bottom out in the threaded hole. The step will swing from the bolts.

Install the Suspension Cylinders from the 9D-2680 Front Suspension and Install the Steering Arms from the 9D-3030 Steering Link

Table 38

Required Parts for Installation of Front Suspension Cylinders
Item	Quantity	Part Number	Description
1	2	9D-2498	Key
2	2	4T-4756	Front Suspension Cylinder
3	32	7B-9215	Bolt (1 1/8-12)
4	32	3S-1356	Full Nut
5	64	3S-1349	Washer
6	8	2H-3758	Bolt (1 1/4-7)
7	8	5D-0764	Hard Washer
8	24	116-2673	Shim

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Illustration 51	g00528445
Cleaned Areas for Mounting the Front Suspension Cylinders

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Illustration 52	g00638820
Mounting Location for Front Suspension Cylinder

1. Use 4C-4188 Paint Remover to remove the paint. Use 4C-4079 Brake and Electrical Cleaner in order to clean the mating surfaces.

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Illustration 53	g00638824

2. Remove any burrs from the mating surfaces. Make sure that mating surfaces are smooth.

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Illustration 54	g00528448
Bearing Cap and Grease Line

3. After disconnecting the grease line, remove the bearing cap.

4. Use 4C-4079 Brake and Electrical Cleaner in order to clean the bearing cap.

   Note: Install the bearing cap on 4T-4756 Front Suspension Cylinder (2) before you install the suspension cylinder on the frame. The clearance is not adequate in order to install the bearing cap on a left side suspension cylinder that is bolted on the frame.

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Illustration 55	g00528449

5. Install one key (1). Align the key in order to allow the bolts through the bolt holes.

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Illustration 56	g00528451

6. Position the suspension cylinder (2) on the truck frame. Align the charging valve for the suspension cylinder toward the front of the machine.

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Illustration 57	g00528452

7. Use the components that follow in order to secure the suspension cylinder (2) on the truck frame: 16 bolts (3), 16 nuts (4) and 32 washers (5) .

8. Tighten bolts (3) to a torque of 1170 ± 47 N·m (865 ± 35 lb ft).

   Note: After you tighten 16 bolts (3), fit the required number of shims (8) behind the bearing cap in order to eliminate any gap. Tighten the bolts for the bearing cap to a torque of 370 ± 50 N·m (275 ± 35 lb ft).

   Note: Connect all grease lines.

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Illustration 58	g00528453

9. Clean the mating surface for the steering arm on the spindle. Remove any burrs from the mating surface.

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Illustration 59	g00528579

Note: Before you install the steering arm, make sure that the mating surfaces are clean.

10. Use four bolts (6) and four washers (7) in order to fasten the steering arms on the spindle of each suspension cylinder. Tighten four bolts (6) to a torque of 1800 ± 200 N·m (1325 ± 150 lb ft).

    Note: If the ballstuds are removed, clean the tapers and apply 4C-5593 Anti-Seize Compound . Next, install the castle nuts. Tighten the castle nuts to a torque of 1360 N·m (1000 lb ft). Insert the cotter pin through the castle nut. If the hole for the cotter pin is not aligned, tighten the castle nut more.

Installation of 174-3732 Front Hydraulic Oil Cooler Lines and Front Service Brake Lines

Note: The 174-3732 Hydraulic Oil Cooler Lines are part of the 174-3449 Front Brake Arrangement . The 8X-6472 Service Brake Lines are also part of the 174-3449 Front Brake Arrangement . Machines that are equipped with 105-3211 Service Brakes are not equipped with front oil cooler lines. 105-3211 Service Brakes are disc type brakes. Machines that are equipped with 105-3211 Service Brakes also have 129-7237 Brake Lines instead of 8X-6472 Service Brake Lines .

Table 39

Required Parts for Installation of Front Oil Cooler Lines and Front Service Brake Lines
Item	Quantity	Part Number	Description
1	10	4J-0522	O-Ring Seal
2	16	1P-4578	Half Flange
3	32	8T-5360	Washer
4	24	8T-8916	Bolt (1/2-13)
5	4	103-5422	Hose Assembly
6	2	8X-7949	Plate
7	2	8X-5150	Block
8	2	5T-0967	Block
9	4	8T-9101	Bolt (3/8-16)
10	4	8T-4896	Hard Washer
11	2	6V-8398	O-Ring Seal
12	2	6V-9873	Connector
13	2	3J-1907	O-Ring Seal
14	2	8X-7920	Hose Assembly
15	8	8C-6877	Bolt (7/16-14)

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Illustration 60	g00528581

1. Remove the shipping covers in order to install the oil cooler lines.

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Illustration 61	g00640814

2. Use the components that follow in order to install two hoses (5) : four O-ring seals (1), eight half flanges (2), 16 washers (3), 12 bolts (4) and four bolts (15) .

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Illustration 62	g00528585

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Illustration 63	g00528589

3. Use the components that follow in order to install the hose (14) : plate (6), O-ring seal (1), block (7), block (8), two bolts (9), two washers (10), O-ring seal (11), connector (12) and O-ring seal (13) .

4. Repeat Step 1 through Step 3 for the other side of the machine.

Install the 129-7237 Brake Lines on Machines That Are Equipped with 105-3211 Service Brakes

Illustration 64	g00641087

Remove the protective cap from the service brake line and from the elbow in the wheel assembly. Make sure that the O-ring seals are in good condition. Connect the service brake line to the elbow in the wheel assembly.

Install the 114-0937 Fuel Tank

Table 40

Required Parts for Installation of Fuel Tank
Item	Quantity	Part Number	Description
1	1	114-0937	Fuel Tank
2	4	5D-5654	Mounting
3	2	0S-1627	Bolt (3/4-10)
4	2	9D-9438	Washer
5	2	5P-8248	Hard Washer
6	2	1K-6870	Locknut
7	1	6G-7803	Vent Assembly
8	1	5P-2230	Hose Clamp
9	1	139-0156	Hose Assembly

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Illustration 65	g00528590

1. Use 4C-4188 Paint Remover to remove the paint from the mating surfaces. Use 4C-4079 Brake and Electrical Cleaner to clean the mating surfaces. Remove any burrs that are present.

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Illustration 66	g00528598

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Illustration 67	g00528599

2. Position fuel tank (1) on the right side of the truck.

3. Use two 6G-5294 Caps , four 9X-8887 Bolts , and four 5P-8248 Hard Washers in order to secure the fuel tank.

   Note: The caps, the bolts, and the hard washers are on the frame.

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Illustration 68	g00640823

4. Position two mountings (2) on each side of the 108-7919 Bracket . Use the components that follow in order to secure fuel tank (1) on the 108-7919 Bracket : two bolts (3), two washers (4), two washers (5) and two locknuts (6) .

   Note: The components that are listed are shipped on the bracket.

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Illustration 69	g00528601

5. Connect the fuel lines to the outlets on the back of the fuel tank. Attach the hose from the primary fuel filter to the outlet that has the shutoff valve.

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Illustration 70	g00641045

6. Use one vent (7) and one clamp (8) in order to install hose (9) from the fuel tank to the filter for the vent.

Install the 115-5706 Platform or Install the 114-0936 Platform

Note: The 114-0936 Platform is used on trucks that are equipped with a muffler. The 115-5706 Platform is used on trucks with the exhaust that goes through the body. Parts from the 192-6419 Ladder are also required.

Table 41

Required Parts for Installation of Platform
Item	Quantity	Part Number	Description
1	1	175-0183	Support
2	16	0S-1585	Bolt (1/2-13)
3	16	8T-4223	Hard Washer
4	4	4L-6454	Bolt (3/8-16)
5	12	5P-1075	Hard Washer
6	4	6V-8801	Nut
7	4	8T-2502	Bolt (3/8-16)

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Illustration 71	g00528602

1. Position support (1) to the truck frame.

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Illustration 72	g00528603

2. Use 16 bolts (2) and 16 washers (3) in order to secure support (1) to the truck frame.

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Illustration 73	g00638883
(A) 113-7960 Guard Assembly

3. Trucks that are equipped with the 115-5706 Platform Group have a 5T-3492 Plate that covers the opening for the exhaust on the 175-0183 Support . The plate is secured with four bolts (4) and with four washers (5) .

   Note: The plate may already be installed on the support. Also, the 113-7960 Guard Assembly may already be attached on the support.

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Illustration 74	g00640991

4. Use the items that follow in order to secure support (1) to the ladder: four bolts (7), eight washers (5) and four nuts (6) .

Install the 114-0954 Air Lines

Table 42

Required Parts for Installation of Air Lines Group
Item	Quantity	Part Number	Description
1	4	127-7455	Bracket
2	8	5S-7379	Bolt (3/8-16)
3	24	5P-1075	Hard Washer
4	1	127-7452	Tube
5	8	8T-2501	Bolt (3/8-16)
6	8	2K-4973	Locknut
7	12	8T-4988 (1)	Hose Clamp
8	2	127-7450	Air Inlet Hose
9	2	4P-5104 (1)	Elbow
10	1	127-7451	Tube
11	4	127-7453	Strap
12	1	161-9926	Pressure Sensor
13	1	172-0195	Adapter
14	2	6V-5048	O-Ring Seal
15	7	7X-1181	Strap
16	2	4P-7581	Clip
17	1	118-7952	Turbocharger Sensor Harness Assembly

( 1 )

Install the part when the air cleaner is installed.

Illustration 75	g00528604

1. Use four bolts (2) and four washers (3) in order to install two brackets (1) on the left side of the platform.

2. Use the components that follow in order to install one tube (4) on two brackets (1) : two straps (11), four bolts (5), eight washers (3) and four locknuts (6) .

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Illustration 76	g00528605

3. Use two clamps (7) in order to clamp one hose (8) on the outlet from the turbocharger.

   Note: Before you install the air inlet hose, remove the protective tape from the outlet.

4. Use two clamps (7) in order to secure one end of tube (4) on hose (8) .

5. Use two clamps (7) in order to secure the top end of tube (4) on elbow (9) .

6. On tube (4), install the components that follow: pressure sensor (12), adapter (13) and two O-ring seals (14) .

7. Connect the electrical wiring to the pressure sensor. Use one cable strap (15) and one clip (16) in order to secure the electrical wiring on bracket (1) .

   Note: Use cable straps (15) in order to secure the electrical wiring from the pressure sensor on the frame.

8. Repeat Step 1 through Step 5 in order to install tube (10) .

Install the 192-6421 Catwalk

Table 43

Required Parts for Installation of Catwalk
Item	Quantity	Part Number	Description
1	1	191-7929	Catwalk
2	38	4L-6454	Bolt (3/8-16)
3	24	8T-4896	Hard Washer
4	1	116-4690	Catwalk
5	12	5S-7379	Bolt (3/8-16)
6	1	8W-4484	Pipe
7	26	5P-1075	Hard Washer
8	1	191-7927	Rail
9	1	6G-0115	Brace
10	1	7F-5462	Lug (1)
11	2	8T-8917	Bolt (1/2-13)
12	4	8T-4223	Hard Washer
13	4	6V-8801	Nut
14	1	161-2606	Handle
15	2	8T-9383	Bolt (1/2-13)
16	1	161-2605	Handle

( 1 )

The lug is welded on the catwalk.

Illustration 77	g00638885

Note: It is easier to install the catwalk before you mount the cab on the machine. Support the cab on suitable stands.

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Illustration 78	g00638886

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Illustration 79	g00638887

1. Position the catwalk (4) on the side of the cab. Use 12 bolts (5) and 12 washers (3) in order to secure the catwalk (4) on the cab.

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Illustration 80	g00638893
Typical example

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Illustration 81	g00638891

2. Position catwalk (1) on the front of the cab. Use eight bolts (2) and eight washers (3) in order to secure catwalk (1) to the cab.

3. Use the items that follow in order to secure catwalk (1) to catwalk (4) : four bolts (2), four washers (12) and four nuts (13) .

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Illustration 82	g00528720

4. Use two bolts (15) and two washers (12) in order to install one handhold (14) on the right side of the cab.

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Illustration 83	g00528723

5. Use two bolts (2) and two washers (7) in order to install one handhold (16) above the left side cab door.

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Illustration 84	g00518912

6. Use eight bolts (2) and eight washers (7) in order to install the pipe (6) on the end of the catwalk (4) .

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Illustration 85	g00718058

7. Use 16 bolts (2) and 16 washers (7) in order to secure rail (8) to the catwalks.

   Note: Rail (8) and the catwalks are shown in position on the truck. Rail (8) can be installed before the catwalks are installed on the truck.

Note: Install brace (9) after you install the cab and the left front fender on the truck.

8. Use two bolts (11) and two washers (12) in order to secure brace (9) to the catwalk and to the fender. Secure brace (9) to the catwalk at lug (10) .

   Note: Lug (10) is welded on the catwalk.

Install the 169-3774 Frame and the 117-5044 Cab Mounting

Table 44

Required Parts for Installation of Cab Mounts and Cab
Item	Quantity	Part Number	Description
1	1	106-6310	Support
2	8	9S-1367	Bolt (1-14)
3	8	5P-8250	Washer
4	32	163-0042	Cab Mount
5	12	163-3127	Sleeve
6	1	106-1840	Support
7	10	8F-3895	Bolt (1 1/8-12)
8	10	3S-1349	Washer
9	4	183-7800	Sleeve
10	4	6H-1628	Bolt (1 1/4-7)
11	8	5T-5807	Retainer
12	4	1K-9420	Bolt (1 1/4-7)
13	8	8W-7879	Washer
14	8	5B-5473	Bolt (1-8)

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Illustration 86	g00528606

1. Remove the lifting eye and the shipping cover. Discard the bolts that secured the shipping cover. The bolts will not be used again.

2. Clean the mating surfaces on the chassis.

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Illustration 87	g00528607

3. Use eight bolts (2) and eight washers (3) in order to secure support (1) on the chassis. Tighten the bolts to a torque of 1050 ± 150 N·m (775 ± 110 lb ft).

   Note: Before you install support (1), clean the mating surface of the support. Also, apply 4C-5593 Anti-Seize Compound on the threads of the bolts.

4. Install eight sleeves (5) and 16 cab mounts (4) on support (1) and on the front cab mount of the chassis.

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Illustration 88	g00528608

5. Use 10 bolts (7) and 10 washers (8) in order to secure support (6) on the chassis. Tighten the bolts to a torque of 1450 ± 150 N·m (1070 ± 110 lb ft).

   Note: When you install the support, do not use the bolts that secured the shipping cover.

6. Install four sleeves (5) and eight cab mounts (4) on support (6) .

7. Install four sleeves (9) and eight cab mounts (4) on the rear cab mount of the chassis.

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Illustration 89	g00638998

8. Use the lifting points on the cab in order to raise the cab. Align the cab on the frame and on the support assemblies.

9. Use the components that follow in order to secure the cab on the rear cab mount and on the rear support: eight retainers (11), four bolts (10) and four bolts (12). Tighten the bolts to a torque of 2100 ± 250 N·m (1550 ± 185 lb ft).

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Illustration 90	g00717546
(5) Sleeve (4) Cab Mount (13) Washer (14) Bolts

10. Use eight washers (13) and eight bolts (14) in order to secure the cab on the front cab mount and on the front support. Tighten the bolts to a torque of 1050 ± 150 N·m (775 ± 110 lb ft).

Install the 114-0956 Air Cleaner and the 114-0954 Air Lines

Table 45

Required Parts for Installation of Air Lines
Item	Quantity	Part Number	Description
1	2	160-9821	Air Cleaner
2	4	119-8361	Support
3	12	4L-6454	Bolt (3/8-16)
4	32	5P-1075	Hard Washer
5	12	6V-8801	Nut
6	2	4P-5104 (1)	Elbow
7	4	8T-4989 (1)	Hose Clamp
8	2	7W-7417	Service Indicator
9	2	5K-5068	Nipple
10	2	5P-4400	Air Brake Connector
11	1	126-6603	Bracket
12	2	5P-4428	Elbow
13	2	5P-0756	Tube
14	2	8M-2772	Clip
15	8	8T-2502	Bolt (3/8-16)
16	4	8T-4988 (1)	Hose Clamp

( 1 )

The part is from the air lines.

Note: To make the installation of the air cleaners easier, remove the platform and place the platform on the ground.

Illustration 91	g00528613
Air Cleaners

1. Use the components that follow in order to attach two supports (2) to each air cleaner (1) : four bolts (15), eight washers (4) and four nuts (5) .

2. Use four bolts (3) and four washers (4) in order to install each air cleaner (1) .

   Note: For 777D Off-Highway Trucks, use the mounting locations that are farthest back on the platform in order to secure the air cleaners.

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Illustration 92	g00528614
Elbows That Are Attached on Air Cleaners

3. Use two clamps (7) and two clamps (16) in order to install one elbow (6) on each air cleaner.

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Illustration 93	g00528615

4. Install the components that follow on the bracket (11) : two nipples (9), two connectors (10) and two service indicators (8) .

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Illustration 94	g00639094

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Illustration 95	g00639112

5. Use the components that follow in order to attach the bracket (11) on the air cleaners: two bolts (3), four washers (4) and two nuts (5) .

6. Install one elbow (12) on each air cleaner. Use two tubes (13) in order to connect two connectors (10) and two elbows (12) .

7. Use the components that follow in order to secure the two tubes (13) : two clips (14), two bolts (3), two washers (4) and two nuts (5) .

Install the 107-2739 Fender Group and the Baffle Assembly from the 192-6418 Hood

Note: Parts from the 192-6419 Ladder are also required.

Table 46

Required Parts for Installation of Fenders and Guards
Item	Quantity	Part Number	Description
1	1	173-0585	Fender
2	64	5P-1075	Hard Washer
3	22	5S-7379	Bolt (3/8-16)
4	1	120-9726	Guard
5	34	6V-8801	Nut
6	4	5P-8167	Bolt (3/8-16)
7	2	6G-3361	Mud Flap
8	5	5S-7382	Bolt (3/8-16)
9	2	2G-6916	Strip
10	20	8T-2502	Bolt (3/8-16)
11	1	113-9960	Guard
12	12	5M-3062 (1)	Bolt (3/8-16)
13	1	8W-6062	Deflector
14	1	8W-6063	Strip
15	9	4L-6454	Bolt (3/8-16)
16	1	8W-9781	Baffle
17	1	8X-9699	Guard
18	1	5T-6553	Plate
19	4	8T-2561	Washer
20	1	2G-2258	Strip

( 1 )

Six bolts may already be installed in the 113-9960 Guard .

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Illustration 96	g00641113
Typical example

1. Use nine washers (2) and nine bolts (3) in order to install fender (1) on the left side of the machine.

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Illustration 97	g00641134

2. Use the items that follow in order to secure fender (1) to the left ladder: four bolts (10), eight washers (2) and four nuts (5) .

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Illustration 98	g00528620

3. Use the components that follow in order to install guard (4) on the left side of the machine: five bolts (8), nine washers (2), five nuts (5) and four bolts (6) .

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Illustration 99	g00528622

4. Use the components that follow in order to install mud flaps (7) on guard (4) : strip (9), seven washers (2), seven bolts (10) and seven nuts (5) .

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Illustration 100	g00528623

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Illustration 101	g00528624

5. Use six bolts (12) and six washers (2) in order to secure guard (11) to the right side of the chassis.

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Illustration 102	g00641149

6. Use the components that follow in order to install mud flap (7) on guard (11) : strip (9), seven washers (2), seven bolts (10) and seven nuts (5) .

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Illustration 103	g00528626

7. Use the components that follow in order to install deflector (13) on the right side platform: strip (14), nine bolts (15), nine washers (2) and nine nuts (5) .

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Illustration 104	g00651446

8. Use four bolts (3) and four washers (19) in order to install baffle (16) below the right side cab door.

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Illustration 105	g00651447

9. Use the components that follow in order to install guard (17) below the left side of the cab: strip (20), nine bolts (3) and nine washers (2) .

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Illustration 106	g00641174

10. Use the components that follow in order to secure guard (17) to the rear cab support: plate (18), two bolts (10), two washers (19) and two nuts (5) .

Connect Air Lines and Wire Harnesses at the Right Side of the Cab

Illustration 107	g00528636
Air Line and Connections at the Right Side of the Cab

Note: The air hoses and the wire harnesses are connected on the right side of the cab. Each opening in the plate at the cab has an identification number. The air hoses are marked with numbers that correspond. Match the numbers in order to connect the air lines. The openings for the electrical plugs are not marked. However, each connector only fits into one plug.

Note: To make the connection of the air hoses and of the wire harnesses easier, remove the platform and place the platform on the ground.

Table 47

Configuration of Air Lines
Port Number	Standard Brakes without ARC	Standard Brakes and ARC	Oil Cooled Brakes without ARC	Oil Cooled Brakes and ARC
1	Air Start ONLY	Air Start ONLY	Air Start ONLY	Air Start ONLY
2	Supply Line to Inversion Valve	Supply Line to Inversion Valve	Supply Line to Inversion Valve	Supply Line to Inversion Valve
3	Supply Line to Relay Valve	Supply Line to Relay Valve	Supply Line to Relay Valve	Supply Line to Relay Valve
3	Signal Line to Air Compressor Governor	Signal Line to Air Compressor Governor	Signal Line to Air Compressor Governor	Signal Line to Air Compressor Governor
4	Signal Line to Front Relay Valve (1)	Signal Line to Front Relay Valve (1)	Empty	Empty
5	Signal Line to Rear Relay Valve (2)	Signal Line to Rear Relay Valve (2)	Signal Line to Relay Valve for Service Brakes (3)	Signal Line to Relay Valve for Service Brakes (3)
6	Empty	Signal Line to Relay Valve for ARC (4)	Empty	Signal Line to Relay Valve for ARC (4)
7	Signal to Secondary Brake Valve	Signal to Secondary Brake Valve	Signal to Secondary Brake Valve	Signal to Secondary Brake Valve
8	Signal Line to Inversion Valve	Signal Line to Inversion Valve	Signal Line to Inversion Valve	Signal Line to Inversion Valve

( 1 )	The Front Relay Valve actuates the master cylinder for the front brakes.
( 2 )	The Rear Relay Valve actuates the master cylinder for the rear brakes.
( 3 )	The relay valve for the Service Brakes actuates the master cylinders for the rear brakes and for front oil cooled brakes.
( 4 )	The relay valve for the Automatic Retarder Control (ARC) actuates the master cylinders for the rear brakes on trucks that are equipped with standard front brakes.

1. Install the hose that is marked "1" on port 1. Port 1 is only for the air start attachment.

2. Install the hose that is marked "2" on port 2. Port 2 supplies a relay valve.

3. Install the hose that is marked "3" on port 3. Port 3 supplies a relay valve. Port 3 is also a signal for the air compressor governor.

4. Install the hose that is marked "4" on port 4. Port 4 is a signal for the front relay valve.

5. Install the hose that is marked "5" on port 5. Refer to the chart.

6. Install the hose that is marked "6" on port 6. Refer to the chart.

7. Install the hose that is marked "7" on port 7. Port 7 is a signal to the secondary brake valve.

8. Install the hose that is marked "8" on port 8. Port 8 is a signal to the inversion valve.

9. For tractors, install the brake signal line on port 9. Port 9 is not listed in the chart.

10. Connect the harness assembly for the Caterpillar Monitoring System at location 10.

11. Connect the harness assembly for the transmission at location 11.

12. Connect the harness assembly for the chassis at location 12.

13. Connect the power harness assembly at location 13.

14. Connect the harness assembly for the engine at location 14.

15. Connect the harness assembly for the Truck Payload Measurement System (TPMS) at location 15.

Install the Heater Hoses and the Air Conditioner Lines

Table 48

Required Parts for Installation of Heater and Air Conditioner Lines
Item	Quantity	Part Number	Description
1	2	5D-1026	Hose Clamp
2	7	6D-1641	Clip
3	6	8T-4896	Hard Washer
4	1	5P-1075	Hard Washer
5	7	5S-7379	Bolt (3/8-16)
6	1	3S-2093	Cable Strap

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Illustration 108	g00528664

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Illustration 109	g00641186

1. Run two hoses (A) and (B) along the top of the radiator.

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Illustration 110	g00641201

2. Next, run the hoses down the right side of the radiator.

3. Use the parts that follow in order to secure the hoses (A) and (B) : seven clips (2), cable straps (6), six washers (3), washer (4) and seven bolts (5) .

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Illustration 111	g00641228

4. Use one clamp (1) on each hose in order to connect the hose at the heater valve.

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Illustration 112	g00641240

5. Connect hose (C) from the evaporator to the receiver-dryer.

6. Connect hose (D) from the evaporator to the hose coupling of the compressor.

7. Route the drain line for the air conditioner inside the right side of the radiator cowling.

Install the 169-6582 Steering Lines

Table 49

Required Parts for Installation of Steering Lines
Item	Quantity	Part Number	Description
1	2	5K-9090	O-Ring Seal
2	2	6V-9746	O-Ring Seal
3	1	174-6583	Guard
4	3	7X-0772	Hard Washer
5	4	5M-3062	Bolt (3/8-16)
6	1	174-6565	Bracket
7	4	8T-4896	Hard Washer

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Illustration 113	g00641248

1. Remove the caps that were used for shipping. Inspect two O-ring seals (1) and two O-ring seals (2) .

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Illustration 114	g00641268

2. Connect the hoses to the tube assemblies that have corresponding numbers.

3. Connect hose (A) for the air horn.

4. Connect pilot line (B) for the hydraulic steering pump.

5. Use one bolt (5) and one washer (7) in order to install bracket (6) .

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Illustration 115	g00641291

6. Use three washers (4) and three bolts (5) in order to secure guard (3) on the cab support and on bracket (6) .

Install Hoses from the 156-1854 Window Washer

Table 50

Required Parts for Installation of the Hoses for the Windshield Washer
Item	Quantity	Part Number	Description
1	5 m (16.4 ft)	5P-0715	Hose
2	6	4D-7794	Clip
3	6	5M-3062	Bolt (3/8-16)
4	6	8T-4896	Hard Washer

Note: The components in the chart are shipped in the washer fluid bottle.

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Illustration 116	g00641329

1. Connect hose (1) at the washer fluid bottle.

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Illustration 117	g00641376

2. Route hose (1) along the frame toward the windshield wiper. Use the items that follow in order to secure the hose to the frame: six clips (2), six bolts (3) and six washers (4) .

3. Connect the opposite end of hose (1) at the windshield wiper.

   Note: Cut the hose to the required length.

Connect the Battery Cables

Illustration 118	g00641641

Illustration 119	g00528717

Connect the battery terminals, as shown.

Install the Right Side Handholds

Use components from the part numbers that follow:

• 192-6419 Ladder

• 192-6418 Hood

• 114-0936 Platform Group

• 115-5706 Platform Group

Table 51

Required Parts for Installation of Handholds
Item	Quantity	Part Number	Description
1	1	9D-4721	Rail
2	34	4L-6454	Bolt (3/8-16)
3	14	8T-4896	Hard Washer
4	1	113-1520	Rail (1)
5	1	116-0012	Rail (2)
6	20	5P-1075	Hard Washer
7	1	5T-4228	Rail
8	4	8T-8919	Bolt (1/2-13)
9	4	8T-4223	Hard Washer

( 1 )	Part of the 115-5706 Platform Group
( 2 )	Part of the 114-0936 Platform Group

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Illustration 120	g00641645

1. Use four bolts (2) and four washers (3) in order to install rail (1) on the right side of the machine.

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Illustration 121	g00657162

2. Use 20 bolts (2) and 20 washers (6) in order to install rail (5) on the 114-0936 Platform Group .

   Note: Use 20 bolts (2) and 20 washers (6) in order to install rail (4) on the 115-5706 Platform Group .

3. Use 10 bolts (2) and 10 washers (3) in order to install rail (7) on the chassis.

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Illustration 122	g00641648

4. Use four bolts (8) and four washers (9) to secure the left access ladder.

Install the 5T-6547 Rear View Mirror

Table 52

Required Parts for Installation of Rear View Mirror
Item	Quantity	Part Number	Description
1	1	2G-0266	Bracket
2	6	4M-5283	Bolt (1/4-20)
3	8	8T-4205	Hard Washer
4	1	2G-1255	Brace
5	2	5S-7349	Bolt (1/4-20)
6	1	6V-6962	Mirror
7	2	6V-6961	Knob
8	2	5P-9865	Mirror Spacer
9	1	153-9136	Bracket
10	2	5S-7379	Bolt (3/8-16)
11	3	2K-4973	Locknut
12	2	8T-2502	Bolt (3/8-16)
13	2	6V-8801	Nut
14	4	8T-4896	Hard Washer
15	1	5P-6872	Mirror
16	2	8D-8011	Plate

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Illustration 123	g00518914

1. Use six bolts (2) and six washers (3) in order to install bracket (1) .

2. Use two bolts (5) and two washers (3) in order to install brace (4) .

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Illustration 124	g00518915

3. Use the components that follow in order to install mirror (6) : two knobs (7), two plates (16), two spacers (8), two locknuts (11), two bolts (12), two washers (14) and two nuts (13) .

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Illustration 125	g00641762

4. Use the parts that follow in order to install bracket (9) and mirror (15) : two bolts (10), two washers (14) and locknut (11) .

5. Adjust the mirrors and tighten the mirrors.

Install the 8X-9966 Rear View Mirror

Table 53

Required Parts for Installation of Rear View Mirror
Item	Quantity	Part Number	Description
1	2	7D-9969	Support
2	2	7X-0326	Bolt (1/2-13)
3	2	8T-4223	Hard Washer
4	1	8W-7904	Tube
5	1	8T-2287	Mirror
6	2	5S-7379	Bolt (3/8-16)
7	2	5P-1075	Hard Washer

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Illustration 126	g00518942

1. Use two bolts (2) and two washers (3) in order to install two supports (1) on the rail assembly.

   Note: Leave bolts (2) loose until you install the tube (4) .

2. Insert tube (4) in two supports (1) .

3. Use two bolts (6) and two washers (7) in order to install mirror (5) .

4. Adjust the mirror and tighten the mirror.

Use the 169-3770 Wiring and Lighting Group to Install the Headlamps and Signal Lamps

Table 54

Required Parts for Installation of Headlamps and Signal Lamps
Item	Quantity	Part Number	Description
1	2	135-0427	Signal Lamp
2	2	157-0305	Headlight (High Beam)
3	2	161-0908	Headlight (Low Beam)
4	4	8T-4205	Hard Washer
5	6	8T-4134	Nut
6	2	130-5300	Clip
7	2	5P-4115	Washer
8	4	161-8044	Bracket
9	4	5M-3062	Bolt (3/8-16)
10	4	8T-4896	Hard Washer
11	4	5P-2955	Bolt (5/16-18)
12	8	8T-4224	Hard Washer
13	4	3E-9860	Locknut

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Illustration 127	g00641775

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Illustration 128	g00641817

1. Use the components that follow in order to install one signal lamp (1) on each side of the machine: three nuts (5), two washers (4), clip (6) and washer (7) .

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Illustration 129	g00641882

Note: The harness connector must go through the large hole of the fender.

2. Connect the wiring for the signal lamp. Use clip (6) in order to secure the wiring for the signal lamp.

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Illustration 130	g00641887

3. Use the components that follow to install one bracket (8) on each headlight (2) and on each headlight (3) : one bolt (11), one locknut (13) and two washers (12) .

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Illustration 131	g00641911

4. Use one bolt (9) and one washer (10) in order to install one headlight (2) in the outer position of each fender.

5. Use one bolt (9) and one washer (10) in order to install one headlight (3) in the inner position of each fender.

6. Connect the wiring for the headlamps. The high beams that are in the inner positions are connected to the 200-BK wires and to the 611-PU wires. The low beams that are in the outer positions are connected to the 200-BK wires and to the 619-GR wires.

7. Adjust the headlamps and tighten the headlamps.

Use the 6G-7877 Front Wheel to Install the Front Tires

Table 55

Required Parts for Installation of Front Wheels
Item	Quantity	Part Number	Description
1	40	5D-0764	Hard Washer
2	40	5D-0765	Full Nut

1. Make sure that all paint has been removed from the wheel studs and from the mating surfaces.

   Note: Use 4C-4188 Paint Remover in order to remove paint. Use 4C-4079 Brake and Electrical Cleaner in order to clean the mating surfaces.

2. Raise the front of the truck 1117 mm (44 inch) above the ground. Support the truck with suitable blocks or suitable stands. Leave the hoist attached to the truck until the tires are installed.

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Illustration 132	g00518947

3. Use a tire handler in order to install a tire and rim on the wheel at each side of the truck.

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Illustration 133	g00528735

Note: Apply 4C-5593 Anti-Seize Compound on the washer faces and on the threads.

4. Install 20 washers (1) and 20 nuts (2) on each wheel. Tighten nuts (2) to a torque of 1210 ± 55 N·m (890 ± 40 lb ft).

   Note: Leave the truck on stands in order to align the front wheels and charge the suspension cylinders.

Use the 125-6793 Rear Wheel and Use the 6G-7852 Rim to Install the Rear Wheels

Table 56

Required Parts for Installation of Rear Wheels
Items	Quantity	Part Number	Description
1	80	5D-0764	Hard Washer
2	80	5D-0765	Full Nut
3	1	6G-8018	Tire Valve
4	2	6G-0333	Clamp
5	8	9B-7237	Bolt (3/8-16)
6	8	5P-1075	Hard Washer
7	1	6G-8019	Tire Valve

1. Make sure that all paint has been removed from the wheel studs and from the mating surfaces.

   Note: Use 4C-4188 Paint Remover in order to remove paint. Use 4C-4079 Brake and Electrical Cleaner in order to clean the mating surfaces.

2. Raise the rear of the truck 1118 mm (44 inch). Support the truck with suitable blocks or suitable stands. Leave the hoist attached to the truck until the tires are installed.

Inner Rear Tires

Note: Use 4C-4188 Paint Remover in order to remove paint. Use 4C-4079 Brake and Electrical Cleaner in order to clean the mating surfaces.

1. Locate the four bolt holes on each rear wheel assembly. The four bolt holes mount the clamp for the valve stem extension. Mark the rear wheel assemblies in order to locate the bolt holes. When you install the inner rear wheels, align the valve stem extensions with the marks.

2. Use a tire handler in order to install an inner tire and rim on the truck.

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Illustration 134	g00648382

Note: Apply 4C-5593 Anti-Seize Compound on the faces of the washers and on the threads.

3. Use 20 washers (1) and 20 nuts (2) to secure the inner rear tire and rim to the rear wheel assembly. Tighten 20 nuts (2) to a torque of 1200 ± 50 N·m (885 ± 37 lb ft).

   Note: The ring should be facing outward.

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Illustration 135	g00648383

4. Install tire valve (3) on the inner rear rim.

5. Use four bolts (5) and four washers (6) in order to install one clamp (4) over the tire valve (3) .

6. Use the 6V-4040 Inflation Group to inflate the inner rear tire. Refer to Special Instruction, SMHS7867, "Use of 6V-4040 Nitrogen Tire Inflation Group ".

7. Repeat Step 1 through Step 6 for the other inner rear tire.

Outer Rear Tires

Note: Use 4C-4188 Paint Remover in order to remove paint. Use 4C-4079 Brake and Electrical Cleaner in order to clean the mating surfaces.

1. Use a tire handler in order to install an outer tire and rim on the truck.

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Illustration 136	g00648386

2. Use 20 washers (1) and 20 nuts (2) to secure the outer rear tire and rim to the rear wheel assembly. Tighten 20 nuts (2) to a torque of 1200 ± 50 N·m (885 ± 37 lb ft).

   Note: The ring should be facing inward. This will cause the rings to face each other between the tires.

3. Use the 6V-4040 Inflation Group to inflate the inner rear tire. Refer to Special Instruction, SMHS7867, "Use of 6V-4040 Nitrogen Tire Inflation Group ".

4. Repeat Step 1 through Step 3 for the other outer rear tire.

Front Wheel Alignment

Note: The front wheels must be off the ground. The suspension cylinders should be fully extended.

1. Move the wheels until the wheels face straight ahead.

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Illustration 137	g00528760

2. Measure the distance (A) between the front tires.

3. Mark location (A) on each front tire. Rotate the tires until the marks are 180 degrees from point (A) .

4. Measure the distance (B) between the marks on the tires.

5. Subtract distance (B) from distance (A). This value will be 64.3 mm (2.53 inch) when the toe-out is correct.

6. If necessary, adjust the tie rods in order to set the toe-out. Loosen clamps (1) on the left side. Loosen clamps (2) on the right side. Turn each tie rod by the same amount. Make sure that the tie rods are the same length.

7. When the toe-out is set, tighten clamps (1) and clamps (2) to a torque of 285 N·m (210 lb ft).

   Note: Make sure that there is a gap of at least 3.18 mm (0.125 inch) before you tighten the clamps on the tie rods.

8. Lower the front of the truck to the ground.

Use the 130-6841 Body Mounting to Install the Body

Table 57

Required Parts for Installation of Body
Item	Quantity	Part Number	Description
1	2	8W-8454	Pin
2	2	8W-2897 (1)	Thrust Washer
3	2	9D-3432 (1)	Thrust Washer
4	2	8W-8456	Plate
5	12	5P-2566	Bolt (1/2-13)
6	12	8T-4223	Hard Washer
7	2	3B-8489	Grease Fitting
8	2	9D-5004	Plate
9	8	6V-8188	Nut
10	2	9D-5006	Baffle
11	2	9D-5005	Plate
12	16	9B-7237	Bolt (3/8-16)
13	16	6V-8801	Nut

( 1 )

Use the 8W-2897 Thrust Washer only when the 9D-3432 Thrust Washer will not fit.

1. Use 4C-4188 Paint Remover to remove the paint from the mating surfaces of the truck body and the frame.

2. Insert one 8W-8454 Pin (1) into the outer pivot pin bore on each side of the truck body.

3. Use a suitable lifting device in order to position the truck body on the truck frame.

4. Align the pivot pin bores of the truck body and the pivot pin bores of the truck frame.

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Illustration 138	g00519162

5. At each side of the machine, insert one washer (3) between the outer ear of the truck body and the truck frame.

   Note: If washer (3) does not fit, insert one washer (2). The washer (2) is 2.0 mm (0.079 inch) thinner than washer (3) .

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Illustration 139	g00519159

6. Drive pins (1) through the pivot pin bores of the truck body and of the truck frame.

7. Use the components that follow in order to secure the pins (1) in place: two plates (4), four bolts (5) and four washers (6) .

8. Install two grease fittings (7) .

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Illustration 140	g00648389

9. Use the components that follow in order to install one plate (8) on each side of the body: four bolts (5), four washers (6) and four nuts (9) .

10. Use the components that follow in order to install one baffle (10) on plate (8) on each side of the body: one plate (11), eight bolts (12) and eight nuts (13) .

Use the 9D-2725 Cylinder and Mounting to Install the Hoist Cylinders

Table 58

Required Parts for Installation of Hoist Cylinders
Item	Quantity	Part Number	Description
1	2	5T-9266	Pin
2	4	9D-2316	Spacer
3	2	5T-5528	Plate
4	4	5P-2566	Bolt (1/2-13)
5	4	8T-4223	Hard Washer
6	2	4S-7606	Elbow
7	2	4K-3026	Extension
8	2	4D-2560	Pipe Connector
9	2	3B-8489	Grease Fitting
10	2	7D-3973	Hose Assembly

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NOTICE
The paint must be removed from the cylinder rod before the cylinder is retracted. Extend the cylinder and remove the paint. The paint must be completely removed from the rod surface. No painted surface may pass through the lip seals. Failure to remove the paint correctly will damage the lip seals and contaminate the hydraulic system.

Note: Use 4C-4188 Paint Remover in order to remove the paint from the rods for the hoist cylinders.

1. Remove the protective caps from the bolt holes in the body near the pin bores. Remove the paint from the contact surfaces around the pin bores in the body. Remove the paint from the contact surfaces on the hoist cylinders.

2. Before you remove the shipping brackets from the hoist cylinders, use a chain and a lever puller in order to stabilize the hoist cylinders.

3. Use a suitable lifting device in order to align the pin bores of the truck body and the hoist cylinders.

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Illustration 141	g00519166

4. Place one spacer (2) on each side of the hoist cylinder bearing. At each side of the machine, insert one pin (1) through the truck body and through the hoist cylinder bearing.

   Note: Before you install pins (1), apply 4C-5593 Anti-Seize Compound to the pins.

5. Use the components that follow in order to secure each pin (1) : one plate (3), two bolts (4) and two washers (5) .

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Illustration 142	g00528789

6. Use the components that follow in order to install one hose (10) on each hoist cylinder: one extension (7), one elbow (6), one grease fitting (9) and one pipe connector (8) .

Use the 130-6841 Body Mounting to Install the Body Retaining Pins

Table 59

Required Parts for Installation of Retaining Pins
Item	Quantity	Part Number	Description
1	2	5D-3887	Rod
2	2	6F-8499	Spring
3	4	054-3788	Orifice
4	4	3B-4615	Cotter Pin
5	2	6G-8161	Pin

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Illustration 143	g00519175

1. Use the components that follow in order to install each rod (1) in the truck body: one spring (2), two orifice (3) and two cotter pins (4) .

2. Install each pin (5) in the truck body. Secure each pin with rod (1) .

Use the 130-6841 Body Mounting to Install the Shims for the Body

Table 60

Required Parts for Installation of Shims for the Body
Item	Quantity	Part Number	Description
1	2	8W-4931	Shoe
2	2	5T-2031	Pin
3	2	5T-2029	Plate
4	14	8T-8919	Bolt (1/2-13)
5	34	8T-4223	Hard Washer
6	6	106-8225	Pad
7	18	106-8227	Shim
8	20	5P-2566	Bolt (1/2-13)

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NOTICE
An improper hydraulic oil level can result in machine damage.

1. Raise the truck body and install the body retaining pins.

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Illustration 144	g00528792

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Illustration 145	g00528795

2. Use the components that follow in order to install one 8W-4931 Shoe (1) on each side of the frame: one pin (2), one plate (3), two bolts (4) and two washers (5) .

3. Use the following method to calculate the number of shims (7) that are required for each body support pad (6) :

   1. Make sure that the truck is parked on a level surface. Remove the body retaining pins and lower the truck body to the frame rails.

   2. Use the center mounting block on the truck body in order to mark the locations for the pad assemblies on the frame rails.

   3. Raise the truck body and install the retaining pins.

   4. Place one shim (7) and one body support pad (6) at each of the four locations that are marked on the frame rails.

   5. Remove the body retaining pins and lower the truck body firmly against the shims and against the pads.

   6. Add shims at any pads that are loose. Add enough shims in order to eliminate all gaps.

   7. Tilt each shoe (1) until the shoe is parallel to the body.

   8. Measure the gap between the shoe and the body.

   9. Measure a pad and add enough shims in order to obtain a thickness that is 1.5 mm (0.060 inch) thicker than the gap between the body and the shoe.

4. Raise the body approximately 200 mm (8.0 inch). Place blocking material between the body and the frame rails.

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Illustration 146	g00528796

5. Use five bolts (4) and five washers (5) to install one body support pad (6) and shims (7) on each shoe (1) .

6. Use five bolts (8) and five washers (5) to install one body support pad (6) and shims (7) at each location on the frame rail.

Use the 130-6841 Body Mounting to Install the Rock Ejectors

Table 61

Required Parts for Installation of Rock Ejectors
Item	Quantity	Part Number	Description
1	2	8W-1155	Rock Ejector Assembly
2	2	6G-7773	Pin As
3	4	3B-4647	Cotter Pin
4	16	1D-0503	Washer
5	2	153-7448 (1)	Plate
6	1	5T-9442 (2)	Plate
7	1	5T-9443 (3)	Plate

( 1 )	The 153-7448 Plate is used on bodies with flat floors.
( 2 )	The 5T-9442 Plate is used on dual slope bodies.
( 3 )	The 5T-9443 Plate is used on dual slope bodies.

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Illustration 147	g00528797

1. Use the steps that follow in order to install the plate assemblies that mount rock ejector (1) :
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   Illustration 148	g00648627
   (A) 140 mm (5.5 inch) (B) 272 mm (10.7 inch) (C) 37 mm (1.45 inch)

   1. Install a pin (2) in each plate assembly.

   2. Use strings to attach a plumb bob to each pin. Position a plate assembly on the left and on the right underside of the truck body.

      Note: Make sure that the string that is attached to the plumb bob hangs below the center of the rear wheel assembly.

   3. Center the strings in the plate assemblies that will hold the rock ejectors.

   4. Move the plate assemblies in order to position the strings centrally between the two rear tires at each side of the machine.

   5. After the strings are positioned centrally, move the plate assemblies in order to obtain a clearance of 272 mm (10.7 inch) between the strings and the rear wheels.

   6. Weld the plate assemblies in place.

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Illustration 149	g00519174

2. Use the components that follow in order to install one rock ejector (1) in each plate assembly: one pin (2), two cotter pins (3) and eight washers (4) .

   Note: Use washers (4) in order to center rock ejectors (1) between the two rear tires on each side of the machine.

Use the 130-6841 Body Mounting to Install the Visual Body Down Indicator

Table 62

Required Parts for Installation Of Visual Body Down Indicator
Item	Quantity	Part Number	Description
1	1	113-1218	Baffle
2	2	031-9831	Bolt (3/8-16)

Illustration 150	g00519177

Use two bolts (2) in order to install the baffle (1) on the canopy.

Use the 130-6841 Body Mounting to Install the Magnetic Assembly for the Body Down Indicator

Table 63

Required Parts For Installation of Magnetic Assembly
Item	Quantity	Part Number	Description
1	1	3E-0461	Electronic Control
2	1	180-0468	Bracket
3	4	4M-6425	Bolt (5/16-18)
4	4	5P-4116	Washer
5	4	5S-7379	Bolt (3/8-16)
6	2	5P-1075	Hard Washer
7	1	5G-7820	Magnet Assembly
8	1	109-5286	Bracket
9	2	6V-8189	Nut
10	2	8T-4896	Hard Washer
11	1	8T-4896 (1)	Hard Washer
12	1	5S-7379 (1)	Bolt (3/8-16)
13	1	9G-9152 (1)	Clip

( 1 )

The part is from the 169-3770 Wiring and Lighting Group .

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Illustration 151	g00543703

1. Use two nuts (9), two bolts (3), and two washers (4) in order to secure magnet assembly (7) to the bracket (8) .

2. Use two bolts (5) and two washers (10) in order to install bracket (8) on the truck body.

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Illustration 152	g00543704

3. Use two bolts (3) and two washers (4) in order to install electronic control (1) on bracket (2) .

   Note: Do not tighten the bolts completely in order to allow an adjustment.

4. Use two bolts (5) and two washers (6) in order to install bracket (2) to the truck frame.

   Note: Do not tighten the bolts completely in order to allow an adjustment.

5. Attach the wiring connector of electronic control (1) to the connector plug of the transmission harness. Use a 3E-3362 Plug Lock Wedge in order to secure the connection. Use one bolt (12), one washer (11), and one clip (13) in order to secure the wiring connection to bracket (2) .

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Illustration 153	g00648649
(B) 4.0 ± 1.0 mm (0.16 ± 0.04 inch) (C) 12.7 mm (0.50 inch) Reference

6. Use a 4.0 mm (0.16 inch) shim in order to set the gap at the magnet assembly and at the electronic control. Slide bracket (2) forward. Remove the shim and tighten the bolts.

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Illustration 154	g00540982
(A) 295 ± 10 mm (11.6 ± 0.4 inch)

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NOTICE
An improper hydraulic oil level can result in machine damage.

7. Raise the truck body 295 ± 10 mm (11.6 ± 0.4 inch). Place blocking material between the truck body and the frame.

8. Slide the electronic control on bracket (2) until the yellow light illuminates on the top of the control. Tighten the bolts.

9. Raise the truck body. Remove the material that was used to block the body in position.

10. Lower the truck body.

Install Payload Lamps from the 174-3710 Cab Wiring and the 125-9274 Sensor Wiring

Table 64

Required Parts for Installation of Payload Lamps
Item	Quantity	Part Number	Description
1	1	8K-1433	Grommet
2	1	8W-4812	Bracket
3	8	5M-3062	Bolt (3/8-16)
4	4	8T-4896	Hard Washer
5	2	9G-9150	Clip

1. Remove the rear cover in order to access the wiring for the payload lamps.

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Illustration 155	g00651546

2. Install grommet (1) in the side wall of the cab.

3. Route the wiring connectors for the payload lamp through the grommet.

4. Connect two wires at each lamp.

5. Secure the connections at each lamp with a clip (5) .

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Illustration 156	g00528799

6. Use four bolts (3) and four washers (4) in order to install bracket (2) on the left side of the cab.

7. Use four bolts (3) to install the payload lamp on the right platform.

   Note: The payload lamp is shipped in the compartment below the seat on the right side.

8. Connect the wiring for the payload lamps on the right platform.

Install the Exhaust for the Truck

For Trucks with a Body That Is Not Heated, Install the 8W-9078 Exhaust Pipe and the 7C-4013 Muffler

Table 65

Required Parts for Installation of Exhaust Pipe and Muffler
Item	Quantity	Part Number	Description
1	4	8T-4122	Washer
2	1	111-4368	Tube
3	2	8W-5558	Angle
4	2	4L-6454	Bolt (3/8-16)
5	4	8T-2561	Washer
6	2	7K-3215	Boss
7	2	8T-2501	Bolt (3/8-16)
8	1	186-4178	Bracket
9	4	5S-7379	Bolt (3/8-16)
10	20	8T-4896	Hard Washer
11	2	8W-4261	Strap
12	2	8T-8917	Bolt (1/2-13)
13	6	8T-4223	Hard Washer
14	4	6V-8188	Nut
15	1	111-4352	Muffler Assembly
16	1	4N-9330	Clamp
17	1	5P-2424	Bolt (1/2-13)
18	2	8W-4260	Strap
19	8	8T-2501	Bolt
20	8	6V-8801	Nut
21	1	129-9477	Exhaust Extension
22	1	6N-9298	Clamp
23	1	8T-4835	Bolt (1/2-13)

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Illustration 157	g00648684

1. Remove the shipping cover.

   Note: Save the bolts and the washers.

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Illustration 158	g00823123

2. Use four washers (1) and four 8T-9393 Bolts in order to install tube (2) .

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Illustration 159	g00823124

3. Use the items that follow in order to secure tube (2) on the platform: two angles (3), two bolts (4), four washers (5), two bosses (6) and two bolts (7) .

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Illustration 160	g00717848

4. Use four bolts (9) and four washers (10 ) in order to install bracket (8) on the platform.

5. Use the components that follow in order to install two straps (11) on bracket (8) : two bolts (12), four washers (13) and two nuts (14) .

Note: Apply 4C-5599 Anti-Seize Compound on the tube.

6. Slide muffler (15) over tube (2). Position the muffler in order to fit inside straps (11) .

7. Use the items that follow in order to secure muffler (15) on the tube: clamp (16), bolt (17), two washers (13) and nut (14) .

8. Tighten nut (14) to a torque of 25 ± 7 N·m (220 ± 60 lb in).

9. Use the items that follow in order to install two straps (18) to muffler (15) : eight bolts (19), 16 washers (10) and eight nuts (20) .

10. Tighten nuts (20) to a torque of 25 ± 7 N·m (220 ± 60 lb in).

Note: Apply 4C-5599 Anti-Seize Compound to the top of the muffler.

11. Install exhaust extension (21) on the muffler.

12. Use the items that follow in order to secure exhaust extension (21) on the muffler: clamp (22), bolt (23) and nut (14) .

13. Tighten nut (14) to a torque of 25 ± 7 N·m (220 ± 60 lb in).

For Trucks with a Body That Is Heated, Install the 6G-7856 Exhaust Pipe

Table 66

Required Parts for Installation of Exhaust Pipe
Item	Quantity	Part Number	Description
1	1	5T-3492	Plate As
2	4	4L-6454	Bolt (3/8-16)
3	10	5P-1075	Hard Washer
4	1	6G-7031	Elbow
5	1	6G-7038	Seal Ring
6	1	5T-3369	Piston
7	1	5T-2762	Spring
8	1	5T-3367	Elbow
9	3	9D-2836	Lock
10	6	0L-1351	Bolt (3/8-16)
11	4	2D-9345	Stud
12	8	5P-8247	Hard Washer
13	8	7K-1270	Washer
14	4	4K-0367	Nut

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Illustration 161	g00648684

1. Remove the shipping cover.

   Note: Save the bolts and the washers.

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Illustration 162	g00823333
Top view of the right hand platform

2. Install plate (1) to the right hand platform with four bolts (2) and four washers (3) .

   Note: Plate (1) may already be installed on the platform.

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Illustration 163	g00823336

3. Use the components that were removed from Step 1 to install elbow (4) on the truck frame.

   Note: Leave the bolts loose until the elbow is adjusted.

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Illustration 164	g00717855

4. Install seal ring (5) on piston (6). Place spring (7) on the piston. Slide the piston and the spring into elbow (8) .

5. Use the components that follow in order to secure piston (6) in elbow (8) : three locks (9), six bolts (10) and six washers (3) .

Note: Apply 4C-5593 Anti-Seize Compound on studs (11) .

6. Use the items that follow in order to install elbow (8) on the truck body: four studs (11), four washers (12), four washers (13) and four nuts (14) .

7. Adjust two setscrews and two jam nuts in order to align elbow (4) with elbow (8) on the truck body. When the body is down, the compressed length of spring (7) should be 89 mm (3.5 inch). When the body raises, the piston should extend an additional 16 mm (0.63 inch). Tighten the bolts that hold elbow (4) .

For Trucks with an Exhaust Diverter Valve, Install the 130-5897 Exhaust Pipe and the 130-5898 Exhaust Flow Control Group

Table 67

Required Parts for Installation of Exhaust Diverter Valve
Item	Quantity	Part Number	Description
1	4	0S-1589	Bolt (5/8-11)
2	4	5P-8247	Hard Washer
3	4	7K-1270	Washer
4	2	4B-3586	Setscrew
5	2	1D-5117	Jam Nut
6	1	1B-4430	Jam Nut
7	1	2G-2477	Hose Assembly
8	1	2G-6523	Hose Assembly
9	1	3N-7235	Hose Assembly
10	1	3T-3048	Clip Assembly
11	1	4D-4065	Rod End
12	7	7K-1181	Cable Strap
13	2	7W-3447	Spacer
14	1	8M-8489	Dowel
15	1	125-4122	Cylinder
16	1	136-6964	Plate
17	1	170-1004	Exhaust Diverter Harness Assembly
18	1	3S-6115	Tee
19	2	0S-1595	Bolt (1/2-13)
20	1	0T-0573	Bolt (3/8-16)
21	2	4K-8302	Clip
22	2	4L-6454	Bolt (3/8-16)
23	2	4P-7429	Clip
24	4	5H-4778	Elbow
25	3	5K-8451	Clip
26	3	5P-1075	Hard Washer
27	1	5S-7383	Bolt (3/8-16)
28	3	6V-8801	Nut
29	3	8T-4896	Hard Washer

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Illustration 165	g00648779

1. Use the items that follow in order to install the exhaust pipe on the truck frame: four bolts (1), four washers (2) and four washers (3) .

   Note: To allow the exhaust pipe to be adjusted, do not tighten the bolts.

   Note: Apply 8T-9013 Silicone Sealant to the mounting surface of the exhaust pipe in order to seal the joint.

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Illustration 166	g00648762

2. Use setscrews (4) in order to position the exhaust diverter valve against the truck body. When the body is down, the collar of the exhaust diverter valve should compress 41 mm (1.6 inch). Use two jam nuts (5) in order to secure the setscrews. Tighten four bolts (1) in order to secure the exhaust diverter valve on the truck frame.

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Illustration 167	g00648782

3. Use the items that follow in order to secure the rod end of cylinder (15) to the lever of the exhaust diverter valve: nut (28), two washers (26), bolt (27), rod end (11), dowel (14) and jam nut (6) .

4. Use the items that follow in order to secure the opposite end of cylinder (15) to the exhaust diverter valve: nut (28), two spacers (13), washer (26) and bolt (20) .

5. Use a elbow (24) in order to connect hose (8) to the head end of cylinder (15). Connect the opposite end of hose (8). Refer to Illustration 167.

6. Use a elbow (24) in order to connect hose (9) to the rod end of cylinder (15). Connect the opposite end of hose (9). Refer to Illustration 167.

7. Use the items that follow in order to secure the hose assemblies that run to the cylinder: three washers (29), three bolts (22) and three clips (25) .

8. Disconnect the air hose from port (3) on the right side of the cab. Remove the elbow from the port. Install tee (18) in port (3) .

9. Connect the air hose that was removed from the cab to one side of tee (18). Connect hose (7) to the opposite side of the tee.

10. Connect the opposite end of hose (7). Refer to the Illustration 167.

11. Use two bolts (19) and two clips (21) in order to secure hose (7) to the platform.

12. Use the items that follow in order to secure harness (17) to the truck frame: two clips (23), seven cable straps (12) and clip (10) .

Use the 125-4166 Film to Install the Decals

Table 68

Required Parts for Installation of Film
Item	Quantity	Part Number	Description
1	1	100-5615	Film
2	2	131-5415	Film
3	1	125-4163	Film
4	1	125-4164	Film
5	1	125-4162	Film
6	1	125-4160	Film
7	1	8C-5563	Film
8	1	8C-5353	Film

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Illustration 168	g00528802

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Illustration 169	g00528804

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Illustration 170	g00651899
(A) 300 mm (11.8 inches) (B) 10 ± 1 mm (0.4 ± 0.04 inch) (C) 20 ± 1 mm (0.79 ± 0.04 inch) (D) 25 mm (0.98 inch) (E) 190 mm (7.5 inches) (F) 4 ± 1 mm (0.16 ± 0.04 inch) (G) 35 mm (1.38 inches) (H) 280 mm (11.02 inches)

1. Install one film (1) and two films (2) on the front of the canopy.

   Note: Align the red stripe across the front of the canopy.

2. Install film (3) on the left side of the truck body. Install film (6) on the right side of the truck body.

   Note: Center the films in the available spaces.

3. Install film (7) on the side of the right front fender. Install film (8) on the side of the left front fender.

   Note: Films must be installed on the sides of the front fenders before films are installed on the front of the fenders.

4. Install film (4) on the front of the right side fender. Install film (5) on the front of the left side fender.

   Note: Align the red stripes on the front and on the side of the fender.

Purge the Air from the Hydraulic Brake System

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Personal injury or death can result from air in the oil for the brake hydraulic system. Air in the system can prevent complete brake application and it is possible that the wheels on the machine can not be stopped. Air must not be in the oil for the brake hydraulic system to function properly.

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When the parking brakes are released manually, the machine has no brakes. To avoid possible personal injury, the tires must be blocked securely before the parking brakes are manually released.

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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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
An improper hydraulic oil level can result in machine damage.

Note: Before you start the engine, make sure that all fluid compartments are filled. Make sure that all hydraulic tanks are filled. Check the levels in all remaining fluid compartments. Fill any compartments that are not properly filled. Refer to Operation and Maintenance Manual, SEBU7261, "776D Tractor and 777D Off-Highway Truck" or Operation and Maintenance Manual, SEBU7268, "777D HAA Off-Highway Truck" for specific information.

Before you purge the air from the brakes, the makeup oil tank for the brakes must be full. The system air pressure should be above 550 kPa (80 psi). Attach a drain hose to each purge valve in order to collect the oil that is expelled.

Purging Procedure for the 777D Off-Highway Trucks with Front Service Brakes

Service Brakes

1. Operate the engine for twenty seconds after each application of the brakes in order to fill the makeup oil tank.

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Illustration 171	g00528766

2. When the brake pedal is held down, open purge valve (S) at the rear wheel station. Leave purge valve (S) open until there is a constant flow of oil. Close purge valve (S) and release the brake pedal. Repeat the process until no air is present in the stream of oil that is expelled. Repeat the procedure for the opposite rear wheel.

3. Operate the engine for twenty seconds after each application of the brakes in order to fill the makeup oil tank.

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Illustration 172	g00652897

4. When the brake pedal is held down, open purge valve (S) at the front service brake. Leave purge valve (S) open until there is a constant flow of oil. Close purge valve (S) and release the brake pedal. Repeat the process until no air is present in the stream of oil that is expelled. Repeat the procedure for the opposite front wheel.

Parking Brakes

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Illustration 173	g00786618

1. Start the engine. Hold down service brake pedal (2). Move parking brake lever (1) to the OFF position.

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Illustration 174	g00528766

2. Open purge valve (P) on one of the rear wheel stations. Leave purge valve (P) open until no air is present in the stream of oil that is expelled. Close purge valve (P) .

3. Repeat the procedure for the opposite rear wheel.

   Note: If the parking brake light is illuminated on the dash panel, indicator (R) in the brake air over hydraulic cylinder must be reset.

Purging Procedure for the 776D Tractors and for the 777D Off-Highway Trucks with Front Caliper Service Brakes

Service Brakes

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Illustration 175	g00786617

1. When the engine is running, move selector switch (1) for the front brakes to the OFF position.

2. Operate the engine for twenty seconds after each application of the brakes in order to fill the makeup oil tank.

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Illustration 176	g00528766

3. When the brake pedal is held down, open purge valve (S) at the rear wheel station. Leave purge valve (S) open until there is a constant flow of oil. Close purge valve (S) and release the brake pedal. Repeat the process until no air is present in the stream of oil that is expelled. Repeat the procedure for the opposite rear wheel.

4. Move selector switch (1) for the front brakes to the ON position.

5. Operate the engine for twenty seconds after each application of the brakes in order to fill the makeup oil tank.

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Illustration 177	g00648885

6. When the brake pedal is held down, open the two purge valves at the front wheel. Leave the purge valves open until there is a constant flow of oil. Close the two purge valves and release the brake pedal. Repeat the process until no air is present in the stream of oil that is expelled. Repeat the procedure for the opposite front wheel.

Parking Brakes

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Illustration 178	g00786618

1. Start the engine. Hold down service brake pedal (2). Move parking brake lever (1) to the OFF position.

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Illustration 179	g00528766

2. Open purge valve (P) on one of the rear wheel stations. Leave purge valve (P) open until no air is present in the stream of oil that is expelled. Close purge valve (P) .

3. Repeat the procedure for the opposite rear wheel.

   Note: If the parking brake light is illuminated on the dash panel, indicator (R) in the brake air over hydraulic cylinder must be reset.

Suspension Cylinder Charging Procedure

Refer to Testing and Adjusting for the suspension cylinders for the correct charging procedure. Lower the machine to the ground before charging the suspension cylinders.

Note: The body must be installed before the suspension cylinders can be correctly charged.

Differences for the 777D High Altitude Arrangement (HAA) Off-Highway Trucks

The 777D High Altitude Arrangement (HAA) Off-Highway Truck has a 3512B Engine. The larger engine is used in order to operate the truck at elevations that are greater than 3048 m (10,000 ft). The 3508B Engine will not maintain 745 kW (1000 hp) at an altitude of 3048 m (10,000 ft). The 3512B Engine will maintain 745 kW (1000 hp) up to 4876 m (16000 ft) of altitude. The front of the truck is modified in order to accept the additional length of the 3512B Engine. Minor changes are made to the systems that follow:

• The frame

• The hood

• The oil lines

• The fuel lines

• The air lines

• The water lines

The remainder of the truck is unchanged from the standard 777D Off-Highway Truck.

The chassis for the 777D HAA Off-Highway Truck weighs 23135 kg (51004 lb).

Differences in the Systems for the 777D HAA Off-Highway Trucks

Table 69

Part Numbers for 777D HAA Off-Highway Trucks
Part Number	Description
149-4466	Engine Exhaust
8W-9078	Exhaust Pipe
169-6610	Lighting and Wiring Group
136-0894	Air Cleaner
136-0895	Air Lines

Install the 136-0894 Air Cleaner and the 136-0895 Air Lines

Table 70

Required Parts for Installation of Air Lines
Item	Quantity	Part Number	Description
1	2	135-5285	Air Cleaner
2	2	119-8361	Support
3	12	4L-6454	Bolt (3/8-16)
4	32	5P-1075	Hard Washer
5	12	6V-8801	Nut
6	2	135-5294 (1)	Elbow
7	4	8T-4990 (1)	Hose Clamp
8	2	7W-7417	Service Indicator
9	2	5K-5068	Nipple
10	2	5P-4400	Air Brake Connector
11	1	135-5288	Bracket
12	2	5P-4428	Elbow
13	2	5P-0756	Tube
14	2	8M-2772	Clip
15	8	8T-2502	Bolt (3/8-16)
16	4	8T-4988 (1)	Hose Clamp
17	1	135-5290	Support
18	1	135-5293	Support
19	2	7W-0629	Filter Adapter

( 1 )

This part is from the air lines.

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Illustration 180	g00649795

1. Use the components that follow in order to attach one support (2) to each air cleaner (1) : two bolts (15), four washers (4) and two nuts (5) .

2. Use the components that follow in order to attach one support (18) to both air cleaners (1) : two bolts (15), four washers (4) and two nuts (5) .

3. Use four bolts (3) and four washers (4) in order to install each air cleaner (1). Also install one support (17) in order to support the air cleaner.

   Note: Use the mounting locations that are farthest forward on the platform in order to secure the air cleaners.

4. Install the components that follow on bracket (11) : two nipples (9), two connectors (10) and two service indicators (8) .

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Illustration 181	g00717927

5. Use two clamps (7) and two clamps (16) in order to install one elbow (6) on each air cleaner.

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Illustration 182	g00639094

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Illustration 183	g00639112

6. Use the components that follow in order to attach bracket (11) on the air cleaners: two bolts (3), four washers (4) and two nuts (5) .

7. Install one elbow (12) and one filter adapter (19) on each air cleaner. Use two tubes (13) in order to connect two connectors (10) and two elbows (12) .

8. Use the components that follow in order to secure two tubes (13) : two clips (14), two bolts (3), four washers (4) and two nuts (5) .

Install the 136-0895 Air Lines

Table 71

Required Parts for Installation of Air Lines Group
Item	Quantity	Part Number	Description
1	4	127-7455	Bracket
2	8	5S-7379	Bolt (3/8-16)
3	24	5P-1075	Hard Washer
4	1	136-5692	Tube
5	8	8T-2501	Bolt (3/8-16)
6	8	2K-4973	Locknut
7	12	8T-4988 (1)	Hose Clamp
8	2	127-7450	Air Inlet Hose
9	2	135-5294 (1)	Elbow
10	1	136-5691	Tube
11	4	127-7453	Strap
12	1	161-9926	Pressure Sensor
13	1	172-0195	Adapter
14	2	6V-5048	O-Ring Seal
15	7	7X-1181	Strap
16	2	4P-7581	Clip
17	1	118-7952	Turbocharger Sensor Harness Assembly

( 1 )

Install this part when the air cleaner is installed.

Illustration 184	g00528604
Air Lines for the Turbocharger

1. Use four bolts (2) and four washers (3) in order to install two brackets (1) on the left side of the platform.

2. Use the components that follow in order to install one tube (4) on two brackets (1) : two straps (11), four bolts (5), eight washers (3) and four locknuts (6) .

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Illustration 185	g00528605
Air Lines for the Turbocharger

3. Use two clamps (7) in order to secure one hose (8) on the outlet from the turbocharger.

   Note: Before you install the air inlet hose, remove the protective tape from the outlet.

4. Use two clamps (7) in order to secure one end of tube (4) on hose (8) .

5. Use two clamps (7) in order to secure the top end of tube (4) on elbow (9) .

6. On tube (4), install the components that follow: pressure sensor (12), adapter (13) and two O-ring seals (14) .

7. Connect the electrical wiring to the pressure sensor. Use one cable strap (15) and one clip (16) in order to secure the electrical wiring on bracket (1) .

   Note: Use cable straps (15) in order to secure the electrical wiring from the pressure sensor on the frame.

8. Repeat Step 1 through Step 5 in order to install tube (10) .

Perform the Commissioning Procedure for the Machine

This section contains assembly checks and functional checks of systems. Perform the checks before you deliver the machine to a customer.

Prepare the Machine Before the Machine Is Started

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Illustration 186	g00648890

1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind the operator seat. The laptop computer should have JERD2142 or JERD2129 data subscription. Use a 7X-1570 Data Link Cable , 7X-1700 Communication Adapter , NEXG4523 Service Program Module, and a 7X-1688 Cable in order to connect the laptop computer.

2. In order to power the electrical system of the truck, perform the steps that follow:

   1. Connect the batteries.

   2. Turn the battery disconnect switch ON.

   3. Turn the key of the machine ON.

   4. DO NOT START THE TRUCK.

3. Start the Electronic Technician (ET). ET will list all of the electronic control modules for the machine. There will be at least an "ENGINE CONTROL" and a "TRANSMISSION CONTROL". If the truck has the Automatic Retarder Control (ARC) or the Automatic Electronic Traction Aid (AETA), the ET screen should show the features.

4. ET should also display the truck model for each control. Make sure that the model is correct for each control.

5. Choose the "ENGINE CONTROL". Next, choose "CONFIGURATION".

6. Change the Equipment Identification Number in order to correspond to the Product Identification Number (PIN) of the truck.

7. If the truck has the engine prelubrication system, choose "ENGINE PRELUBE". Turn on the engine prelubrication system. Engine prelube should be off if the system is not on the truck.

8. If the truck is equipped with a starting aid, choose "ETHER CONTROL" or "STARTING AID". Turn on the ether control or the starting aid. The starting aids should be off if the systems are not on the truck.

9. Check the "HORSEPOWER" parameter. The choices are 920 HP or 1000 HP. Select 1000 HP.

10. Choose "ACTIVE CODES" from the ET menu. Click on the button on the bottom of the screen. The button reads "INCLUDE ALL ECMS". If "NO ACTIVE CODES" appears, then continue. If active fault codes are present, resolve the active faults.

11. Choose "LOGGED CODES" from the ET menu. Click on the button at the bottom of the screen that reads "INCLUDE ALL ECM's". Clear all logged codes.

12. Choose "DIAGNOSTICS" and choose "EVENTS" from the ET menu. Click on the button that reads "INCLUDE ALL ECM's". Clear all logged events.

13. Choose "DIAGNOSTICS" and choose "DIAGNOSTIC TESTS" from the ET menu. Next, choose "OVERRIDE PARAMETERS".

14. If the truck has the engine prelubrication system, choose "PRELUBRICATION". Choose "CHANGE". Turn on the engine prelube. The pump for the engine prelube should start. Choose "CHANGE" again and turn off the feature.

15. If the truck has a starting aid or an ether aid, choose "STARTING AID" or choose "ETHER AID". Choose "CHANGE" and turn on the feature. You should hear the click of the ether aid or the starting aid solenoid on the chassis. Choose "CHANGE" again and turn off the feature.

16. From the ET menu, select" DATA LINK". Next, select "SELECT ECM". Next, select "TRANSMISSION CONTROL". Next, select "CONFIGURATION".

    1. Change the Equipment Identification Number in order to correspond to the Product Identification Number (PIN) of the truck.

    2. Check the "BODY UP GEAR LIMIT" parameter. The parameter should be set to 1.

17. If the truck has the AUTOMATIC RETARDER system, select "DATA LINK" from the ET menu. Next, select "CHOOSE ECM". Next, select "AUTOMATIC RETARDER". Finally select "CONFIGURATION".

    1. Change the Equipment Identification Number in order to correspond to the Product Identification Number (PIN) of the truck.

Check the Monitoring System

1. Turn the key for the machine to the OFF position for two seconds. Turn the key for the machine to the ON position. Do not start the engine. Watch the lights of the machine monitoring system. When the key for the machine is in the ON position, all ten lights of the machine monitoring system should illuminate for approximately one second. Also, all LCD segments in the LCD panel should be illuminated. Also, the warning buzzer that indicates a fault should sound for approximately one second.

2. Turn the key for the machine OFF for two seconds. Turn the key for the machine ON. Do not start the engine. Watch the quad gauge. All four gauges should jump to one half of full scale and all four gauges should return to zero. Next, the four gauges should move to full scale. After reaching full scale, the gauges should return to the current values of the machine. Allow a three seconds test cycle in order to perform the check.

3. Turn the key for the machine OFF for two seconds. Turn the key for the machine ON. Do not start the engine. Watch the tachometer gauge. The indicator needle should jump to one half of full scale and the indicator needle should return to zero. Next, the indicator needle should move to full scale. After reaching full scale, the indicator needle will return to zero since the engine is not running. When you perform the check procedure, the actual gear readout should illuminate all segments of the readout. The readout should display two spaces.

4. Turn the key for the machine OFF for two seconds. Turn the key for the machine ON. Do not start the engine. Watch the speedometer. The speedometer will turn on every segment of the display. Next, the numbers will scroll to zero.

5. Check the gauges now. The gauges should read the following values:
   • The coolant temperature gauge should have the indicator needle between the far left and the center.

   • The brake oil temperature gauge should have the indicator needle between the far left and the center.

   • The gauge for the system air pressure should have the indicator needle between the far left and the center.

   • The fuel level gauge should have a reading at the indicator needle that matches the gauge on the side of the tank.

   • The speedometer should read zero. If the speedometer reading is blank, there is a problem.

   • The gear indicator should read N. If the gear indicator is blank, there is a problem.

   • The hour meter should read zero to fifty hours.

6. Clear the faults and set the units.
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   Illustration 187	g00648891

   1. Locate the "S" switch and the "C" switch behind the operator seat. Push the "S" switch and the "C" switch at the same time. When the display of the Caterpillar Monitoring System shows "-1-", release both switches. The display should read "57" for the 777D Off-Highway Truck and "58" for the 776D Tractor. The "57" indicates that the Caterpillar Monitoring System is set for a 777D Off-Highway Truck. The "58" indicates that the Caterpillar Monitoring System is set for a 776D Tractor.

   2. Push the "S" switch and push the "C" switch at the same time. When the display of the Caterpillar Monitoring System shows "-3-", release both switches. The display should show "---". If the display does not show "---", there are still logged faults or active faults that are present. If faults are present, a number will flash on the screen. If the "SERV CODE" indicator is not illuminated in the upper right corner of the screen, the fault is a logged fault. Clear the fault by pressing the "C" switch until the fault disappears. Continue to clear the faults until the "---" appears on the screen. If you reach a fault that illuminates the "SERV CODE" indicator, you will need to resolve the problem before you may clear the fault.

   3. Locate the "S" switch and the "C" switch behind the operator seat. Push the "S" switch and push the "C" switch at the same time. When the display of the Caterpillar Monitoring System shows "-4-", release both switches. Press the "C" switch only and hold the "C" switch for approximately two seconds. All of the gauges should go to readings of zero.

   4. Locate the "S" switch and the "C" switch behind the operator seat. Push the "S" switch and the "C" switch at the same time. When the display of the Caterpillar Monitoring System shows "-5-", release both switches. If the truck's destination is the United States, the display will probably read US. If the truck's destination is not the United States, hold down the "C" switch until the screen reads "SI". When the screen reads "SI", all readouts will display metric units.

   5. Turn the key for the machine OFF.

Check the Suspension Cylinders

Make sure that the suspension cylinders are charged correctly. Refer to Testing and Adjusting for the suspension cylinders.

Check the Truck Payload Measurement System (TPMS)

Note: The Truck Payload Measurement System (TPMS) will not operate properly until the suspension cylinders are charged correctly. Refer to Testing and Adjusting for the suspension cylinders.

Note: The TPMS needs proper calibration before operation. Refer to Service Manual, SENR4733, "Truck Payload Measurement System (With Real Time Clock)".

1. Remove the four screws that hold the TPMS display in the overhead panel. Pull out the display. Do not disconnect the display.

2. Turn on the TPMS display. Use the rocker switch at the far left of the display.

3. Install the TPMS display in the overhead compartment.

4. Turn the engine start switch to the ON position in order to permit the TPMS display to perform a check procedure. When the check procedure is complete, the screen will be blank. If the red lights and green lights are not flashing on the display, the system is operating correctly.

5. Set the truck model. Press the button on the rear of the display until the display shows "1". Release the button. The number that is displayed is the model of the truck. The models should be set to the following value: 777D: "14h". Use the set switch on the front of the display in order to change the model. Make sure that the model corresponds to the truck.

6. Set units mode of the system. Press the button on the rear of the display until the display shows "2". If the truck's destination is the United States, the display will probably read "1u". The display will read US tons. Use the switch on the front of the display in order to set the units mode. If the truck's destination is not the United States, the display should read "0u". The display will read Metric tonnes.

7. Turn the engine start switch to the OFF position.

Activation of the Hoist Controls for the Truck Body

The truck might appear to have a problem with the body hoist controls. The 184-4671 Software Group will set the parameters for the hoist system.

Note: ET Software must be used to set these parameters.

Note: On the 2.4 ET Software, when the parameters are not visible or accessible on the configuration screen, disconnect the connection and reconnect the connection until the parameters appear. This establishes the communication to the transmission control.

Note: On the 3.0 ET Software and the 3.1 ET Software, the parameters appear on the configuration screen.

Adjustment for the Hoist Lower Valve (A Programmable Parameter)

The command for the hoist lower valve is adjustable. This compensates for the differences in the valves. The adjustment range is -5 to +5 with zero as the default. A positive adjustment factor will increase the lower valve command. This causes the body to come down harder. A negative adjustment factor will decrease the lower valve command. This causes the body to come down softer.

The adjustment for the Hoist Lower Valve may not be available on earlier ECM systems. The adjustment range may be from 0 to 10 with 5 as the default on some early ECM systems.

Note: When the adjustment of the Hoist Lower Valve is set too high, too much oil can be diverted to the hoist system while the hoist system is in float mode. This causes the brake oil to heat up faster. Retarding capability is also decreased. To set the adjustment for the Hoist Lower Valve, follow the procedure below.

1. Raise the body of the truck and install the body retaining pins.

2. Place a 6V-7830 Tetragauge or place a 3.45 MPa (500 psi) gauge with a hose extension on the outlet port of the hoist pump.

   Note: Remove the body pins and lower the body to the frame.

3. While the body is down, place the hoist lever in the HOLD position.

4. Enter the configure parameter screen through the service menu in the Electronic Technician (ET).

5. Change the adjustment for the Hoist Lower Valve to a setting that is desired from -5 to 5. The procedure begins at 0. Adjust the settings in increments of 1 in the positive position or in the negative position.

   Note: If you are using a 3.45 MPa (500 psi) gauge, remove the gauge from the extension.

6. Raise the body to the middle position.

7. Lower the body to the frame.

8. If a 6V-7830 Tetragauge is not installed, shut off the engine and install a 3.45 MPa (500 psi) gauge. Start the engine and run the engine to high idle. Cycle the hoist lever to the FLOAT position and to the HOLD position. Do not power down or raise the bed if you are using a 3.45 MPa (500 psi) gauge. Damage may occur to the gauge.

9. While the engine is running, place the hoist lever in the FLOAT position.

10. Run the engine to high idle. Verify that the pressure at the hoist outlet port is less than 1724 kPa (250 psi).

Note: When the pressure is greater than 1724 kPa (250 psi), the adjustment is set too high. This causes too much oil to be diverted to the hoist valve. This causes the brake oil to overheat when the body is in the FLOAT position. Lower the adjustment setting and repeat Step 4 through Step 10. This lowers the pressure below 1724 kPa (250 psi).

Note: If you change the adjustment setting and there is no corresponding change in pressure, cycle the hoist lever again. A change will occur in the settings between 2 and 5.

Hoist Enable Parameter (A Programmable Parameter)

The Hoist Enable Parameter is set at a value of "2" for all trucks that are shipped from the factory with the 184-4671 Software Group and with a body that is not installed. Parameter Value 2 will prevent the hoist cylinders from being activated by accident. After the body is installed, change the Parameter Value to "1". The hoist system should function properly. When the hoist system does not work, check the items below.

Table 72

Setting the Parameter to Enable the Hoist System
Parameter Value	Description
0	This value is used when the hoist system is not installed. The hoist lever will not function, and no diagnostics will be logged on the hoist lever or on the solenoids.
1	This value is used for normal operation when the hoist system is installed and enabled.
2	This is the default value that is set in the factory when the hoist system is installed but disabled. The solenoids and the hoist lever have diagnostics, but the hoist lever is ignored. The solenoids are kept in the HOLD position.

1. Verify that the hoist system is enabled in the Configurable Parameters Screen through the service menu in the Electronic Technician (ET).

2. Disconnect ET and then reconnect the line if the Hoist Enable Status does not appear on the configuration screen. The hoist enable parameter flexes with the 3.0 ET Software when the parameter connects. Occasionally, ET misses the flexed parameters at the time of the connection.

   Note: The hoist enable parameter is standard on the configuration screen of the 3.1 ET Software.

3. If the Hoist Enable Status does not change, check the following potential causes:
   • The engine should not be running. When the engine is running, the engine may cause the signal from the Transmission Output Speed (TOS) to fluctuate. The TOS must be zero in order to change the Hoist Enable Status.

   • The truck should not be moving.

   Note: Press the "F5" key on the laptop computer in order to access the configuration screen on ET.

Body Down Snub Function (A Non-Programmable Parameter)

The body down snub function cushions the shock when the body hits the bed of the truck. When the body is lowered, the body up switch detects the position of the body when the body is close to the rail of the truck. This causes the ECM to go into snub mode.

When the operator's request is less than the snub mode, the ECM will use the operator's request. This ensures that the snub function will never cause the body to go down faster than the hoist lever modulation (operator's request).

The body down snub function will be cancelled as the operator moves the hoist lever out of the FLOAT position or out of the LOWER position. The body down snub function will not start until the body goes above the body up switch activation level.

Connect the Electronic Technician In Order To Prepare the Truck for the Final Check

1. Connect a laptop computer to the Caterpillar Diagnostic Connector on the fuse panel behind the operator seat. The laptop computer should have JERD2142 or JERD2129 Electronic subscription. Use a 7X-1570 Data Link Cable , 7X-1700 Communication Adapter , NEXG4523 Service Program Module, and a 7X-1688 Cable in order to connect the laptop computer.

2. In order to power the electrical system of the truck, perform the steps that follow:

   1. Connect the batteries.

   2. Turn the battery disconnect switch ON.

   3. Turn the engine start switch ON.

   4. DO NOT START THE TRUCK.

3. Start the Electronic Technician (ET). ET will list all of the electronic control modules for the machine. There will be at least an "ENGINE CONTROL" and a "TRANSMISSION CONTROL". If the truck has the Automatic Retarder Control (ARC) or the Automatic Electronic Traction Aid (AETA), the ET menu should show the features.

4. Choose "ACTIVE CODES" from the ET menu. Click on the button on the bottom of the screen. The button reads "INCLUDE ALL ECMS". If "NO ACTIVE CODES" appears, then continue. If active fault codes are present, resolve the active faults.

5. Choose "LOGGED CODES" from the ET menu. Click on the button at the bottom of the screen that reads "INCLUDE ALL ECM's". Identify the cause of all logged faults. Make sure that the causes of the logged faults have been resolved. Clear all logged codes.

6. Choose "DIAGNOSTICS" and choose "LOGGED EVENTS" from the ET menu. Click on the button that reads "INCLUDE ALL ECM's". Clear all logged events.

7. Locate the "S" switch and the "C" switch behind the operator seat. Push the "S" switch and push the "C" switch at the same time. When the display of the Caterpillar Monitoring System shows "-3-", release both switches. The display should show "---". If the display does not show "---", there are still logged faults or active faults that are present. If there are faults, a number will flash on the screen. If the "SERV CODE" indicator is not illuminated in the upper right corner of the screen, the fault is a logged fault. Identify the cause of the fault. Make sure that the cause of the fault has been resolved. Clear the fault by pressing the "C" switch until the fault disappears. Continue to clear the faults until the "---" appears on the screen. If you reach a fault that illuminates the "SERV CODE" indicator, you will need to resolve the problem before you may clear the fault.

Final Check

Use the Service Manual and use the Operation and Maintenance Manual in order to correct any system problems before you deliver the truck.

Note: After eight hours of operation, replace the cleanout filter elements with standard filter elements for the systems that follow: the parking brake filter, the transmission filter, the steering system filter and the torque converter charging oil filter.

After you complete the final check, please sign your name and the name of the dealer.

Make copies of the check procedure. Mail the copies to the following address:

Caterpillar Inc.
Attention: CMT Product Support
777D Truck and 776D Tractor
N. 27th and Pershing Road
Decatur, IL 62525

Dealer:____________________

Customer:____________________

Product Identification Number:____________________

1. Before you start the engine, make sure that all hydraulic systems are full. Also, make sure that all pump case drains are full.

2. Check that the system pressures are set correctly.
   • Pump

   • YES ____ NO ____

   • Brake

   • YES ____ NO ____

   • Steering Pressure

   • YES ____ NO ____

   • Transmission

   • YES ____ NO ____

   • Torque Converter

   • YES ____ NO ____

   • Differential

   • YES ____ NO ____

3. Check the machine lights.
   • Operational

   • YES ____ NO ____

   • Cab and Dash

   • YES ____ NO ____

4. Check the controls in the cab.
   • Check if the cab door opens. Check if the cab door closes.

   • YES ____ NO ____

   • Check if the Operation and Maintenance Manual is in the literature pouch on the back of the operator's seat.

   • YES ____ NO ____

   • Check if the horn functions.

   • YES ____ NO ____

   • Check if the windshield wipers and washers function.

   • YES ____ NO ____

   • Check if the seat belts operate.

   • YES ____ NO ____

   • Check if the fan switch operates.

   • YES ____ NO ____

   • Check if the heater functions.

   • YES ____ NO ____

   • Check if the air conditioner functions.

   • YES ____ NO ____

   • Check the test light. The test light is for the EMS.

   • YES ____ NO____

   • Check if the hour meter operates.

   • YES ____ NO ____

   • Check if the implements operate:

   • Hoist

   • YES ____ NO ____

   • Steering Action

   • YES ____ NO ____

   • Check if the steering column functions.

   • YES ____ NO ____

   • Check if the parking brake functions.

   • YES ____ NO ____

5. Check if all fluid levels are full.
   • YES ____ NO ____

6. Correct any unusual noises or unusual leaks.
   • YES ____ NO ____

7. Check if all lubrication lines are filled with grease.
   • YES ____ NO ____

8. Check if all quality requirements are fulfilled. Check if all variances have been corrected.
   • YES ____ NO ____

9. Check if the backup alarms function.
   • YES ____ NO ____

10. Check if the machine is repainted to the factory specifications.
    • YES ____ NO ____

11. Check if there was damage to the machine from shipment.
    • YES ____ NO ____

12. Check if all required parts were shipped with the machine.
    • YES ____ NO ____

13. Sign your name in the space below.
    • Hydraulic

    • ____________________

    • Electrical

    • ____________________

    • Structural

    • ____________________

    • Other

    • ____________________

14. Comments
    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

    • ________________________________________

Table 73

Specifications for the Commissioning Procedure
Description	Specifications	Actual	Comments
Engine Low Idle rpm	700 +30 -10 rpm
Engine High Idle	1935 ± 30 rpm
Pressure of Brake Retract Pump at High Idle	4690 ± 200 kPa (680 ± 30 psi)
Relief Pressure of Hoist Pump	18950 ± 520 kPa (2750 ± 75 psi)
Steering High Pressure Cutoff	21200 ± 350 kPa (3075 ± 50 psi)
Steering Cycle Time	6.5 seconds at 66 °C (150 °F)
Relief Pressure of Transmission Pressure at High Idle	3200 kPa (465 psi) Maximum
Pressure of Transmission Lubrication at High Idle	110 ± 30 kPa (16 ± 4 psi)
Torque Converter Outlet Pressure at Stall	450 ± 70 kPa (65 ± 10 psi) (1)

( 1 )

690 ± 70 kPa (100 ± 10 psi) for 776D Tractors