TNM 777G

20/3/22, 18:47 SIS 2.
2021/11/03 Assembly Procedure for the 777G Off-Highway Trucks {1000, 7000, 7960} (M0106746-04)
SMCS - 1000, 7000, 7960 i08644657

Off-Highway Truck/Tractor
777G (S/N: T5A2000-UP; TNM2000-UP; RDR2000-UP; T4Y2000-UP)
Revision History:
Revision Summary of Changes
Step 6 in Section "Install the 365-4788 Rear Housing Group, the 315-6272 Transmission Arrangement, and the 315-3183 Hydraulic
04
Oil Cooler Lines Group" is updated.
03 Content updated in Section "Steering System Pressure Testing Procedure" , Section "Primary Steering Pressure", and Table 125.
Remove 346-7706 Lighting Wiring Gp and add 539-6283 Flood Lighting Gp, 539-6284 Flood Lighting Gp, and 453-6602 Flood
02
Lighting Gp tables
01 Updated torque for assembly of 329-7328 Convex Mirror to mounting post to 2.37 ± 0.11 N·m (21 ± 1 lb in).
Table 1
Introduction
Reference: Specifications, SENR3130, "Torque Specifications"
Reference: Special Instruction, SEHS0030, "Field Procedure to Install the Rear Axle Lubrication Kit (If Equipped) on Certain 777G Off-Highway
Trucks"
Reference: Special Instruction, SEHS0031, "Field Instructions to Install the Engine Oil Metering Group (If Equipped) on Certain 777G Off-Highway
Trucks"
Reference: Special Instruction, REHS9320, "Procedure to Install the Cold-Weather Cover Group onto Certain Tier IV 773G, 775G, and 777G Off-
Highway Trucks"
This special instruction contains information and procedures that are required to assemble 777G Off-Highway Trucks.
Note: Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" for any information concerning
suspension cylinders. The Special Instruction includes Tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging
(oil and nitrogen).
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 assembled.
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, M0106094, "777G Off-Highway Trucks" or Operation and
Maintenance Manual, M0106096, "777G Off-Highway Trucks" to prepare the machine for operation. Use the Parts Manual and use the Service
Manual in addition to this special instruction.
https://sis2.cat.com/#/print-preview/service/%257B%2522title%2522%253A%2522Assembly%2520Procedure%2520for%2520the%2520777G%2520Off-Highway%2520Trucks%2520%257B1000%252C%2520700… 1/221
20/3/22, 18:47 SIS 2.0
Note: Determine if there are any outstanding product improvement programs (PIP) on the truck. If there are, determine the optimum time during
truck assembly to complete the program.
Illustration 1 g06094436
Note: A protective coating is now being applied to Quarry Trucks and Off-Highway Truck/Tractors. The coating of corrosion protection is applied to
any surface of the machine that is not painted and also to certain areas of the machine that may be affected by corrosive environments during
transportation to its final destination. The coating can be left on the machine to provide long lasting component protection, however it can be
removed using a high pressure 8275 kPa (1200 psi) hot alkaline washing (PH of 11 or higher) followed by a water rinse or by using low-pressure
steam.
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.
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, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.
Dispose of all fluids according to local regulations and

mandates.
Weights and Specifications

Approximate Weight of Empty Machine
Sales Model Empty Weight

777G 67676 kg (149200 lb) to 75279 kg (165962 lb)(1)
Table 2
(1)
Total machine weight will vary depending on emission option, body type, and other machine options.
Approximate Weight of Body Assembly

242-3170 Body and Canopy As with 297-2804 Body Liner Gp 21827 kg (48120 lb)
242-3170 Body and Canopy As with 242-3145 Body Liner Gp 23017 kg (50744 lb)
242-3170 Body and Canopy As 16132 kg (35565 lb)
20/3/22, 18:47 SIS 2.0

Table 3
Approximate Weights of Components
Name Weight
Chassis 19879 kg (43827 lb)
Skid and Cab 1435 kg (3160 lb)
Skid and Front Struts 4220 kg (9300 lb)
Parts Box 765 kg (1680 lb)
Skid and Fuel Tank 465 kg (1020 lb)
Skid and Hand Rails 535 kg (1180 lb)
Skid and Ladders 1335 kg (2940 lb)
Rear Axle Housing and Transmission 10605 kg (23380 lb)
Front Strut 1996 kg (4400 lb)
Right-Hand Platform 175 kg (386 lb)
Right-Hand Support Assembly 30 kg (66 lb)
Left-Hand Support Assembly 71 kg (157 lb)
Right-Hand Ladder 59 kg (130lb)
Right-Hand Rail 45 kg (99 lb)
Hood Hand Rail 28 kg (62 lb)
Right-Hand Ladder Hand Rail 30 kg (66 lb)
Front Hand Rail 21 kg (46 lb)
Front Cab Support 160 kg (350 lb)
Rear Cab Support 230 kg (500 lb)
Standard Cab 875 kg (1929 lb)
Left-Hand Platform 180 kg (397 lb)
Operator Access Ladder 54 kg (119 lb)
Left-Hand Ladder Rail 12 kg (26lb)
Left-Hand Catwalk Railing 68 kg (150 lb)
Tire and Rim 1960 kg (4320 lb)
Table 4
Required Tools
Tool Part Number Description

AA 148-0357 Strut Lifting Group
BB 4C-5593 Anti-Seize
CC 7K-1181 Cable Straps
DD 3S-2093 Cable Straps
EE 9S-3263 Thread Lock Compound
Table 5
Parts List
Reference: Service Parts, PECP9067, "One Safe Source".
Required Parts for the Installation of the Rear Axle Housing and Hydraulic Oil Cooler Lines
Qty Part Number Description

16 7X-2584 Bolt(1)
20/3/22, 18:47 SIS 2.0
32 217-9902 Washer(1)

4 8B-5144 Bolts(2)
1 321-1386 Tube As(3)
1 321-1387 Tube As(3)
1 321-1388 Tube As(3)
1 321-1389 Tube As(3)
4 4J-0528 O-Ring Seal(3)
17 8T-4184 Bolt(3)
33 8T-4223 Hard Washer(3)
16 1P-4582 Half Flange(3)
4 4J-0527 O-Ring Seal(3)
16 8T-8919 Bolt(3)
1 194-7882 Spacer(3)
4 6D-8305 Clamp(3)
1 6V-1867 Clip(3)
1 6V-1868 Clip(3)
1 6V-1869 Grommet(3)
2 8T-4779 Bolt(3)
1 6V-1249 Grommet(4)
1 9C-4937 Breather As(5)
1 7D-6282 Hose As(5)
1 5K-9660 Clip(5)
1 6V-4248 Bolt(5)
2 7K-1181 Cable Strap
Table 6
(1)
(2) Part of the 365-4802 Axle Housing Support Gp
(3) Bolts attached to the drive shaft in a bag
(4) Part of the 315-3183 Hydraulic Oil Cooler Lines Gp
(5) Part of the 310-7615 Chassis Wiring Gp
Part of the 365-4788 Rear Housing
Required Parts for the Installation of the 309-1346 Power Train Oil Lines Gp
1 150-4043 Connector As
2 173-1437 Half Flange
4 1P-4579 Half Flange
4 1P-4582 Half Flange
1 198-0143 Elbow As
1 4J-0522 O-Ring Seal
1 9X-8250 Clip
12 8T-4183 Bolt
21 8T-4223 Hard Washer
4 8T-6868 Bolt
4 8T-8919 Bolt
2 5P-7468 Clip
2 5P-7469 Clip
2 8T-4196 Bolt
2 8T-4133 Nut
20/3/22, 18:47 SIS 2.0
2 6V-0545 Grommet
1 5P-7466(1) Clip
1 5P-7467(1) Clip
1 5P-8112(1) Grommet
2 7X-7729(1) Hard Washer
Table 7
(1)
Part of the 309-1352 Service Brake Control Gp
Required Parts for Installation of the Front Suspension Cylinders

335-6352(1)
2 Front Suspension Gp

335-6351(2)
2 9D-2498 Key
28 6C-3218 Bolt
28 329-3710 Nut
56 329-3699 Hard Washer
8 299-7351 Bolt
Table 8
(1)
(2) Non-European part number
European part number
Required Parts for Installation of the Front Oil Cooler Lines Group and Front Brake Lines Group

2 381-3168(1) Hose As
2 381-3169(1) Hose As
8 1P-4582(1) Half Flange
6 4J-0527(1) O-Ring Seal
16 8T-4183(1) Bolt
2 4J-0524(1) O-Ring Seal
16 8T-4223(1) Hard Washer
2 8T-4186 Bolt
2 8T-4133 Nut
2 281-5975 Elbow As
2 319-6228 Elbow As
Table 9
(1)
Part of the 309-1339 Hydraulic Oil Cooler Lines Gp
Required Parts for Installation of the Fuel Tank

312-0924 Fuel Tank As(1)
1
1 381-6900 Bracket As
4 8T-4193 Bolt
2 6G-5294 Cap
4 8T-4187 Bolt
6 8T-4123 Washer
4 8X-5299 Mounting
2 8C-8478 Bolt
2 9D-9438 Washer
20/3/22, 18:47 SIS 2.0
2 8T-4131 Nut
Table 10
(1)
(2) 1140 L (300 US gal)
1325 L (350 US gal)
Required Parts for Installation of the Ladder Gp

2 358-6840 Step Gp
Table 11
Required Parts for Installation of the Cab Mounts and the Cab

1 311-7760 Support As
8 173-9684 Bolt
10 7X-2583 Bolt
1 343-6060 Sleeve
8 117-8131 Mount As
1 152-0604 Bolt
4 252-0080 Washer
3 343-6059 Sleeve
3 8T-0674 Bolt
4 8T-4195 Bolt
4 7X-7729 Washer
4 240-2261 Pin As
1 8T-4137(1) Bolt
Table 12
(1)
Part of the 310-7614 Chassis Wiring Gp
Required Parts for Installation of the Fittings for the 309-1352 Service Brake Control Gp
Item Qty Part Number Description

1 1 238-5080 O-Ring Seal
2 1 8T-0077 Connector
3 1 319-6240 Connector As
4 1 319-6226 Elbow As
5 1 3G-8057 Clip
6 1 3G-8054 Clip
7 1 3G-8047 Grommet
8 1 6D-4246 Clip
9 2 8T-4121 Hard Washer
10 2 8T-4196 Bolt
Table 13
Required Parts for Installation of the Steering Lines Gp

3 1 319-6222 Elbow As
20/3/22, 18:47 SIS 2.0
4 2 1F-7854 Spacer
5 2 281-5619 Rod
6 2 7G-5985 Clip
7 2 7G-5984 Clip
8 2 6V-1876 Grommet
9 1 5P-7462 Clip
10 1 5P-7463 Clip
11 1 6V-0683 Grommet
12 2 344-5675 Nut
13 2 7X-7729 Washer
Table 14
Required Parts for Installation of the Exhaust Pipe Group

1 295-5183 Exhaust Pipe Gp
6 7X-2563 Bolt
1 357-2923(1) Tube
2 4N-9330(1) Clamp
4 5P-8245(1) Hard Washer
2 6V-3823(1) Bolt
2 6V-7687(1) Locknut
Table 15
(1)
Part of the 357-2930 Exhaust Lines Gp
Required Parts for the Installation of the Muffler Group

1 327-2486 Tube
1 342-8714 Plate As
1 357-2917 Strap
8 5P-8245 Hard Washer
4 6V-3823 Bolt
4 6V-7687 Locknut
4 7X-2563 Bolt
1 357-2923(1) Tube
2 4N-9330(1) Clamp
Table 16
(1)
Required Parts for Installation of the Right-Hand Platform Group

1 312-0810 Platform Gp
Table 17
Required Parts for Installation of the Left-Hand Walkway Group

1 310-8090 Walkway Gp
Table 18
20/3/22, 18:47 SIS 2.0
Required Parts for the Installation of the 351-8950 Payload Monitor Gp Which is part of the 345-9839 Monitor Wiring Gp (If
Equipped)
2 351-8950 Payload Monitor Gp
1 351-8952 Mounting Bracket As
1 357-6649 Plate
1 150-5931 Grommet
2 7X-7729 Washer
4 8T-4136 Bolt
6 8T-4139 Bolt
6 8T-4194 Bolt
2 8T-4195 Bolt
Table 19
Required Parts for the Installation of the Fender Assembly and the Support Assembly
1 358-9520 Fender As
2 319-5435 Plate
2 357-0497 Plate
4 8T-4186 Bolt
8 7X-7729 Washer
4 8T-0389 Locknut
Table 20
Required Parts for Installation of the Platform Assembly

1 357-6650 Platform As (LH)
Table 21
Required Parts for Installation of the Ladder Group

1 358-6679 Step As
2 7T-8332 Mount
8 7X-0590 Hard Washer
4 8T-4183 Bolt
2 8T-4244 Nut
2 8T-4648 Bolt
Table 22
Required Parts for Installation of the Ladder Group

1 358-6678 Step As
2 7T-8332 Mount
4 8T-4184 Bolt
2 8T-4244 Nut
2 8T-4910 Bolt
20/3/22, 18:47 SIS 2.0
Table 23
Required Parts for Installation of the Handrail Group

2 354-6976 Handrail As
6 8T-4956 Bolt
8 115-3580(1) Plate
16 5P-7468(1) Clip
16 5P-7469(1) Clip
16 6V-1874(1) Grommet
38 7X-3392(1) Hard Washer
24 8T-4139(1) Bolt
16 8T-4183(1) Bolt
10 8T-4195(1) Bolt
16 8T-4244(1) Nut
Table 24
(1)
Part of the 312-0840 Handrail Gp
Required parts for Installation of the 310-7621 Platform Wiring Gp

1 3E-5169 Switch Guard
1 271-2178 Toggle Switch
1 353-4515 Toggle Switch Gp
2 8T-4137 Bolt
1 8Y-8606 Grommet
3 130-5300 Clip
1 219-6485 Flood Lamp Gp
1 271-4532 Film
1 281-7268 Film
Table 25
Required Parts for Installation of the 354-8040 Mirror Gp

1 12 7K-1181 Cable Strap
2 1 7X-7468 Convex Mirror
3 2 133-6934 Spacer
20/3/22, 18:47 SIS 2.0
4 6 134-0989 Block
5 2 144-2227 Mirror Gp
6 1 295-8899 Plate
7 1 478-0059 Tube As
8 2 478-0060 Tube As
9 1 129-3180 Locknut
10 1 221-9264 Rear View Mirror Gp
11 1 3K-6060 Locknut
12 3 5P-1076 Hard Washer
13 1 5P-7468 Clip
14 1 5P-7469 Clip
17 4 8T-4137 Bolt
18 12 8T-4182 Bolt
19 1 8T-4183 Bolt
20 2 8T-4185 Bolt
21 1 352-3964 Clip
22 4 4P-7581 Clip
Table 26
Required Parts for the Installation of the 336-4450 Mirror Gp

4 7D-9969 Support
2 134-0989 Block
2 144-2227 Mirror Gp
2 329-7328 Convex Mirror
2 334-1004 Tube As
1 358-6015 Tube As
1 358-6020 Tube As
4 7X-7729 Washer
11 7Y-5262 U-Bolt
4 8F-8398 Clamp
24 8T-0389 Locknut
4 8T-4137 Bolt
4 8T-4182 Bolt
4 8T-4184 Bolt
2 8T-4186 Bolt
3 8T-4195 Bolt
4 8T-6868 Bolt
Table 27

6 3S-2093 Cable Strap
6 7D-9969 Support
20/3/22, 18:47 SIS 2.0
1 7X-7468 Convex Mirror

2 134-0989 Block
2 323-5341 Tube As
1 326-3097 Baffle As
2 329-7328 Convex Mirror
4 338-5116 Wiring Harness
1 338-9280 Plate
1 338-9281 Plate
1 358-6015 Tube As
1 358-6020 Tube As
2 031-9831 Bolt
1 3K-6060 Locknut
4 7X-7729 Washer
10 7Y-5262 U-Bolt
4 8F-8398 Clamp
24 8T-0389 Locknut
3 8T-4136 Bolt
4 8T-4137 Bolt
4 8T-4182 Bolt
4 8T-4184 Bolt
2 8T-4186 Bolt
2 8T-4198 Bolt
6 8T-6868 Bolt
Table 28
Required Parts for the Installation of the 539-6283 Flood Lighting Gp
Table 29
1 3 219-6485 Flood Lamp Gp
Table 30
20/3/22, 18:47 SIS 2.0
1 4 441-0315 Head Lamp Gp
Table 31
Required Parts for the Installation of the Roof Antenna 310-7629 Wiring Gp (If Equipped)
1 284-8533 Antenna Assembly
1 283-5837 Plate
15 3S-2093 Cable Straps
1 2G-1133 Grommet
1 8S-7583 Grommet
1 7G-3228 Grommet
Table 32
Required Parts for the Installation of the 310-7629 Antenna Mounting Gp (If Equipped)
1 283-5837 Plate
1 346-9376 Antenna As
1 2G-1133 Grommet
1 377-7091 Cable As
1 7G-3228 Grommet
2 8S-7583 Grommet
Table 33
Required Parts for Installation of the Fender Group

1 340-3605 Guard
1 340-3607 Guard
1 346-7672 Rubber Guard
1 358-9150 Guard
1 376-6617 Guard
1 356-6038 Sideboard As
1 357-6592 Guard
18 8T-4196 Bolt
4 8T-4195 Bolt
22 7X-7729 Washer
1 358-6038 Plate As
16 357-0497 Plate
1 346-8338 Plate As
1 358-9152 Plate As
Table 34
20/3/22, 18:47 SIS 2.0
Required Parts for Installation of the 347-5894 Chassis Harness As

2 8R-0721 Spacer
1 341-6647 Plate As
4 5P-2369 Clip
3 8T-4137 Bolt
2 8T-4185 Bolt
1 8T-4197 Bolt
Table 35
Required Parts for Installation of the 308-3212 Front Wheel

40 339-3284 Hex Nut
Table 36
Required Parts for Installation of the Rear Wheels

2 420-0526 Tire Valve Gp
80 339-3284 Hex Nut
2 329-8262(1) Stem Extension Gp
Table 37
(1)
Remove and reuse a valve cap from rear rims to protect the core on extension group.
Required Parts for Installation of the 377-6260 Truck Body Mounting Gp

16 1D-0503 Washer
4 5D-3887 Rod
2 5T-5528 Plate
2 5T-9266 Pin As
4 6F-8499 Spring
2 6G-7773 Pin
2 8W-8454 Pin As
2 8W-8456 Plate
4 9D-2316 Spacer
4 054-3788 Washer
2 253-7490 Ejector
2 270-7034 Pin As
2 322-5067 Mud Guard
2 322-5068 Plate
2 331-5956 Plate
8 3B-4615 Cotter Pin
4 3B-4647 Cotter Pin
8 5P-2566 Bolt
20 6V-8801 Nut
28 8T-4183 Bolt
8 8T-4244 Nut
20/3/22, 18:47 SIS 2.0
20 9B-7237 Bolt

Thrust Washer
1 8W-2897
(1)

2 9D-3432 Thrust Washer(1)
20 106-8227 Shim
6 229-6177 Pad As
326-3097
Baffle As(2)
1
113-1218
Baffle As
2 031-9831 Bolt
Table 38
(1)
(2) Use thrust washers if necessary and as required to shim between the body and frame assemblies at outside pivot pin areas to reduce gaps to less than 3 mm (0.12 inch).
Part of the 321-6518 Rear View Mirror Gp
Required Parts for Installation of the 309-1212 Central Lubrication Lines Gp

14 5P-9085 Clip
12 8T-4191 Bolt
2 5M-3062 Bolt
Table 39
Required Parts for Installation of the 309-1213 Automatic Lubrication Gp

2 5M-3062 Bolt
14 5P-9085 Clip
12 8T-4191 Bolt
Table 40
Required Tools for Installation of the 510-5059 Rear Axle Lubrication Kit (If Equipped)
Tool Qty Part Number Part Description
1 FT-1114 Vacuum Cap
1 5P-0306 Vacuum Transducer
A
1 6V-4142 Fitting
1 5K-5068 Fitting
Table 41
Required Parts for Installation of 345-8140 Power Train Filter Lines Gp Part of the 510-5059 Rear Axle Lubrication Kit
(If Equipped)

4 8T-4186 Bolts
4 8T-7934 Hard Washers
1 327-0361 Manifold
6 8T-4178 Bolts
1 192-3841 Oil Filter Gp
3 112-3926 Bolts
3 6V-5841 Hard Washers
3 373-7132 Spacers
20/3/22, 18:47 SIS 2.0
3 226-4192 Hard Washers

4 329-3356 Nuts
1 249-7012 Axle Oil Cooler Pump and Motor Gp
4 3D-2824 O-Ring Seals
6 6V-9746 O-Ring Seals
2 6V-9007 Elbows
1 327-0357 Hose As
3 323-0049 Clips
4 8T-4137 Bolts
2 4J-0527 O-Ring Seals
1 345-8141 Hose As
4 1P-4582 Half Flanges
8 8T-4184 Bolts
1 345-8143 Hose As
4 8C-3206 Half Flanges
8 8T-4196 Bolts
2 6V-9004 Elbow
2 3K-0360 O-Ring Seal
2 6V-9874 Connectors
1 6V-8637 Connector
1 327-0358 Hose As
1 327-0355 Hose As
1 5P-7854 Clip
2 5K-9090 O-Ring Seal
2 7M-8485 O-Ring Seal
1 6V-9008 Elbow
1 6V-9005 Elbow
1 472-6163 Hose As
1 130-5300 Clip
2 7K-1181 Cable Straps
2 228-7093 O-Ring Seals
2 8T-6684 Elbows
1 228-7088 O-Ring Seal
1 6V-8627 Elbow
1 6V-5134 O-Ring Seal
1 133-2198 Spring
1 2S-4078 O-Ring Seal
1 3T-9549 Adapter
1 391-7125 Bypass Switch
Table 42
Required Parts for Installation of 319-1856 Rear Axle Lubrication Lines Gp Part of the 510-5059 Rear Axle Lubrication
Kit (If Equipped)

2 8T-4172 Bolts
10 8T-4121(1) Hard Washers
20/3/22, 18:47 SIS 2.0
1 333-0362 Control Manifold Gp

6 228-7093(2) O-Ring Seals
1 6V-9008 Elbow
1 373-2088(3) Hose and Tube As
1 371-5876(3) Tube As
2 5P-8444(3) Grommets
2 5P-7468 Clips
2 5P-7469 Clips
2 8T-4196(4) Bolts
2 344-5675(5) Nuts
1 358-9424 Hose and Tube As
2 6V-7359 Grommets
2 5P-7465 Clips
2 5P-7464 Clips
3 8T-5005 Bolts
2 1F-1609 Spacers
1 4D-7388 Clip
4 8T-4195 Bolts
1 379-9732 Hose As
1 6V-8641 Connector
1 342-0704 Hose As
1 358-9416 Hose As
1 358-9417 Hose As
2 8T-7088 Grommets
2 7G-5984 Clips
2 7G-5985 Clips
4 7X-7729 Washers
2 6V-0826 Grommets
2 8T-1890 Clips
2 8T-1889 Clips
1 189-8772 Spacer
1 8T-4192 Bolt
1 504-1375(6) Hose As
1 142-3331 (6) Bracket As
2 8T-7087 (6) Grommets
1 6V-1581 (6) Clip
1 6V-1582 (6) Clip
1 8T-4182 (6) Bolt
Table 43
(1)
(2) 10 Hard Washers required with 486-0544 Rear Axle Lubrication Kit.9 Hard Washers required with 510-5059 Rear Axle Lubrication Kit.
(3) 6 O-Ring Seals required with 486-0544 Rear Axle Lubrication Kit .5 O-Ring Seals required with 510-5059 Rear Axle Lubrication Kit .
(4) Only required with 486-0544 Rear Axle Lubrication Kit .
(5) 2 Bolts required with 486-0544 Rear Axle Lubrication Kit1 Bolt required with 510-5059 Rear Axle Lubrication Kit.
(6) 2 Nuts required with 486-0544 Rear Axle Lubrication Kit.1 Nut required with 510-5059 Rear Axle Lubrication Kit.
Only required with 510-5059 Rear Axle Lubrication Kit.
Required Parts for Installation of 295-5166 Engine Oil Tank and Mounting Gp Part of the 484-0956 Engine Conversion
Ar (If Equipped)
20/3/22, 18:47 SIS 2.0
8 7T-8331 Supports
8 8T-4910 Bolts
8 7G-8839 Spacers
1 327-2477 Engine Oil Tank As
4 7M-8485 O-Ring Seals
3 9Y-9236 Sight Gauge
1 9G-5127 Breather As
1 6G-9333 Filler Cap
7 8T-4137 Bolts
1 371-1177 Guard As
1 371-1176 Hose As
1 110-8827 Fitting
1 8T-6466 Bolt
4 1S-0994 Clips
1 6W-6672 Spacer
1 375-1526 Hose As
2 8T-4136 Bolts
3 8S-0948 Clips
1 9G-7101 Spacer
1 197-7481 Stud
1 8T-4133 Nut
1 3D-2824 O-Ring Seal
1 8T-0404 Elbow
1 6V-8938 Reducer
1 6V-8555 Face Seal Nut
1 333-8391 Hose As
1 327-2482 Plate
1 5C-9553 Bolt
1 9X-8256 Washer
Table 44
Required Parts for Installation of 310-7632 Oil Renewal System Wiring Gp Part of the 484-0956 Engine Conversion Ar
(If Equipped)

2 172-8660 Liquid Level Switch
1 340-4391 Indicator Lamp
1 340-4393 Indicator Lamp
5 8T-4137 Bolts
4 130-5300 Clips
4 4P-7581 Clips
1 314-9920 Engine Harness As
5 7K-1181 Cable Straps
20/3/22, 18:47 SIS 2.0
1 8T-4171 Bolt
1 9X-8256 Washer
1 3E-5239 Relay As
Table 45
Required Parts for Installation of 337-8825 Engine Oil Metering Gp Part of the 484-0956 Engine Conversion Ar (If
Equipped)

1 8T-6466 Bolt
1 235-0266 Metering Valve Gp
1 8T-4195 Bolt
1 8T-4172 Bolt
1 304-7975 Adapter
1 337-8823 Tube As
1 234-8937 Integral Seal
1 337-8821 Plate
2 5S-7382 Bolts
1 6V-8641 Connector
1 337-8822 Hose As
1 6V-9849 Elbow
Table 46
Required Parts to Install the 449-0978 Cover Gp onto the 777G Off-Highway Truck
1 449-0977 Cover As
4 8T-4189 Bolt
1 320-3061 Pressure Sensor
1 446-0464 Wiring Harness
1 458-3399 Engine Software(1) Engine Ratings Electronic Software Gp
Table 47
(1)
Replaces 451-0606 Engine Ratings Electronic Software Gp or earlier software version for 777G
Required Parts for Installing the 377-3154 Monitor Display Ar

1 271-6768 Plate
1 347-3568 Plate
1 348-9226 Grommet Assembly
20/3/22, 18:47 SIS 2.0
1 2V-8260 Grommet
2 347-1668 Camera Gp
1 4P-8134 Clip
4 5C-2890 Nut
1 5P-7468 Clip
1 5P-7469 Clip
1 6V-1874 Grommet
2 8T-4136 Bolt
1 8T-4183 Bolt
1 8T-4244 Nut
4 9X-8256 Washer
1 315-5391 Nut
Table 48
Required Parts to Install the 377-3153 Monitor Display Ar

2 283-0659 Cable As
1 305-3747 Plate As
2 305-3748 Plate As
2 347-1668 Camera Gp
1 162-9112 Split Grommet
4 5C-2890 Nut
1 348-9226 Grommet Assembly
2 8M-2773 Clip
11 8T-4133 Nut
2 8T-4136 Bolt
8 8T-4195 Bolt
6 8T-6466 Bolt
4 9X-8256 Washer
1 358-9562 Plate As
3 8T-4137 Bolt
1 315-5391 Nut
Table 49
Required Parts to Install the 377-3152 Object Detection Installation Ar

32 8T-9655 Isolation Mount
16 8T-9658 Spacer
16 9N-0869 Hard Washer
4 365-8490 Sensor and Mounting
1 392-4618 Plate
20/3/22, 18:47 SIS 2.0
4 5C-7261 Nut
8 6V-3964 Hard Washer
16 6V-7357 Bolt
12 7X-0818 Bolt
2 7Y-5262 U-Bolt
4 8T-0389 Locknut
10 8T-4195 Bolt
4 8T-6912 Bolt
2 4P-7581 Clip
1 8T-4137 Bolt
Table 50
Required Parts for Installation of the 320-5104 Wheel Chock Gp

2 7D-7496 Pin As
2 155-3597 Wheel Chock
4 8T-4195 Bolt
Table 51
Required Parts for Installation of the Film Gp

1 380-6904 Film
1 380-6905 Film
1 380-6906 Film
Table 52
Required Parts for Installation of the 461-6865 Fire Suppression Ar

2 488-7131(1)(2)(3) Cartridge As
2 488-7064(1)(2)(3) Actuator
2 488-7089(2)(4) Cable
1 290-5562(4) Mount
18 7K-1181(4) Cable Strap
1 488-7063(2)(4) Controller As
4 8T-4136(4) Bolt
4 9X-8256(4) Washer
1 488-7066(2)(4) Bracket
2 8T-4136(4) Bolt
1 488-7065(2)(4) Actuator As
1 488-7140(5) Film
2 148-8337(1) Connector As
Table 53
(1)
(2)
From the 461-6979 Fire Suppression Lines Gp
20/3/22, 18:47 SIS 2.0
( )
(3) Cat part number for reference only. Part is not serviced through the Cat parts system
(4) Part supplied by representative authorized to service the manufacture's system.
(5) From the 486-3730 Front Wiring Gp
From the 497-2244 Film Gp
Required Parts for the Installation of the 507–7284 Bottle Group Washer and Mud Flap Assembly
Item Qty Part Name Part Description
1 1 118-6878 Bracket As
2 1 1S-0994 Clip
3 1 240-2172 Spout
4 1 290-5562 Mount
5 1 343-2388 Clip
6 1 507-7283 Window Washer Tank Gp
7 1 550-5932 Cap As
8 2 5P-4295 Clip
9 2 5P-9085 Clip
11 7 7X-7729 Washer
12 2 7X-7958 Hose Clamp
13 1 8L-6990 Clip
15 4 8T-4137 Bolt
16 3 8T-4189 Bolt
17 2 8T-4195 Bolt
20 1 476-9273 Bracket
21 1 467-1101 Bracket
22 4 198-4778 Hard Washer
23 12 8T-4956 Bolt
25 14 8T-4196 Bolt
26 2 507-1678 Bracket
27 1 467-5113 Mud Flap
28 27 cm 8I-1362 Hose
29 56 cm 9X-2133 Hose
30 4 8T-0389 Locknut
31 2 357-0497 Plate
Table 54
Prepare to Assemble the Machine

Before you unload the chassis and related components, read the information that follows to make the job easier.
Site Layout
20/3/22, 18:47 SIS 2.0
Typical view of the layout for the 777G Off-Highway Truck
View from above the work area
(AA) Chassis

Tires and Rims
(AB) Skid for the

(AC) Skid for the Handrails and Left-Hand Walkway
(AD) Crate for Components

(AE) Skid for the Right-Hand

Platform, Cab Mounting, Stairways, and Exhaust box
(AF) Skid for the Cab

(AG) Skid for the Wheel, Brake, and Front Suspension
(AH) Skid for the Fuel Tank

(AJ) Power Train
1. To assemble the machine, select an area that is smooth, flat, and well drained. An area 25 m (82 ft) wide and 30 m (98 ft) long, is needed for
the assembly of the truck. Place the chassis in the center of the area.
2. The truck chassis should be located in the center of the assembly area. Keep the assembly area around the truck chassis clear. Also, the
assembly area should be left unobstructed in order for the crane to lift the components.
3. The contents of each box should be consumed throughout the progression of the build. Do not unload boxes until the contents are required.
4. Do not open plastic bags of hardware until the contents are required. The plastic bags are marked with the group part number. Individual
components are marked 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.
Approximate Weights
Personal injury or death can result from improper lifting or

blocking.
When a hoist or jack is used to lift any part or component, stand

clear of the area. Be sure the hoist or jack has the correct
capacity to lift a component. Install blocks or stands before
performance of any work under a heavy component.
Approximate weights of the components are shown. Clean all

surfaces where parts are to be installed.
The chassis weighs 19879 kg (43827 lb).
The cab assembly weighs 1435 kg (3165 lb).

20/3/22, 18:47 SIS 2.0
The front suspension cylinder weighs 1996 kg (4400 lb).
The rear axle housing and transmission weigh 10605 kg (23380 lb).
The tire and rim assembly weighs 1960 kg (4320 lb).
The standard body and canopy assembly weighs 15851 kg (34945 lb).
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 front suspension cylinder to a torque of 1175 ± 48 N·m (870 ± 35 lb ft).
Tighten the bolts that mount the front steering arm to a torque of 1800 ± 200 N·m (1328 ± 148 lb ft).
Tighten the cab support mounting bolts at the front support to a torque of 800 ± 110 N·m (590 ± 81 lb ft)
Tighten the cab support mounting bolts at the rear support to a torque of 1600 ± 200 N·m (1180 ± 150 lb ft).
Tighten the cab mounting bolts at the front and rear of the cab to a torque of 800 ± 100 N·m (600 ± 75 lb ft).
Tighten the nuts that mount the front wheel rim and rear wheel rim to a torque of 1700 ± 200 N·m (1254 ± 148 lb ft).
Tighten the clamps on the steering tie rods to a torque of 285 N·m (210 lb ft).
Hoist Capacity
Chassis Assembly
When the differential housing is on supports, a hoist with a capacity of 10000 kg (22000 lb) is necessary to lift the chassis at the front lifting point.
When the front frame cross-member is on supports, a hoist with a capacity of 8600 kg (19000 lb) is necessary 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 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 to lift the truck at the rear lifting points.
Machine Dimensions
General Machine Dimensions 777G
Dual Slope Flat Floor Coal Body 1 Coal Body 2
1 Height to Top of ROPS 4730 mm (186.22inch) 4730 mm (186.22inch) 4730 mm (186.22inch) 4730 mm (186.22inch)
2 Overall Body Length 9830 mm (387.00 inch) 10070 mm (396.46 inch) 10274 mm (404.49 inch) 10445 mm (411.22inch)
3 Inside Body Length 6580 mm (259.05 inch) 7037 mm (277.05 inch) 7562 mm (297.72 inch) 7734 mm (304.49 inch)
4 Overall Length 10535 mm (414.76 inch) 10758 mm (423.54 inch) 10968 mm (431.81 inch) 11140 mm (438.58 inch)
5 Wheel Base 4560 mm (179.53 inch) 4560 mm (179.53 inch) 4560 mm (179.53 inch) 4560 mm (179.53 inch)
6 Rear Axle to Tail 3062 mm (120.55 inch) 3263 mm (128.46 inch) 3473 mm (136.73 inch) 3644 mm (143.46 inch)
7 Ground Clearance 896 mm (35.28 inch) 896 mm (35.28 inch) 896 mm (35.28 inch) 896 mm (35.28 inch)
8 Dump Clearance 965 mm (38.00 inch) 893 mm (35.16 inch) 935 mm (36.81 inch) 821 mm (32.32 inch)
9 Loading Height - Empty 4380 mm (172.44 inch) 4429 mm (174.37 inch) 4851 mm (190.98 inch) 5321 mm (209.49 inch)
10 Inside Body Depth - Max 1895 mm (74.61 inch) 1777 mm (69.96 inch) 2223 mm (87.52 inch) 2693 mm (106.02inch)
11 Overall Height - Body Raised 9953 mm (391.85 inch) 10071 mm (396.50 inch) 10319 mm (406.26 inch) 10319 mm (406.26 inch)
12 Operating Width 6687 mm (263.27 inch) 6687 mm (263.27 inch) 6706 mm (264.02 inch) 6706 mm (264.02 inch)
13 CL Front Tire Width 4170 mm (164.17 inch) 4170 mm (164.17 inch) 4170 mm (164.17 inch) 4170 mm (164.17 inch)
14 Engine Guard Clearance 864 mm (34.02 inch) 864 mm (34.02 inch) 864 mm (34.02 inch) 864 mm (34.02 inch)
15 Overall Canopy Width 6200 mm (244.09 inch) 6200 mm (244.09 inch) 6404 mm (252.13 inch) 6404 mm (252.13 inch)
16 Outside Body Width 5524 mm (217.48 inch) 5682 mm (223.70 inch) 6365 mm (250.59 inch) 6368 mm (250.71 inch)
17 Inside Body Width 5200 mm (204.72 inch) 5450 mm (214.57 inch) 6150 mm (242.13 inch) 6150 mm (242.13 inch)
18 Front Canopy Height 5200 mm (204.72 inch) 5370 mm (211.42 inch) 5840 mm (229.92 inch) 5840 mm (229.92 inch)
20/3/22, 18:47 SIS 2.0
19 Rear Axle Clearance 902 mm (35.51 inch) 902 mm (35.51 inch) 902 mm (35.51 inch) 902 mm (35.51 inch)
20 CL Rear Dual Tire Width 3576 mm (140.79 inch) 3576 mm (140.79 inch) 3576 mm (140.79 inch) 3576 mm (140.79 inch)
21 Overall Tire Width 5223 mm (205.63 inch) 5223 mm (205.63 inch) 5223 mm (205.63 inch) 5223 mm (205.63 inch)
Table 55
Required Tools
When you are instructed, apply 4C-5593 Anti-Seize Compound to threads.
Use a 6V-6080 Torque Multiplier to tighten the components that follow: the steering arm mounting nuts, the ball stud nuts, and the rim
mounting nuts.
Use a 6V-8720 Torque Multiplier 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 ball stud nuts.
Use an 9U-6545 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 to pump oil to the suspension cylinders.
Use a 6V-4040 Inflation Group to inflate the tires with nitrogen.
Use an 8H-8536 Socket.
Use an 8T-0859 Pressure Gauge on the front suspension cylinders.
Use a 7S-5437 Nitrogen Charging Group to charge the tires and the suspension cylinders.
Use a 8T-5230 Torque Wrench that is regulated by air pressure to obtain a maximum torque of 300 N·m (220 lb ft).
Required Supplies and Required Equipment

Refer to the information that follows to gather supplies and equipment.
Have one 208 L (55 US gal) barrel of hydraulic oil (HYDO).
Obtain 6 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. Three 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 to inflate the tires and charge the suspension cylinders.
Have one portable air compressor. The air compressor should have enough capacity 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 stepladder that is 1.8 m (6 ft) tall. Have another stepladder 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 inch) tall. The blocks should be 203 mm (8.0 inch) wide. The blocks should be
406 mm (16.0 inch) long.
20/3/22, 18:47 SIS 2.0
Have at least 40 hardwood blocks that are 203 mm (8.0 inch) tall. The blocks should be 203 mm (8.0 inch) wide. The blocks should be
914 mm (36.0 inch) 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 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.
Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices to lift components. Refer to the manufacturers literature 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
to see the effect of the lift angle on the working load limit.
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.
Tire Inflation Pressure and Mounting

Refer to Operation and Maintenance Manual, M0106094, "777G Off-Highway Truck" and Operation and Maintenance Manual, M0106096, "777G
Off-Highway Truck" for specific information.
Chassis Lifting Points
20/3/22, 18:47 SIS 2.0
Lifting points on the 777G Off-Highway Trucks

Position the Chassis for Assembly
Typical view of 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 to install the tires.
3. When you place the supports at the rear of the chassis, provide 1092 mm (43 inch) of ground clearance to install the tires.
Flow Chart
20/3/22, 18:47 SIS 2.0
Install the 365-4788 Rear Housing Group, the 315-6272 Transmission

Arrangement, and the 315-3183 Hydraulic Oil Cooler Lines Group
Required Parts for the Installation of the Rear Axle Housing and Hydraulic Oil Cooler Lines

1 16 7X-2583 Bolt(1)
2 16 217-9902 Washer(1)
3 4 8B-5144 Bolts(2)
4 1 321-1386 Tube As(3)
5 1 321-1387 Tube As(3)
6 1 321-1388 Tube As(3)
7 1 321-1389 Tube As(3)
8 4 4J-0528 O-Ring Seal(3)
9 17 8T-4184 Bolt(3)
10 33 8T-4223 Hard Washer(3)
11 16 1P-4582 Half Flange(3)
12 4 4J-0527 O-Ring Seal(3)
13 16 8T-8919 Bolt(3)
14 1 194-7882 Spacer(3)
15 4 6D-8305 Clamp(3)
16 1 6V-1867 Clip(3)
17 1 6V-1868 Clip(3)
18 1 6V-1869 Grommet(3)
19 2 8T-4122 Hard Washer(3)
20 2 8T-4779 Bolt(3)
21 1 6V-1249 Grommet(4)
22 1 9C-4937 Breather As(5)
23 1 7D-6282 Hose As(5)
20/3/22, 18:47 SIS 2.0
24 1 5K-9660 Clip(5)

25 1 6V-4248 Bolt(5)
26 1 8T-7934 Hard Washer(5)
Table 56
(1)
(2) Part of the 365-4802 Axle Housing Support Gp
(3) Bolts attached to the drive shaft in a bag
(4) Part of the 315-3183 Hydraulic Oil Cooler Lines Gp
(5) Part of the 310-7615 Chassis Wiring Gp
Part of the 365-4788 Rear Housing
(A) Bolts
(B) Hard washer
(C) Guard
1. Remove nine bolts (A) and nine washers (B) that secure guard (C). Remove guard (C) and retain hardware.
Typical view

(D) Drive shaft
2. Remove the attached bag of parts from drive shaft (D). Retain four bolts (3) contained in the bag.
3. Remove the straps that secure the suspension A-frame and the rear suspension cylinders.
4. Remove wood block from inside tube that supports drive shaft.
5. Remove the paint from the rear axle assembly. Clean the mounting areas on the rear axle assembly.
20/3/22, 18:47 SIS 2.0
6. Remove paint from the suspension a-frame mounting surfaces and bolt hole spot faces. Clean the mounting areas and bolt hole spot faces
on the suspension A-frame.
(E) Nut
(F) Washer
(G) Bolt

(H) Pin
7. Remove the following components from the rear suspension cylinders: two nuts (E), four washers (F), two bolts (G) and two pins (H). Retain
all hardware.
8. Remove any paint or debris from two pins (H).
(J) Nut
(K) Hard
washer
(L) Soft washer

(M) Bolt

(N) Pin
9. Remove the following components from the right-hand rear of the chassis: nut (J), hard washer (K), two washers (L), bolt (M) and pin (N).
Retain all hardware.
10. Remove any paint or debris from pin (N).
20/3/22, 18:47 SIS 2.0
View from the rear of the machine

11. Remove the wire ties from the hoses for the final drives and the transmission.
Typical view rear axle housing

NOTICE
Do not crush the hoses or do not pinch the hoses that are
located in the rear of the chassis.
12. Place a suitable lifting device under the rear axle assembly or use a crane to lift the rear axle assembly. Lift the rear axle assembly to the
frame. The weight of the rear axle assembly is 10605 kg (23380 lb).
(J) Nut

(K) Hard
washer
(L) Soft washer

(M) Bolt

(N) Pin

rod
(P) Control
Note: Grease pin (N) with 4C-5593 Thread Lubricant before reassembling.
13. Align control rod (P) with the frame. Install the following components to control rod (P) and to the frame: pin (N), nut (J), hard washers (K),
two washers (L) and bolt (M).
20/3/22, 18:47 SIS 2.0
(1) Bolt
(2) Washer
Note: Ensure that the paint has been removed from the 16 bolt holes on the A-frame.
14. Install 16 bolts (1) and 32 washers (2). Bolts (1) will secure the rear axle assembly to the suspension A-frame.
Note: Tighten bolts (1) with an impact wrench. Do not torque bolts (1) at this time.
15. Align the rear suspension cylinders with the rear axle housing.
(E) Nut
(F) Washer
(K) Hard washer
(G) Bolt

(N) Pin
16. Install pins (N) to the rear axle housing and to the rear suspension cylinders.
Note: Lubricate pins (N) with Tooling 4C-5593 Thread Lubricant (BB) before installation.
17. Install the following components to the rear suspension cylinder and to the rear axle housing: two nuts (E), four washers (F), two hard
washers (K) and two bolts (G).
18. Repeat Step 15 through Step 17 for the other rear suspension cylinder.
(1) Bolt
(2) Washer
19. Torque bolts (1) that secure the rear axle assembly to the suspension a-frame. Tighten bolts (1) to a torque of 1800 ± 200 N·m
(1330 ± 150 lb ft).
Note: Use a 6V-6080 Torque Multiplier Gp to reach the correct torque.
20/3/22, 18:47 SIS 2.0
(M) Bolt

(P) Control rod
20. Tighten bolt (M) to secure control rod (P).
21. Clean any paint, dirt, rust, grease, or debris from the mounting surfaces and threaded holes of the drive shaft slip joint and the transmission
yoke.
Typical view

(D) Drive shaft
(3) Bolt
22. Align drive shaft (D) to the transmission. Install four bolts (3) to secure the drive shaft to the transmission. Tighten bolts (3) to a torque of
270 ± 15 N·m (200 ± 11 lb ft).
Note: Bolts (3) are located in the bag of parts that was removed in Step 2.
(A) Bolt
(B) Washer
(C) Guard
23. Reinstall guard (C) to the frame with nine bolts (A) and nine washers (B) that were removed in Step 1.
20/3/22, 18:47 SIS 2.0
View of A arm and support bar

24. Remove the support bracket along with the four bolts and four washers that secured the suspension a-arm to the chassis. Discard the bracket
and reinstall hardware back onto the chassis and a-frame.
25. Repeat Step 24 for the opposite side of the machine.
26. Slowly lower the rear axle assembly. Remove the lifting device from the rear axle assembly.
Typical view

27. Remove the four nuts and the four washers that secure the plate to the wheel. Remove the plate from the wheel. Reinstall the four nuts and
washers once the plate has been removed. Repeat the procedure for the other wheel.
Install the Brake Oil Cooler Lines

Note: Lubricate the O-ring seals with the fluid being sealed.
Typical view of final drive

1. Remove the shipping caps from the final drives.
20/3/22, 18:47 SIS 2.0
Tubes for the left-hand brake oil cooler
(6) Tube assembly

(7) Tube assembly

(8) O-ring seal

(9) Bolt

(10) Hard
washer
(11) Half flange
2. Install O-ring seal (8) in the end of tube (7).
3. Use the following components to secure tube (7) to the top port of the final drive four bolts (9), four hard washers (10), and two half flanges
(11).
Note: Install tube (7) before installing tube (6).
5. Secure tube (6) to the bottom port of the final drive using four bolts (9), four hard washers (10), and two half flanges (11).
Typical view of clipping under the frame
(15) Clip

(19) Hard
washer
(20) Bolt
6. Secure tube assembly (6) and tube assembly (7) to the support A-frame using two clips (15), hard washer (19), and bolt (20).
Tubes for the right-hand brake oil cooler
(4) Tube assembly

(5) Tube assembly
(8) O-ring seal

(9) Bolt

(10) Hard
washer
(11) Half flange
20/3/22, 18:47 SIS 2.0
8. Secure tube (4) to the top port of the final drive using four bolts (9), four hard washers (10), and two half flanges (11).
Note: Install tube (4) before installing tube (5).
10. Secure tube (5) to the bottom port of the final drive using four bolts (9), four hard washers (10), and two half flanges (11).
Typical view of clipping under the frame
(15) Clip
(19) Hard washer
(20) Bolt
11. Secure tube assembly (4) and tube assembly (5) to the support A-frame using two clips (15), hard washer (19), and bolt (20).
View looking forward
12. Remove the shipping caps from hose assembly (R), hose assembly (S), hose assembly (T), and hose assembly (U).
Tubes for the right-hand side brake oil cooling
(S) Hose assembly
(4) Tube assembly
(10) Hard washer
(11) Half flange
(12) O-ring seal
(13) Bolt
13. Secure tube assembly (4) to hose assembly (S) using two half flanges (11), one O-ring seal (12), four hard washers (10), and four bolts (13).
20/3/22, 18:47 SIS 2.0
Tubes for the right-hand side brake oil cooling
(U) Hose assembly
(5) Tube assembly
(10) Hard washer
(11) Half flange
(12) O-ring seal
(13) Bolt
14. Secure tube assembly (5) to hose assembly (U) using two half flanges (11), one O-ring seal (12), four hard washers (10), and four bolts (13).
Note: Hose assembly (U) is attached to the hydraulic tank at the factory.
Tubes for the left-hand brake oil cooling
(R) Hose assembly
(T) Hose assembly
(6) Tube assembly
(7) Tube assembly
(10) Hard washer
(11) Half flange
(12) O-ring seal
(13) Bolt
Note: Hose assembly (T) is attached to the hydraulic tank at the factory.
15. Secure tube assembly (6) to hose assembly (R) using two half flanges (11), one O-ring seal (12), four hard washers (10), and four bolts (13).
16. Secure tube assembly (7) to hose assembly (T) using two half flanges (11), one O-ring seal (12), four hard washers (10), and four bolts (13).
Install the Breather Assembly
20/3/22, 18:47 SIS 2.0
View of left-hand side rear housing gp
(22) Breather assembly
(23) Hose assembly

(24) Clip

(25) Bolt
(26) Hard
washer
1. Install breather assembly (22) onto hose assembly (23). Attach hose assembly to the rear housing group and secure breather assembly to
the frame using clip (24), hard washer (26), and bolt (25).
Install the Electrical Connection
(V) Harness assembly
(W) Harness assembly
(X) Clip

(21) Grommet
1. Install grommet (21) onto harness assembly (V).
2. Position harness assembly (V) to existing harness assembly (W) and secure using existing clip (X).
Install Rear Slack Adjuster Hoses Assemblies
(AB) Hose assembly
(AC) Hose assembly
(AD) Tee assembly

(AE) Tee assembly
Note: Hose assembly (AB) and hose assembly (AC) are installed at the factory.
1. Connect hose assembly (AB) onto tee assembly (AE).
2. Connect hose assembly (AC) onto tee assembly (AD).
Secure Speed Sensor to Tube (If equipped with traction control)
20/3/22, 18:47 SIS 2.0
View of the rear housing assembly
(27) Cable strap
1. Position the mount on the speed sensor and secure the mount with existing cable strap. Secure the speed sensor to the tube assembly using
cable strap (27).
2. Repeat Step 1 for the speed sensor on the opposite side.
Connect the 309-1346 Power Train Oil Lines Group

Required Parts for the Installation of the 309-1346 Power Train Oil Lines Gp
2 2 173-1437 Half Flange
3 4 1P-4579 Half Flange
4 4 1P-4582 Half Flange
5 1 198-0143 Elbow As
6 1 4J-0522 O-Ring Seal
9 1 9X-8250 Clip
10 12 8T-4183 Bolt
13 4 8T-6868 Bolt
14 4 8T-8919 Bolt
15 1 5P-7468 Clip
16 1 5P-7469 Clip
17 2 7X-2544 Bolt
18 2 6D-6668 Spacer
20 1 5P-7466(1) Clip
21 1 5P-7467(1) Clip
22 1 5P-8112(1) Grommet
23 2 7X-7729(1) Hard Washer
25 1 6V-1867 Clip
26 1 6V-1868 Clip
Table 57
(1)
Part of the 309-1352 Service Brake Control Gp
20/3/22, 18:47 SIS 2.0
(A) Hose assembly
(B) Hose assembly
(C) Hose assembly
(D) Hose assembly
1. Remove the cable straps from hose assembly (A), hose assembly (B), hose assembly (C), and hose assembly (D).
View of the left-hand side of the transmission arrangement
(B) Hose assembly

(E) Tube assembly

(2) Half flange

(6) O-ring seal
(10) Bolt

(11) Hard washer
2. Connect hose assembly (B) to existing tube assembly (E) using O-ring seal (6), two half flanges (2), four hard washers (11), and four bolts
(10).
View of the front side of the transmission arrangement
(A) Hose assembly

(1) Connector assembly
(5) Elbow assembly

(9) Clip
3. Install connector assembly (1), and elbow assembly (5) to the transmission.
4. Connect hose assembly (A) to elbow assembly (5).
20/3/22, 18:47 SIS 2.0
5. Secure hose assembly (A) onto the transmission using clip (9).
View of the right-hand side of the transmission arrangement
(F) Shipping cover
(G) Shipping cover
6. Remove shipping cover F and shipping cover (G) from the transmission.
View of right-hand side
(C) Hose assembly
(D) Hose assembly
View of the right-hand side of the transmission arrangement
(C) Hose assembly
(D) Hose assembly
(3) Half flange
(7) O-ring seal
(10) Bolt
(11) Hard washer
(13) Bolt
7. Install hose assembly (D) onto the transmission using O-ring seal (7), two half flanges (3), four hard washers (11), and four bolts (10).
8. Install hose assembly (C) onto the transmission using O-ring seal (7), two half flanges (3), four hard washers (11), and four bolts (13).
20/3/22, 18:47 SIS 2.0
(C) Hose assembly
(D) Hose assembly
(12) Hard washer
(15) Clip
(16) Clip
(17) Bolt
(18) Spacer
(19) Grommet
(24) Grommet
(25) Clip
(26) Clip
9. Secure hose assembly (C) and hose assembly (D) with 1 grommet (19), one clip (15), one clip (16.), one spacer (18), two bolts (17), two hard
washers (12), 1 grommet (24), 1 clip (25), and one clip (26).
(H) Hose assembly
10. Remove cover plate from hose assembly (H).
View of the bottom front side of the transmission arrangement
(H) Hose assembly
(4) Half flange
(8) O-ring seal
(11) Hard washer
(14) Bolt
11. Remove the shipping cover from the lower right-hand side of the transmission.
12. Secure hose assembly (H) onto transmission using O-ring seal (8), two half flanges (4), four hard washers (11), and four bolts (14).
20/3/22, 18:47 SIS 2.0
View of the rear left-hand side
(N) Hose assembly
(P) Strap
(R) Tee adapter
(17) Bolt
(18) Nut
(20) Clip
(21) Clip
(22) Grommet
(23) Hard washer
13. Connect hose assembly (N) onto tee adapter (R). Secure hose assembly (N) to strap (P) using grommet (22), clip (20), clip (21), two hard
washers (23), bolt (17), nut (18).
Connect the Hose Assemblies to the 340-9997 Rear Axle Lubrication Arrangement
(If Equipped)
View of the pump for the rear axle lubrication
(M) Pump
1. Remove the three caps on the pump. Refer to Illustration 48.
20/3/22, 18:47 SIS 2.0
View of the hose assemblies and the pump for the rear axle lubrication
(J) Hose assembly

(K) Hose assembly
(L) Hose assembly

(M) Pump
2. Connect existing hose assembly (J), hose assembly (K), and hose assembly (L) to pump (M).
Install the Suspension Cylinders from the 310-8206 Front Suspension

Group (non-EU part number) or from the 310-8207 Front Suspension
Group (EU part number) and Install the Steering Arms from the 310-8211
Steering Link Group
Required Parts for Installation of the Front Suspension Cylinders

335-6352(1)
1 2 Front Suspension Gp

335-6351(2)
2 2 9D-2498 Key
3 28 6C-3218 Bolt
4 28 329-3710 Nut
7 8 299-7351 Bolt
Table 58
(1)
(2) Non-EU part number
EU part number
Note: Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks" for any information concerning
suspension cylinders. The Special Instruction includes Tooling, pressures, and the correct procedures for purging (oil and nitrogen) and charging
(oil and nitrogen).
Shipping skid

1. Remove the shipping brackets from the front suspension cylinders.
NOTICE
DO NOT allow the steering arm assembly to hang unsupported,
stressing the ball studs. Support the steering arm assembly
with suitable tooling.
20/3/22, 18:47 SIS 2.0
2. Place the appropriate number of blocks under the steering linkage group to prevent the steering linkage group from falling when the shipping
bracket is removed.
3. Remove the shipping bracket from the frame. Retain bolts, hard washers, and nuts.
4. Remove the paint from mating surfaces and bolt hole spot faces. Clean the mating surfaces and bolt hole spot faces. Remove any burrs from
the mating surfaces and bolt hole spot faces. Make sure that mating surfaces are smooth.
NOTICE
DO NOT hang bearing cap by the lubrication line.
(A) Bolt
(B) Hard
washer
(C) Shims

(D) Bearing
cap
5. Remove four mounting bolts (A), eight hard washers (B), bearing cap (D), and shims (C).
6. Clean the bearing cap (D).
20/3/22, 18:47 SIS 2.0
View of the front right-hand side
(2) Key
7. Install one key (2). Align the key to allow the bolts through the bolt holes.
(AA) Strut lifting group
(1) Front suspension group
8. Use Tooling (AA) to position front suspension group (1) on the truck frame. Align the charging valve for the suspension cylinder toward the
front of the machine. The weight of front suspension group (1) is 1996 kg (4400 lb).
Note: The weight of front suspension group (1) includes the weight of the spindle and the weight of the wheel.
(3) Bolt

(4) Nut

(5) Hard
washer
9. Use the following components to secure front suspension group (1) on the frame: 16 bolts (3), 16 nuts (4) and 32 hard washers (5), and two
bolts, four hard washers, and two nuts retained in Step 9.
10. Tighten 16 bolts (3) to a torque of 1175 ± 48 N·m (870 ± 35 lb ft).
20/3/22, 18:47 SIS 2.0
(A) Bolt
(B) Hard
washer
(C) Shims

(D) Bearing
cap
11. Install bearing cap (D) to front suspension group (1). Fit the required number of shims (C) behind bearing cap (D) to eliminate any gap. Install
four bolts (A) and eight washers (B). Repeat the procedure for the other suspension cylinder.
Note: Install with lock ring in the down position.
(E) Grease line

(F) Grease line

(1) Suspension
cylinder
12. Connect grease lines (E) and (F) to suspension cylinder (1). Repeat the procedure for the other suspension cylinder.
(G) Sensor
13. Remove the tie straps and the plastic securing sensor (G) to the harness assembly.
Note: Sensor (G) is shipped connected to the harness assembly on both sides of the machine as shown in Illustration 58.
20/3/22, 18:47 SIS 2.0
(G) Sensor
14. Connect sensor (G) ensure that 3J-1907 O-Ring Seal is installed. Repeat for the other suspension cylinder.
15. Clean the mating surface for the steering arm on the spindle. Remove any burrs from the mating surface. Repeat the procedure for the other
suspension cylinder.
(H) Steering arm
(6) Hard washer

(7) Bolt
Note: Before you install the steering arm (H), make sure that the mating surfaces are clean.
16. Secure steering arm (H) the spindle of each front suspension cylinder using four bolts (7) and four hard washers (6). Tighten four bolts (7) to
a torque of 1800 ± 200 N·m (1325 ± 150 lb ft). Repeat the procedure for the other side.
Note: To prevent damage to the ball studs, support the steering cylinders during assembly. Do not allow the rods to fall out of the steering
cylinders.
Installation of the Hydraulic Oil Cooler Lines and the Front Service Brake
Lines
Note: The 309-1339 Hydraulic Oil Cooler Lines Gp is part of the 349-4812 Hydraulic Ar. The 309-1337 Brake Lines Gp is also part of the 349-4812
Hydraulic Ar.
Required Parts for Installation of the Front Oil Cooler Lines Group and Front Brake Lines Group

1 2 381-3168(1) Hose As
2 2 381-3169(1) Hose As
3 8 1P-4582(1) Half Flange
4 6 4J-0527(1) O-Ring Seal
5 16 8T-4183(1) Bolt
6 2 4J-0524(1) O-Ring Seal
7 16 8T-4223(1) Hard Washer
9 1 349–8519 Connector As
Table 59
(1)
20/3/22, 18:47 SIS 2.0
( )
Part of the 309-1339 Hydraulic Oil Cooler Lines Gp
Procedure for the Left-Hand Side
View of the left-hand brake
(E) Service brake pressure
tap
(F) Parking brake pressure tap
Note: Inspect the left brake to ensure that service brake pressure tap (E) and parking brake pressure tap (F) are located as shown before
installing hose assembly (1) and hose assembly (2) to the brakes.
1. Remove and discard shipping covers and hardware.
View of the front left-hand brake
(1) Hose assembly

(2) Hose assembly
Note: Hose assemblies (1) and (2) are installed on the truck at the factory.
20/3/22, 18:47 SIS 2.0
View of the front left-hand brake

(1) Hose assembly

(2) Hose assembly

(3) Half flange

(4) O-ring seal
(5) Bolt

(7) Hard
washer
2. Install hose assembly (1) to the brakes with O-ring seal (4), two half flanges (3), four hard washers (7), and four bolts (5).
View of left-hand brake

(G) Brake wear indicator
4. Remove the plugs from the wheel

Note: Inspect left brake to ensure that brake wear indicator (G) is installed as shown in Illustration 64.
View of the left-hand side
(H) Hose assembly

(J) Hose assembly

5. Install connector assembly (9) into port marked "P" and install connector assembly (8) into port marked "S" on the brakes. Tighten the
assemblies to 140 ± 21 N·m (103 ± 16 lb ft).
Note: Use a little hydraulic fluid to lubricate the O-ring seals on both elbow assemblies before installing.
6. Install hose assembly (H) onto connector assembly (8) and install hose assembly (J) onto connector assembly (9). Tighten the hose swivel
nuts to 65 ± 10 N·m (48 ± 7 lb ft).
Procedure for the Right-Hand Side

20/3/22, 18:47 SIS 2.0
View of the right-hand side
(A) Bolt

(B) Hard
washer
(C) Half flange

(D) Half flange
1. Remove and discard shipping covers and hardware.
View of the right-hand brake
(1) Hose assembly

(2) Hose assembly
(3) Half flange

(4) O-ring seal
(5) Bolt

(6) O-ring seal
(7) Hard washer
View of the underside of right-hand brake
(E) Service brake pressure tap

(F) Parking brake pressure tap
(G) Brake wear indicator
Note: Inspect the right brake to ensure that service brake pressure tap (E) and parking brake pressure tap (F) are located as shown before
installing hose assembly (1) and hose assembly (2) to the brakes.
20/3/22, 18:47 SIS 2.0
Note: Inspect right brake to ensure that brake wear indicator (G) is installed as shown in Illustration 68.
View of the right-hand brake
4. Remove the plugs from the wheel
(K) Hose assembly
(L) Hose assembly
5. Install connector assembly (9) into port marked "P" and install Connector assembly (8) into port marked "S" on the brakes. Tighten the
assemblies to 140 ± 21 N·m (103 ± 16 lb ft).
Note: Use hydraulic fluid to lubricate the O-rings on both elbow assemblies before installing.
6. Install hose assembly (K) onto connector assembly (8) and install hose assembly (L) onto connector assembly (9). Tighten the hose swivel
nuts to 65 ± 10 N·m (48 ± 7 lb ft).
Install the Fuel Tank

The required parts for installation of the fuel tank are part of the 500-3854 Fuel Tank Mounting Gp.
Required Parts for Installation of the Fuel Tank

1 1
2 1 381-6900 Bracket As
3 4 8T-4193 Bolt
20/3/22, 18:47 SIS 2.0
5 2 6G-5294 Cap
6 4 8T-4187 Bolt
7 6 8T-4123 Washer
8 4 8X-5299 Mounting
9 2 8C-8478 Bolt
10 2 9D-9438 Washer
11 2 8T-4131 Nut
Table 60
(1)
(2) 1140 L (300 US gal)
1325 L (350 US gal)
Typical view of fuel tank
(1) Fuel tank
1. Remove the paint from the mating surfaces and clean the mating surfaces on the fuel tank. Remove any burrs that are present.
2. Remove the paint from the mating surfaces and clean the mating surfaces on the machine. Remove any burrs that are present.
(2) 381-6900 Bracket As
(3) 8T-4193 Bolt

(4) 198-4780 Hard

Washer
3. Secure bracket assembly (2) to the frame by using four bolts (3) and four hard washers (4).
20/3/22, 18:47 SIS 2.0
Typical view

4. Use a suitable lifting device to position fuel tank assembly (1). Position fuel tank assembly (1) on the right side of the truck.
Note: 312-0924 Fuel Tank As weighs 425 kg (940 lb).
Note: 312-0926 Fuel Tank As weighs 500 kg (1110 lb).
Typical view
(1) Fuel tank
assembly
(5) 6G-5294 Cap

(6) 8T-4187 Bolt

(7) 8T-4123 Washer
Note: Ensure to center fuel tank assembly (1) on the mounts before securing.
5. Secure the fuel tank to the frame by using two caps (5), four bolts (6), and four hard washers (7). Tighten the bolts.
Typical view
(1) Fuel tank
assembly
(2) 381-6900 Bracket As

(7) 8T-4123 Washer

(8) 8X-5299 Mounting
(9) 8C-8478 Bolt

(10) 9D-9438 Washer
(11) 8T-4131 Nut
6. Position two mountings (8) on each side of bracket assembly (2).

Secure the fuel tank to bracket assembly (2) by using four mountings (8), two bolts (9), two washers (10), two washers (7), and two nuts (11).
20/3/22, 18:47 SIS 2.0
Typical view

7. Connect the fuel line (G) and fuel line (H) to the outlets on the back of the fuel tank. Attach hose (H) from the primary fuel filter to the outlet
that has the shutoff valve.
Typical view

8. Route harness (J) to the top of fuel tank and connect to existing harness.
Connect the 384-9671 Hose Assembly Part of the 309-1323 Service Center Group
Which is Part of the 441-3118 Service Center Arrangement or the 441-3119 Service
Center Arrangement (If Equipped)
View of the back side of the fuel tank
(K) Half flange

(L) Bolt

(M) Hard
washer
(N) Cover
1. Remove two half flanges (K). Retain bolts (L), hard washers (M), and half flanges (K).
2. Remove and discard cover (N).
20/3/22, 18:47 SIS 2.0
(P) Valve assembly
(K) Half flange

(L) Bolts

(M) Hard washer
(P) Valve assembly
(R) Hose assembly
3. Connect hose assembly (R) to valve assembly (P) using two half flanges (K), four bolts (L), and four hard washers (M) that were retained in
Step 1.
Installation of the 312–0850 Ladder Group

Required Parts for Installation of the 312-0850 Ladder Gp

1 2 358-6840 Step Gp
Table 61
Right-hand bumper

1. Remove four bolts (A) and four washers (B).
20/3/22, 18:47 SIS 2.0
2. Position ladder (1) to the frame and reinstall four washers (B) and four bolts (A) that were removed in Step 1. Tighten the bolts. Repeat this
procedure for the other side.
Install the 311-8209 Cab Mounting Group , and the 343-8791 Cab
Mounting Group
Required Parts for Installation of the Cab Mounts and the Cab

1 1 311-7760 Support As
2 1 311-7761 Support As
3 8 173-9684 Bolt
5 10 7X-2583 Bolt
7 1 343-6060 Sleeve
8 8 117-8131 Mount As
9 1 152-0604 Bolt
10 4 252-0080 Washer
11 4 343-6059 Sleeve
12 4 8T-0674 Bolt
13 4 8T-4195 Bolt
14 4 7X-7729 Washer
15 4 240-2261 Pin As
16 1 8T-4137(1) Bolt
18 4 310-2582 Washer
Table 62
(1)
Part of the 310-7614 Chassis Wiring Gp
20/3/22, 18:47 SIS 2.0
1. Attach a suitable lifting device to the plate with the lifting eye. The approximate weight of the plate is 40 kg (90 lb).Remove the mounting
bolts, washers, and plate from the front support mounting surface. Discard the bolts, washers, and the plate. These parts will not be used
again.
2. Remove the paint or grease from the mounting surfaces of the cab supports and the mating surfaces on the chassis. Clean the mounting
surfaces of the cab supports and the mating surfaces on the chassis. Remove any burrs that are present.
(2) Support assembly
(3) Bolt

(4) Hard
washer
3. Attach a suitable lifting device to support assembly (2). Position support assembly (2) to the chassis. Use eight bolts (3) and eight hard
washers (4) to secure support assembly (2) on the chassis. Tighten the bolts to a torque of 800 ± 110 N·m (590± 80 lb ft). The weight of
support assembly (2) is 148 kg (325 lb).
Note: When you install the cab support, do not use the bolts that secured the lifting eye.
(1) Support assembly
(5) Bolt

(6) Hard
washer
4. Attach a suitable lifting device to support assembly (1). Position support assembly (1) to the chassis. Use ten bolts (5) and ten hard washers
(6) to secure support assembly (1) on the chassis. Tighten the bolts to a torque of 1600 ± 200 N·m (1180 ± 150 lb ft). The weight of support
(2) is 230 kg (500 lb).
20/3/22, 18:47 SIS 2.0
5. Install two washers (18) and two mount assemblies (8) on support assembly (2), on the front cab mount of the chassis. Install two mount
assemblies (8) and two washers (18) on the rear cab support assembly (1).
View of cab lift points

6. Install suitable lifting devices to the cab. Use the lifting points on the cab to raise the cab. Align the cab to the cab mounting assemblies on
the frame. The approximate weight of the cab is 875 kg (1930 lb).
(8) Mount
(10) Washer

(11) Sleeve

(12) Bolt

(18) Washer
7. Slowly lower the cab assembly over washers (18) and two mounts (8) installed onto the frame earlier.
8. With the cab still suspended, assemble one washer (10), one mount (8), and one sleeve (11) onto bolt (12). Apply Loc-tite to the bolt and
insert from the bottom of the support plate through upper mount (8), washer (18) into the right front boss on the underside of the cab.
Note: Only hand tighten bolt (12), the rest of the cab bolts may need some alignment space.
20/3/22, 18:47 SIS 2.0
9. Repeat the above procedure to secure the left front and left rear cab mounts.
Right rear cab mount
(7) Sleeve
10. Assemble one washer (10), one mount (8), one sleeve (7) onto bolt (9). Apply Loc-Tite to bolt (9) and insert up through mount (8) and washer
(18) into the boss on the underside of the cab to secure the cab on the right rear cab mount on the chassis.
11. Tighten all four bolts to a torque of 800 ± 110 N·m (590± 80 lb ft)
Note: If machine was assembled in cold conditions −10° C (14° F) or below, inspect the mounts in four places under the cab for proper
installation torque of 800 ± 110 N·m (590± 80 lb ft). If the mounts are not seated properly or the torque is low, replace the hardware and
mounts and torque to 800 ± 110 N·m (590± 80 lb ft). The mounts should be stored at −10° C (14° F) or above for at least 24 hours prior to
installation.
View of front left cab pin
(13) Bolt
(14) Hard washer
(15) Pin assembly
12. Install cab pin retainer bolts (13), washers (14), with cab pin assemblies (15) at four corner locations. Tighten the bolts.
View of the right-hand side of the cab
(A) Ground cable
(16) Bolt
(17) Hard washer
20/3/22, 18:47 SIS 2.0
13. Secure ground cable (A) onto the frame using hard washer (17) and bolt (16).
Install the Fittings for 571–2050 Service Brake Control Group

Required Parts for Installation of the Fittings for the 571-2050 Brake Control Gp

1 1 238-5080 O-Ring Seal
2 1 8T-0077 Connector
4 1 319-6226 Elbow As
5 1 3G-8057 Clip
6 1 3G-8054 Clip
7 1 3G-8047 Grommet
8 1 6D-4246 Clip
10 2 8T-4196 Bolt
Table 63
1. Remove all plugs from brake control valve (A) that is on the bottom of the cab. Discard all plugs.
(A) Brake control valve
(1) O-ring seal

(2) Connector

(3) Connector
assembly
(4) Elbow assembly
2. Install elbow assembly (4), connector assembly (3), connector (2) and O-ring seal (1) to brake control valve (A).
Install the 309-1352 Service Brake Control Group Lines
20/3/22, 18:47 SIS 2.0
(B) Hose assembly
(C) Hose assembly
(D) Hose assembly
(1) Elbow assembly
(3) Connector
1. Connect hose assembly (B) to elbow assembly (1).
2. Connect hose assembly (C) to connector assembly (2).
3. Connect hose assembly (D) to connector (3).
View of clips and grommet for securing the 309-1352 Service Brake Control Gp
(B) Hose assembly

(C) Hose assembly
(D) Hose assembly
(5) Clip

(6) Clip

(7) Grommet
(8) Clip

(9) Hard
washer
(10) Bolt
4. Secure grommet (7) around hoses (B) and (C).
5. Secure clip (8) around hose (D). Refer to Illustration for orientation
6. Connect clip (5) and clip (6) around grommet (7).

Refer to Illustration for orientation
7. Secure clips containing the hoses to mounting block (E) using two bolts (10) and two washers (9).
Installation of the 571–1573 Steering Lines Group

Required Parts for Installation of the Steering Lines Gp

3 1 319-6222 Elbow As
20/3/22, 18:47 SIS 2.0
4 2 1F-7854 Spacer
5 2 281-5619 Rod
6 2 7G-5985 Clip
7 2 7G-5984 Clip
8 2 6V-1876 Grommet
9 1 5P-7462 Clip
10 1 5P-7463 Clip
12 2 344-5675 Nut
13 2 7X-7729 Washer
Table 64
View from under the cab towards the front

1. Remove all plugs from the hand metering unit that is under the front of the cab. Discard all plugs.
(1) 281-5982 Connector As
(2) 377-9616 Connector As
(3) 319-6222 Elbow As
Note: Elbow (3)along with steering hose (A) (not shown here)are installed at the factory
2. Install two connector assemblies (1), two connector assemblies (2) to the hand metering unit (HMU).
20/3/22, 18:47 SIS 2.0
Right-hand front side of the chassis
(A) Hose assembly

(B) Hose assembly
(C) Hose assembly
(D) Hose assembly
(E) Hose assembly

(3) Elbow assembly
Note: Hose assembly (A) and elbow assembly (3) are installed at the factory.
3. Connect hose assembly (C) to connector assembly (2) at the bottom rear of the hand metering unit (HMU).
4. Connect hose assembly (E) to elbow assembly (1) at the top rear of the hand metering unit (HMU).
5. Connect hose assembly (D) to connector assembly (2) at the top front of the hand metering unit (HMU).
6. Connect hose assembly (B) to connector assembly (1) at the bottom front of the hand metering unit (HMU).
Install the 421–3194 Exhaust Pipe Group (If Equipped)

Required Parts for Installation of the Exhaust Pipe Group

1 1 421-3194 Exhaust Pipe Gp
2 6 7X-2563 Bolt
4 1 357-2923(1) Tube
5 2 4N-9330(1) Clamp
6 4 5P-8245(1) Hard Washer
7 2 6V-3823(1) Bolt
8 2 6V-7687(1) Locknut
Table 65
(1)
20/3/22, 18:47 SIS 2.0
Typical view

1. Remove four bolts, four washers, and one cover plate. Discard all parts.
2. Remove the paint from the mating surfaces. Clean the mating surfaces. Remove any burrs that are present.

(A) Exhaust lines group
(4) Tube

(5) Clamp

(6) Hard washer
(7) Bolt

(8) Locknut
3. Install tube (10) onto exhaust lines group (A). Secure tube (4) onto exhaust lines group (A) with clamp (5), two hard washers (6), bolt (7), and
locknut (8).

(1) Exhaust pipe group
(2) Bolt

(3) Hard
washer
(4) Tube

(5) Clamp

(6) Hard washer
(7) Bolt

(8) Locknut
4. Install clamp (5), two hard washers (6), bolt (7), and locknut (8) to the end of tube (4). Do not tighten.
5. Use a suitable lifting device to the exhaust pipe group (1). The weight of exhaust pipe group (1) is 100 kg (220 lb).
6. Use six bolts (2) and six hard washers (3) to secure exhaust pipe group (1) to the truck. Secure clamp (5) to the slotted end of exhaust pipe
group (1).
7. Tighten bolts (7) on two clamps (5).
Installation of the 241–3194 Muffler Group (If Equipped)

Required Parts for the Installation of the 295-5186 Muffler Gp
20/3/22, 18:47 SIS 2.0

2 1 327-2486 Tube
3 1 327-2499 Bracket As
4 1 342-8714 Plate As
5 1 357-2917 Strap
7 4 6V-3823 Bolt
8 4 6V-7687 Locknut
9 4 7X-2563 Bolt
10 1 357-2923(1) Tube
11 2 4N-9330(1) Clamp
Table 66
(1)

Typical view

1. Remove four bolts, four washers, and one cover plate. Discard all parts.
2. Remove the paint from the mating surfaces. Clean the mating surfaces. Remove any burrs that are present.

(A) Exhaust lines group
(10) Tube

(11) Clamp

(6) Hard washer
(7) Bolt

(8) Locknut
3. Install tube (10) onto exhaust lines group (A). Secure tube (4) onto exhaust lines group (A) with clamp (11), two hard washers (6), bolt (7),
and locknut (8).
Installation of the 467–1102 Platform (RH)

Required Parts for Installation of the 467–1102 Platform (Right-Hand)

1 1 467-1102 Platform
20/3/22, 18:47 SIS 2.0
Table 67

(A) Bolt
(B) Hard washer
1. Remove eight bolts (A) and eight hard washers (B). Remove the paint from the mating surfaces. Clean the mating surfaces. Remove any
burrs that are present.
2. Attach suitable lifting device to right-hand platform (1). The approximate weight of right-hand platform (1) is 175 kg (385 lb).
3. Install platform group (1).

View of rear mounting bolts
(A) Bolt
(B) Hard washer
4. Secure platform group (1) with four bolts (A) and four hard washers (B) at the rear of the platform.
20/3/22, 18:47 SIS 2.0
View of front platform mounting bolts

(A) Bolt
(B) Hard washer
5. Secure platform group (1) with four bolts (A) and four hard washers (B) at the front of the platform.

View under the right-hand platform
6. Install plug (C) into the receptacle.
Installation of the 453–1009 Walkway Group (LH)

Required Parts for Installation of the 453–1009 Walkway Group (Left-Hand)

1 1 453-1009 Walkway Gp
Table 68

(A) Bolt
(B) Hard
washer
1. Remove eight bolts (A) and eight hard washers (B). Remove the paint from the mating surfaces. Clean the mating surfaces. Remove any
burrs that are present.
20/3/22, 18:47 SIS 2.0

View of left-hand walkway group

2. Remove both guards under walkway group (1) to have access to the mounting area. Retain the guards and the hardware.
3. Attach a suitable lifting device to walkway group (1). The approximate weight of walkway group is 180 kg (400 lb).
4. Install walkway group (1).
5. Secure walkway group (1) with four bolts (A) and four hard washers (B) at the rear of walkway group (1).
6. Secure walkway group (1) with four bolts (A) and four hard washers (B) at the front of walkway group (1).
Install the 358-9520 Fender Assembly (Which is Part of the 461–6944

Fender Group)
Required Parts for the Installation of the Fender Assembly
1 1 358-9520 Fender As
2 2 319-5435 Plate
3 2 341-9454 Plate
4 4 8T-4196 Bolt
5 8 7X-7729 Washer
20/3/22, 18:47 SIS 2.0
6 4 8T-0389 Locknut
7 1 341-9502 Plate As
Table 69
Install the Right-Hand Side Fender Assembly

(A) Bolt

(B) Hard
washer
1. Remove six bolts (A) and six hard washers (B). Retain the hardware.

View of right front of the machine
(7) Plate assembly
2. Install 341-9502 Plate As (7) using two retained bolts (A) and two washers (B) that were removed previously.

(1) 358-9520 Fender As
3. Attach a suitable lifting device to fender assembly (1). The approximate weight of fender assembly (1) is 25 kg (55 lb).
4. Install fender assembly (1).
20/3/22, 18:47 SIS 2.0
5. Secure fender assembly (1) reusing four bolts (A) and four hard washers (B).

View of upper flap mounting
6. Install mud flap (E) between plate (7) and fender assembly (1) and secure using two bolts (4) and two washers (5).

Front right-hand side
(C) Bolt
(D) Hard washer
7. Remove two bolts (C) and two hard washers (D). Retain the hardware

Front right-hand side
(E) Guard assembly
(3) Plate
(C) bolt
(D) washer
8. Position guard assembly (E) with the bottom edge of the platform assembly. Secure the guard assembly (E) between plate assembly (3) and
the platform assembly using two bolts (C) and two washers (D) retained early.
20/3/22, 18:47 SIS 2.0

View under the right-hand side fender assembly
(AA) Harness assembly
(AB) Signal lamp
(1) Fender assembly
9. Connect harness assembly (AA) to signal lamp (AB) on the under side of fender assembly (1).
Install the 473-1432 Platform Assembly Which is part of the 461-6942 Platform
Group
Required Parts for Installation of the 473-1432 Platform As

1 1 357-4691 Support As
2 1 467-6107 Platform As (LH)
Table 70

View of right-hand front

1. Remove four bolts (A) and four washers (B) from the right-hand platform.

View of right-hand front

20/3/22, 18:47 SIS 2.0
2. Attach a suitable lifting device to support assembly (1). The approximate weight of support assembly (1) is 32 kg (7 lb).
3. Install support assembly (1).
4. Secure support assembly (1) using four bolts (A) and four hard washers (B).

View of the front left-hand side
5. Remove six bolts (C) and six hard washers (D) from the left-hand walkway and the support assembly.
6. Attach a suitable lifting device to platform assembly (2). The approximate weight of platform assembly (2) is 71 kg (157 lb).
7. Install platform assembly (2).
8. Secure platform assembly (2) using six bolts (C) and six hard washers (D).
Install the 312-0910 Ladder Group (Step)

Required Parts for Installation of the 312-0910 Ladder Gp (Step)

1 1 358-6679 Step As
2 2 7T-8332 Mount
3 8 7X-0590 Hard Washer
4 4 8T-4183 Bolt
5 2 8T-4244 Nut
6 2 8T-4648 Bolt
Table 71
20/3/22, 18:47 SIS 2.0

(1) Step assembly
1. Attach a suitable lifting device to step assembly (1). The approximate weight of step assembly (1) is 60 kg (132 lb).
2. Install step assembly (1).

(3) Hard washer

(4) Bolt
3. Secure step assembly (1) at the top using four bolts (4) and four hard washers (3).

(1) Step assembly

(2) Mount

(3) Hard washer
(5) Nut

(6) Bolt
4. Secure step assembly (1) at the bottom using two mounts (2), two bolts (6) four hard washers (3), and two nuts (5).
Installing the 491–6943 Ladder Group

Required Parts for Installation of the 491-6943 Ladder Gp

1 1 491-6711 Step As
2 2 7T-8332 Mount
4 4 8T-4184 Bolt
20/3/22, 18:47 SIS 2.0
5 2 8T-4244 Nut
6 2 8T-4910 Bolt
Table 72
1. Attach a suitable lifting device to step assembly (1). The approximate weight of step assembly (1) is 55 kg (122 lb).
2. Install step assembly (1).

(1) Step assembly

(3) Hard washer

(4) Bolt
3. Secure step assembly (1) at the top using four bolts (4) and four hard washers (3).

(1) Step assembly

(2) Mount

(3) Hard washer
(5) Nut

(6) Bolt
4. Secure step assembly (1) at the bottom using two mounts (2), two bolts (6) four hard washers (3), and two nuts (5).
Installing the 310-7621 Platform Wiring Group

Required parts for Installation of the 310-7621 Platform Wiring Gp
20/3/22, 18:47 SIS 2.0

1 1 271-2178 Toggle Switch
2 1 3E-5169 Toggle Switch (Guard)
3 1 353-4515 Toggle Switch Gp
4 2 8T-4137 Bolt
6 2 8Y-8606 Grommet
8 3 130-5300 Clip
10 1 271-4532 Film
11 1 281-7268 Film
Table 73

(A) Wiring harness
1. Remove the bags and cable straps that secure the wiring harnesses (A).

View of the front left-hand side ladder
(A) Harness

(6) 8Y-8606 Grommet
(7) 7K-1181 Cable Strap
2. Route wiring harness (A) down the underside of the left-hand side ladder using cable straps (7) to secure harness at the mounting points.
3. Push the three branch wiring breakout through the access hole near the bottom of the ladder and secure in place with one grommet (6).
Secure the remaining harness breakout receptacle with one cable strap (7).
20/3/22, 18:47 SIS 2.0

Front view of left-hand side steps
(A) Harness

4. Route harness (A) toward the outer plate of the ladder. Secure next harness breakout receptacle with one cable strap (7).

View of left-hand side stair
(3) 353-4515 Toggle Switch
Gp
(10) 271-4532 Film
5. Install one film (10) over the left mounting hole in the ladder plate making sure the hole in the film lines up with the hole in the plate.
6. Mount one toggle switch (3) through the left mounting hole in the ladder plate, making sure to pass through the center hole in film (10). Use
the mounting nut supplied with toggle switch (3) to secure toggle switch (3) in position

View of left-hand side stair

(2) 3E-5169 Switch Guard


Gp
(11) 281-7268 Film
20/3/22, 18:47 SIS 2.0
7. Mount one toggle switch (1) and one switch guard (2) into the mounting location to the right of toggle switch (3) using the supplied mounting
nut.
8. Place one film (11) directly above toggle switch (1).

View of the front of the left-side ladder
(A) Harness
(3) 353-4515 Toggle Switch Gp
9. Connect Toggle switch (1) and toggle switch (3) onto the open receptacles of Harness (A) and secure to the ladder assembly using two cable
straps (7).

View underneath the left-hand platform assembly
(C) Guard
10. Remove guard (C) from the left-hand platform assembly. Retain guard (C) and the mounting hardware.
20/3/22, 18:47 SIS 2.0

(A) Harness assembly
(7) Cable strap
11. Route section of harness assembly (A) under the support assembly and through the existing hole in the rubber guard. If equipped with four
cameras, route harness with harness (A).
12. Secure harness assembly (A) in five locations using five cable straps (7).
13. Connect harness assembly (A) to harness assembly (F) coming from the lights on the side the cowling assembly.
14. Secure harness assembly (A) and harness assembly (F) using clip (8), hard washer (5), bolt (4), and cable strap (7).
15. Secure harness assembly (A) and harness assembly (G) using two cable straps (7).

View of the left-hand side under the platform assembly
(D) Harness assembly
(E) Signal lamp
(7) Cable strap
16. Remove the bags and cable straps that secure the wiring harnesses (D).
17. Route harness assembly (D) along the inside of the left-hand platform assembly over to harness assembly (A).
18. Secure harness assembly (D) using three cable straps (7). Secure at the locations indicated by the arrows in Illustration 139 and Illustration
140.
19. Connect signal lamp (E) to harness assembly (D).

View of the left-hand side under the platform assembly
(A) Harness assembly
(4) Bolt
(5) Hard washer
(7) Cable strap
(8) Clip
20. Connect harness assembly (D) to harness assembly (A).
21. Secure harness assembly (D) and harness assembly (A) using three clips (8), one hard washer (5), one bolt (4), and four cable straps (7).
20/3/22, 18:47 SIS 2.0
Install the 507–7284 Bottle Group-Washer and Mud Flap Assembly

Required Parts for the Installation of the 507–7284 Bottle Group Washer and Mud Flap Assembly
Item Qty Part Name Part Description
1 1 118-6878 Bracket As
2 1 1S-0994 Clip
3 1 240-2172 Spout
4 1 290-5562 Mount
5 1 343-2388 Clip
6 1 507-7283 Window Washer Tank Gp
7 1 550-5932 Cap As
8 2 5P-4295 Clip
9 2 5P-9085 Clip
11 7 7X-7729 Washer
13 1 8L-6990 Clip
15 4 8T-4137 Bolt
16 3 8T-4189 Bolt
17 2 8T-4195 Bolt
20 1 476-9273 Bracket
21 1 467-1101 Bracket
23 12 8T-4956 Bolt
25 14 8T-4196 Bolt
26 2 507-1678 Bracket
27 1 467-5113 Mud Flap
28 27 cm 8I-1362 Hose
29 56 cm 9X-2133 Hose
31 2 357-0497 Plate
Table 74
20/3/22, 18:47 SIS 2.0

Rear view of brackets and mud flap assembly
(11) Washer

(20) Bracket assembly
(25) Bolt

(27) Mud
Flap
1. Attach bracket assembly (20) and (21) to mud flap (27) using two bolts (25) and two washers (11).

View of the front of the cab


(25) Bolt

(22) Washer
2. Mount bracket assemblies (20) and (21) to the mounting blocks on the frame using four bolts (), and four washers ().

View of the front of the cab
(6) Water Bottle assembly


(25) Bolts

(24) Washer
(26) Brackets
3. Mount the water bottle assembly (6) onto bracket assemblies (20) and (21) using two brackets (26), two bolts (23), and two washers (24).
20/3/22, 18:47 SIS 2.0

View of washer tube on front of the cab
(A) Window washer tube

(9) Clip

(14) Washer
(15) Bolt

(21) Bracket Assembly
4. Locate washer tube (A) already installed on the machine.
5. Route washer tube (A) down towards the washer pump and install the washer tube onto the outlet tube near the bottom of the washer pump.
6. Secure washer tube (A) to bracket assembly (21) using two clips (9), two washers (14), and two bolts (15).

View of spout assembly
(3) Spout

(7) Cap assembly
7. Install cap assembly (7) to the threaded end of spout (3).

Note: Be sure that the cap assembly (7) retaining chain slides inside of spout (3).

View of hose assembly
(3) Spout

(6) water bottle assembly
(12) Clamp

(28) Hose
8. Connect hose (28) and spout (3) using one clamp (12).
20/3/22, 18:47 SIS 2.0
9. Insert hose (28) through the hole in bracket assembly (20) and connect to the inlet on water bottle assembly (6) using one clamp (12).

View of vent hose assemblies
10. Assemble two vent hoses (29) onto the two outlets on top of water bottle assembly (6) securing vent hoses (29) with two clamps (19).
11. Attach bracket assembly (1) to the boss on top of the frame using one bolt (15) and one washer (14)
12. Assemble one clip (8) onto each vent hose (29) and secure to bracket assemble (1) using one bolt (17) and one hard washer (11).

View of front left-hand side
(27) Mud guard
(25) Bolt
(11) Washer

View of front left-hand side
(27) Guard
(31) Plate
(25) Bolt
(11) Washer
(30) Locknut
20/3/22, 18:47 SIS 2.0
13. Secure mud guard (27) onto support group using two plates (31), four bolts (25), eight washers (11), and four locknuts (30).
Installing the 312-0840 Handrail Group

Required Parts for Installation of the 312-0840 Handrail Gp

1 2 354-6976 Handrail As
13 6 8T-4956 Bolt
14 8 115-3580(1) Plate
15 16 5P-7468(1) Clip
16 16 5P-7469(1) Clip
17 16 6V-1874(1) Grommet
18 38 7X-3392(1) Hard Washer
19 14 8T-4121(1) Hard Washer
20 24 8T-4139(1) Bolt
21 16 8T-4183(1) Bolt
22 10 8T-4195(1) Bolt
23 32 8T-4223(1) Hard Washer
24 16 8T-4244(1) Nut
25 1 512-5281 Bracket As
26 1 512-5279 Bracket
Table 75
(1)
Part of the 312-0840 Handrail Gp

View of the left-hand platform
(A) Bolt

(B) Hard
washer
(C) Bolt

(D) Hard washer
(E) Bolt

(F) Hard
washer
1. Remove four bolts (A), four hard washers (B), four bolts (C), four hard washers (D), four bolts (E), and four hard washers (F). Retain parts.
20/3/22, 18:47 SIS 2.0

(A) Bolt

(B) Hard
washer
(C) Bolt

(D) Hard
washer
(E) Bolt

(F) Hard washer
(9) Handrail assembly
2. Attach a suitable lifting device to handrail assembly (9). The approximate weight of handrail assembly (9) is 45 kg (100 lb).
3. Install handrail assembly (9) and bracket assembly (25) using four bolts (A), four hard washers (B), four bolts (C), four hard washers (D), four
bolts (E), and four hard washers (F) previously removed.


(18) Hard washer

(20) Bolt
4. Install handrail assembly (2).
5. Secure handrail assembly (2) using six bolts (20) and six hard washers (18).
20/3/22, 18:47 SIS 2.0


(18) Hard washer

(20) Bolt
7. Secure handrail assembly (10) using four bolts (20) and four hard washers (18).

Front view of the machine
(G) Bolt

(H) Hard washer
8. Remove ten bolts (G) and ten hard washers (H). Retain parts.

View of the front
(G) Bolt

(H) Hard
washer
9. Install handrail assemblies (1).
10. Secure handrail assemblies (1) using four bolts (G) and four hard washers (H).
13. Secure handrail assembly (7) using six bolts (G) and six hard washers (H).
20/3/22, 18:47 SIS 2.0

View for the front right-hand side

(18) Hard washer

(20) Bolt


(18) Hard washer

(20) Bolt

View of right-hand side platform
(J) Bolt

(K) Hard
washer
(L) Bolt

(M) Hard washer
18. Remove four bolts (J), four hard washers (K), four bolts (L), and four hard washers (M). Retain parts.
20/3/22, 18:47 SIS 2.0


(J) Bolt

(K) Hard
washer
(L) Bolt

(M) Hard washer
20. Install handrail assembly (8) and bracket assembly (26).
21. Secure handrail assembly (8) and bracket assembly (26) using four bolts (J), four hard washers (K), four bolts (L), and four hard washers (M),


(19) Hard washer

(22) Bolt
20/3/22, 18:47 SIS 2.0

(19) Hard washer

(22) Bolt
26. Secure handrail assembly (6) using six bolts (22) and six hard washers (19).

View of left-hand side
(14) Plate

(15) Clip

(16) Clip
(17) Grommet
(21) Bolt

(23) Hard
washer
(24) Nut
Note: Install plate (14) on the outside of the handrail assemblies. Orient the hardware to prevent a hazard or pinch point.
27. Install two grommets (17), two clips (15), two clips (16), two bolts (21), four hard washers (23), and two nuts (24) in three locations.

(14) Plate
(15) Clip

(16) Clip
(17) Grommet
(21) Bolt

(23) Hard
washer
(24) Nut
28. Install two grommets (17), two clips (15), two clips (16), two bolts (21), four hard washers (23), and two nuts (24) in five locations. Refer to
Illustration 163.
Connect the 546–3447 Chassis Harness Assembly to the Cab

Required Parts for Installation of the 347-5894 Chassis Harness As
1 2 8R-0721 Spacer
20/3/22, 18:47 SIS 2.0
2 1 341-6647 Plate As

3 5 204-8000 Cable Tie Mounting
5 5 8T-4136 Bolt
6 2 8T-4185 Bolt
7 1 8T-4197 Bolt
9 5 204-2281 Cable Strap
Table 76

View of rear of cab showing harness.
(A) Plate

(B) Harness
assembly
1. Uncoil the harness assembly (B) mounted on the back of the cab under plate (A).

View of the right-hand side under the cab
(B) Chassis harness assembly

(1) Spacer

(2) Plate assembly
(4) Hard washer

(6) Bolt
2. Install plate assembly (2) using two spacers (1), two bolts (6), and two hard washers (4).
3. Route chassis harness assembly (B) behind plate assembly (2) and up between the cab and the support assembly.
20/3/22, 18:47 SIS 2.0

Typical view of cab harness connection
(B) Chassis harness
4. Install chassis harness assembly (B) to the receptacles on the back side of the cab.
Note: The openings for the electrical plugs are not marked. However, each connector only fits into one plug.
Note: Harness assembly (B) may come already connected to the Cab assembly from the factory

View of the right-hand side behind the cab
(A) Plate

(B) Chassis
harness assembly
(2) Plate assembly

(3) Clip

(4) Hard
washer
(5) Bolt

(9) Cable strap
5. Secure chassis harness assembly (B) using five clips (3), five bolts (5), five hard washers (4) and five cable straps (9) in the locations
indicated by the arrows.
6. Re-install plate (A).
Install the 351-8950 Payload Monitor Gp Which is part of the 503–0238

Wiring Group (If Equipped)
Required Parts for the Installation of the 351-8950 Payload Monitor Gp Which is part of the 503-0238 Monitor Wiring
Gp (If Equipped)

1 2 351-8950 Payload Monitor Gp
2 1 351-8952 Mounting Bracket As
3 1 357-6649 Plate
20/3/22, 18:47 SIS 2.0
4 1 150-5931 Grommet
6 2 7X-7729 Washer
7 4 8T-4136 Bolt
8 6 8T-4139 Bolt
9 6 8T-4194 Bolt
10 2 8T-4195 Bolt
Table 77

View of the switches on the back of payload monitoring group (1) (right-hand side)

1. Remove and retain the back cover of payload monitoring group (1).
For ton settings, set the switches on payload monitoring group (1) according to Table 78.
For metric tonne settings, set the switches on payload monitoring group (1) according to Table 79.
Once set, secure the retained cover back onto payload monitoring group (1).
Tons
Right-Hand Side Payload Monitoring Group
Switch Position
20/3/22, 18:47 SIS 2.0
1 OFF
2 OFF
3 Unused
4 Unused
5 Unused
6 Unused
7 OFF
8 ON
9 OFF
10 OFF
Table 78
Metric Tonnes
Right-Hand Side Payload Monitoring Group
Switch Position
1 OFF
2 OFF
3 Unused
4 Unused
5 Unused
6 Unused
7 OFF
8 OFF
9 OFF
10 OFF
Table 79
2. Use a suitable lifting device to position payload monitor group (1) onto the right-hand platform. The approximate weight of payload monitor
group (1) is 25 kg (55 lb).
3. Install payload monitor group (1) onto platform using six hard washers (11) and six bolts (8).
4. Connect existing wiring harness into the back of payload monitor group (1).

View of the left-hand side catwalk assembly
(B) Catwalk assembly

(4) Grommet
5. Install grommet (4) onto catwalk assembly (B).
20/3/22, 18:47 SIS 2.0

View of the switches on the back of payload monitoring group (1) (left-hand side)

6. Remove and retain the back cover of payload monitoring group (1).
For ton settings, set the switches on payload monitoring group (1) according to Table 80.
For metric tonne settings, set the switches on payload monitoring group (1) according to Table 81.
Once set, secure the retained cover back onto payload monitoring group (1).
Tons
Left-Hand (Cab) Side Payload Monitoring Group
Switch Position
1 OFF
2 OFF
3 Unused
4 Unused
5 Unused
6 Unused
7 OFF
8 ON
9 ON
10 ON
Table 80
20/3/22, 18:47 SIS 2.0
Metric Tonnes
Left-Hand (Cab) Side Payload Monitoring Group
Switch Position
1 OFF
2 OFF
3 Unused
4 Unused
5 Unused
6 Unused
7 OFF
8 OFF
9 ON
10 ON
Table 81

View of the left-hand side catwalk assembly without the radar mounting bracket
(1) Payload monitor group
7. Use a suitable lifting device to position payload monitor group (1) and, if equipped, the radar mounting bracket onto the left-hand catwalk
assembly. The approximate weight of payload monitor group (1) is 25 kg (55 lb).
8. Connect existing wiring harness into the back of payload monitor group (1).

View of the underside of the left-hand side catwalk
(1) Payload monitor group

(5) Hard washer

(9) Bolt
9. Secure payload monitor group (1) to catwalk assembly using four hard washers (5) and four bolts (9).
20/3/22, 18:47 SIS 2.0

View of the underside of the left-hand side catwalk
(3) Plate

(5) Hard washer
(6) Washer

(9) Bolt

(10) Bolt
10. Install plate (3). Secure plate (3) using two hard washers (5), two bolts (9), two washers (6), and two bolts (10).
Install the 354-8040 Mirror Group (If Equipped)

Required Parts for Installation of the 354-8040 Mirror Gp
3 2 133-6934 Spacer
4 6 134-0989 Block
5 2 144-2227 Mirror Gp
6 1 295-8899 Plate
7 1 478-0059 Tube As
8 2 478-0060 Tube As
9 1 129-3180 Locknut
13 1 5P-7468 Clip
14 1 5P-7469 Clip
17 4 8T-4137 Bolt
18 12 8T-4182 Bolt
19 1 8T-4183 Bolt
20 2 8T-4185 Bolt
21 1 352-3964 Clip
22 4 4P-7581 Clip
Table 82
20/3/22, 18:47 SIS 2.0

(4) Block
(7) Tube assembly
(16) Hard washer

(18) Bolt
1. Secure tube assembly (7) onto left-hand side hand railing using two blocks (4), four washers (16), and four bolts (18).

View of the left-hand side handrail assembly
(1) Strap-cable

(3) Spacers

(7) Tube assembly
(10) Mirror group

(16) Hard washer
(20) Bolt
2. Secure mirror group (10) onto tube assembly (7) with two spacers (3), two bolts (20), and two hard washers (16).
3. Fasten the harness from mirror group (10) to tube assembly (7) using two strap-cables (1).
20/3/22, 18:47 SIS 2.0


(1) Cable strap

(21) Clip-ladder
(22) Clip ladder
4. Route harness assembly (D) up the handrail group to the harness for the mirror group.
5. Attach clip-ladders (21) and (22) using the existing hardware on the bottom mounting block for the mirror group.
6. Secure harness assembly (D) in six locations using six cable straps (1).

View of handrail assemblies in front of the cab
(6) Plate

(9) Locknut
(12) Hard washer
(13) Clip

(14) Clip
(15) Grommet
(19) Bolt

View of front mirror
(2) Convex mirror

(6) Plate

(11) Locknut
(12) Hard washer
7. Secure convex mirror (2) onto front handrail assembly using three hard washers (12), locknut (11), locknut (9), grommet (15), clip (13), clip
(14), bolt (19) and plate (6). Tighten locknut (11) to a torque of 25 ± 5 N·m (221 ± 44 lb in).
20/3/22, 18:47 SIS 2.0

Right side mirror mounts
(4) Block

(8) Tube assembly
(16) Hard washer

(18) Bolt
8. Install tube assemblies (8) onto right handrail assembly. Secure tube assemblies (8) onto the handrail assembly using four blocks (4), eight
bolts (18), and eight hard washers (16).

View of right side mirror groups
(5) Mirror assembly

(8) Tube assemblies

(16) Hard washers

(18) Bolt
9. Install mirror groups (5) onto tube assemblies (8) using four bolts (18) and four hard washers (16).

Few of mirror wiring route

(E) Mirror harness assembly
(1) Strap-cable

(5) Mirror assembly
(22) clip-ladder
10. Route harness assembly (E) up the handrail group to mirror group (5).
20/3/22, 18:47 SIS 2.0
11. Secure harness assembly (E) with four cable straps (1) and three clip ladders (22) using the existing hardware..
Install the 336-4450 Mirror Gp

2 2 133-6934 Spacer
3 8 134-0989 Block
4 2 144-2227 Mirror Gp
5 2 329-7328 Convex Mirror
6 1 358-6015 Tube As
7 1 358-6020 Tube As
8 1 478-0059 Tube As
9 2 478-0060 Tube As
12 4 7X-7729 Washer
13 10 7Y-5262 U-Bolt
14 4 8F-8398 Clamp
15 22 8T-0389 Locknut
17 4 8T-4137 Bolt
18 12 8T-4182 Bolt
19 4 8T-4184 Bolt
20 2 8T-4185 Bolt
21 2 8T-4186 Bolt
22 1 8T-4195 Bolt
Table 83

.Left side handrail
(8) Tube assembly

(3) Block

(16) Hard
washer
(18) Bolt
1. Install tube (8) onto the left side hand rail using two blocks (3), four hard washers (16) and four bolts (18).
20/3/22, 18:47 SIS 2.0

(1) Strap

(2) Spacer
(8) Tube assembly
(11) Mirror group

(16) Hard washer
(20) Bolt
2. Secure mirror group (11) onto tube assembly (8) using two spacers (2), two bolts (16), two hard washers (20).
3. Connect the mirror group harness assembly to tube (7) using two straps (1).

(5) Convex mirror

(6) Tube assembly
(13) U-Bolt

(15) Locknut
(16) Hard washer
4. Install convex mirror (5) onto tube assembly (6). Tighten clamping screws on convex mirror (5) to 2.37 ± 0.11 N·m (21 ± 1 lb in).
5. Install tube assembly (6) and convex mirror (5) onto the left front handrail assembly. Secure tube assembly (6) using six U-Bolts (13), 12 hard
washers (16), and 12 locknuts (15).
20/3/22, 18:47 SIS 2.0

Lower tube installation
(7) Tube assembly

(10) Hard washer

(19) Bolt
6. Mount the lower portion of tube assembly (7) to the right end of the front bumper assembly using four hard washers (10) and four bolts (19).

Right side railing assembly
(7) Tube assembly

(13) U-bolt

(15) locknut
(16) Hard washer
7. Attach tube assembly (7) to the right ladder rail using four U-bolts (13), eight locknuts (15) and eight hard washers (16)

View from above right hand ladder railing
(7) Tube assembly

(12) Hard washer

(14) Clip

(15) Locknut
(21) Bolt
8. Attach tube assembly (7) to the right-hand ladder railing using four clips (14), two bolts (21), four hard washers (12), and two locknuts (15).
20/3/22, 18:47 SIS 2.0

View of rear view mirror
(5) Convex mirror

(7) Tube 7
9. Install mirror (5) onto the mounting stalk on top of tube assembly (7) and tighten the clamping screws in the back of mirror (5) to
2.37 ± 0.11 N·m (21 ± 1 lb in).

View of the right-hand side handrail assembly
(3) Blocks

(9) Tube assembly
(16) Hard washer

(18) Bolt
10. Install tube assemblies (9) onto right-hand handrail assembly . Secure tube assemblies (9) onto handrail assembly using four blocks (3), eight
bolts (18), and eight hard washers (16).

(4) Mirror group

(9) Tube assembly
(16) Hard washer

(17) Bolt
11. Install mirror groups (4) onto tube assemblies (9) using four hard washers (16) and four bolts (17).
20/3/22, 18:47 SIS 2.0


12. Route the harness assembly up the handrail group to mirror group (4).
Install the 342-8700 Mirror Gp (If Equipped)

1 8 3S-2093 Cable Strap
2 1 7V-0762 Spacer
4 2 134-0989 Block
5 2 144-2227 Mirror Gp
6 1 326-3097 Baffle As
7 2 329-7328 Convex Mirror
8 4 338-5116 Wiring Harness
9 1 338-9280 Plate
10 1 338-9281 Plate
11 1 358-6015 Tube As
12 1 358-6020 Tube As
13 2 457-3039 Plate
14 1 478-0054 Tube As
15 2 478-0057 Tube as
16 2 031-9831 Bolt
17 1 173-2087 Spacer
19 1 311-7059 Mirror Gp
20 2 329-3356 Nut
23 2 5P-7468 Clip
24 2 5P-7469 Clip
26 4 7X-7729 Washers
27 10 7Y-5262 U-Bolt
28 4 8F-8398 Clamp
29 24 8T-0389 Locknut
31 3 8T-4136 Bolt
32 4 8T-4137 Bolt
33 12 8T-4182 Bolt
20/3/22, 18:47 SIS 2.0
34 2 8T-4183 Bolt

35 4 8T-4184 Bolt
36 2 8T-4185 Bolt
37 2 8T-4186 Bolt
38 2 8T-4198 Bolt
39 6 8T-4223 Hard washer
40 3 4P-7581 Clip
Table 84

View of right side mirror mounting tube
(4) Block

(14) Tube
assembly
(30) Hard washer
(33) Bolt
1. Secure tube assembly (14) onto the right side railing assembly using two blocks (4), four hard washers (30), and four bolts (33).

(14) Tube assembly

(17) Spacer
(19) Mirror group
(30) Hard washer
(31) Bolt

(36) Bolt
2. Secure mirror group (17) onto tube assembly (14) using two spacers (17), three hard washers (30), two bolts (36), and one bolt (31).
20/3/22, 18:47 SIS 2.0

(3) Convex mirror

(9) Plate

(10) Plate
(21) Locknut
(22) Hard washer
(29) Locknut

(30) Hard washer
(39) Bolt
3. Secure plate (9) and plate (10) onto the left side handrail assembly using two bolts (39), four hard washers (30), and two locknuts (29).
4. Secure convex mirror (3) onto plate (10) using hard washer (22) and locknut (18). Tighten to 25 ± 5 N·m (18 ± 3.70 lb ft)

(11) Tube assembly

(27) U-Bolt

(29) Locknut
(30) Hard washer
5. Install tube assembly (11) onto the front left-side hand rail. Secure tube assembly (11) using six U-Bolts (27), 12 hard washers (30), and 12
locknuts (29).
20/3/22, 18:47 SIS 2.0
6. Install convex mirror (7) onto tube assembly (11). Tighten clamping screws on convex mirror (7) to 2.37 ± 0.11 N·m (21 ± 1 lb in)

View of right front mirror mount
(12) Tube assembly
(18) Hard washer
(35) Bolt
7. Mount tube assembly (12) onto the right side bumper using four bolts (4) and four hard washers (18).

View of tube assembly (12) mounting
(12) Tube assembly
(27) U-bolts
(29) Locknut
(30) Hard washers
8. Attach tube assembly (12) to the right ladder rail using four U-bolts (27), eight locknuts (29) and eight hard washers (30).

Over head view of right hand ladder railing
(12) Tube assembly
(24) Locknut
(26) Hard washer
(28) Clip
(37) Bolt
20/3/22, 18:47 SIS 2.0
9. Attach tube assembly (12) to the right-hand ladder railing using four clips (28), two bolts (37), four hard washers (26), and two locknuts (24).

View of right mirror assembly
10. Install mirror (7) onto the mounting stalk on top of tube assembly (12) and tighten the clamping screws in the back of mirror (7) to
2.37 ± 0.11 N·m (21 ± 1 lb in).
11. Install tube assemblies (15) onto the right side handrail assembly. Secure tube assemblies (15) using four blocks (4), eight bolts (33), eight
hard washers (30), and three clips (40).

(5) Mirror group
(15) Tube assembly
(30) Hard washer
(32) Bolt
12. Install mirrors (5) onto tube assemblies (15) using four hard washers (30) and four bolts (32).
20/3/22, 18:47 SIS 2.0

View of plates install
(13) Plates
(15) Tube assembly
(20) Nut
(23) Clip-half slot
(24) Clip-half tang
(25) Grommet
(31) Bolt
(34) Bolt
(39) Washer
13. Attach two grommets (25) onto the vertical left side handrail assembly.
14. Connect two clip-half slots (23), two clip-half tangs (24) around newly installed grommets (25) and secure using two plates (13), bolts (34),
four washers (39)
15. Secure plates (13) to the mounting tabs on tube assemblies (15) with two bolts (31) and two washers (39).

View of left side harness assemblies
(D) Existing wiring harness
(1) Cable straps
(5) Mirrors
(8) Wiring harness
(15) Tube assembly
16. Install four wiring harnesses (8) to existing wiring harness (D), connect two wiring harnesses (8) to mirrors (5).
17. Secure wiring harnesses (8) to the bottom of tube assemblies (15) using eight cable straps (1).
Install the 539–6283 Lighting Wiring Gp

20/3/22, 18:47 SIS 2.0
Table 85

View of left side flood lamp groups from below.
(A) left side bracket assembly
(3) Flood lamp group
(5) Cable strap

Note: Flood lamp groups 1, 2 and 4 are already installed at the factory.
1. Install two flood lamp group (3) onto left-hand side bracket assembly (A) using the supplied hardware from the lamp groups.

View of wiring harness
(A) Left -hand side bracket
(5) Cable straps
2. Plug flood lamp group (3) into the existing harness. Secure harness with two cable straps (5)

View of right side bracket assembly
(B) Right side bracket assembly
20/3/22, 18:47 SIS 2.0
3. Install two flood lamp group (3) onto right-hand side bracket assembly (A) using the supplied hardware from the lamp groups.

Right hand harness
4. Plug flood lamp group (3) into the existing harness. Secure harness with two cable straps (5).
Install the 539–6284 Lighting Wiring Gp (If Equipped)

Table 86
Note: Flood lamp groups 1, 3, 4, and 5 come already install on the machine from the factory.

View of left side bracket and flood lamps
(A) Left side bracket

1. Attach two flood lamp groups (2) to bracket (A) using the supplied hardware on the flood lamps.
20/3/22, 18:47 SIS 2.0

View of left side wiring harness

(6) Cable strap
2. Connect flood lamps group (2) to the existing harness. Secure the harness to left side bracket (A) using two cable straps (6).

Right side bracket

(B) Right side bracket assembly
3. Attach flood lamp group (2) to right side bracket assembly (B) using the supplied hardware from the flood lamps.

View of right side bracket

4. Connect flood lamp groups (2) onto the existing harness assembly. Secure the harness assembly to bracket (B) using two cable straps (6).
Install the 453–6602 Flood Lighting Gp (If Equipped)

20/3/22, 18:47 SIS 2.0
1 4 441-0315 Head Lamp Gp

Table 87
Note: Flood lighting group (1) is installed at the factory.

View of bracket (A) and flood lamps

1. Attach two flood lamp groups (2) onto left side bracket (A) using the supplied hardware from flood lamp groups (2).

View of left side harness

(3) Cable strap
2. Connect flood lamp groups (2) to the existing left side harness. Secure the existing harness to bracket (A) using two cable straps (3).
20/3/22, 18:47 SIS 2.0

View of the right side bracket
(B) Right side bracket

3. Attach two flood lamp groups (2) onto right side bracket (B) using the supplied hardware from flood lamp groups (2).

View of right side harness
(B) Right side bracket


(3) Cable strap
4. Connect flood lamp groups (2) to the existing left side harness. Secure the existing harness to bracket (B) using two cable straps (3).
Install the 568–8937 Antenna Mounting Group (If Equipped)

Required Parts for the Installation of the 568-8937 Antenna and Mounting Gp (If Equipped)
2 1 132-5789 Clip
3 1 310-1898 Clip
4 1 352-3968 Clip
5 2 4P-7581 Clip
6 1 558-6550 Antenna As
7 1 566-4763 Plate
8 1 568-5139(1) Cable
8 1 7G-3228(2) Grommet
9 2 7Y-5262 U-Bolt
10 2 8S-7583(3) Grommet
13 2 8T-4136 Bolt
14 2 9X-7345(4) Grommet
Table 88
(1)
(2) The 568-5139 Cable is installed at the factory.
(3) 7G-3228 Grommet installed at the factory.
(4) 8S-7583 Grommet installed at the factory.
9X-7345 Grommet installed at the factory
Note: Clip ladders 2, 3, and 5 are installed on the machine with the required hardware at the factory.
20/3/22, 18:47 SIS 2.0

View of then rear of the cab showing cable location

1. Locate the antenna wiring harness on the rear of the cab assembly.

View of the cable assembly coaxial routing

2. Route cable assembly coaxial (A) towards the left side catwalk. Secure the cable using the pre existing mounting hardware along the back
side of the cab assembly using cable straps (1).

View of the underside of left side catwalk
(1) Cable strap

(8) Cable assembly coaxial
(9) Grommet

(11) Grommet
3. Route cable (8) towards the front of the left side catwalk thorough two grommets (11) and one grommet (9), secure to mounting points along
the underside of the catwalk with eight cable straps (1).
20/3/22, 18:47 SIS 2.0

View of left-side railing
(1) Cable strap

(8) Cable assembly coaxial
4. Route cable (8) upwards on the left side railing and secure using five cable straps (1).
1. Install plate (7) to the left-side mirror tube with one clip ladder (4) two U-bolts (10), two locknuts (12), and two hard washers (13).
2. Install antenna assembly (6) to plate (7). Torque to 5 ± 0.5 N·m (44 ± 4 lb in). Secure antenna cable to clip ladder (4) with one cable strap (1).
Installing the 571–2116 Air Conditioner Lines Gp

1. Locate the heater lines and the air conditioner lines that are strapped to the frame.

Right-hand side of the cab under the hood

2. Remove all caps from the air conditioner hose connections. Discard all caps.
20/3/22, 18:47 SIS 2.0


3. Install hose (A) and hose (B) to the fittings on the cab.


4. Install hose (C) and hose (D). Secure hose (C) and hose (D) with clamps (E).
Connect the 455-6746 Lubrication Pump Group or the 418-6494

Lubrication Pump Group to the Chassis (If Equipped)
Connect the 455-6746 Lubrication Pump Group (If Equipped)

(A) Lube reservoir
(B) Hose assembly
(C) Hose assembly
(D) Solenoid valve assembly
(E) Wiring harness
20/3/22, 18:47 SIS 2.0
1. Remove the shipping plug from the lower port of lube reservoir (A).
2. Connect hose assembly (B) (fast fill hose) to lube reservoir (A).
3. Remove shipping cap from the port on solenoid valve assembly (D).
4. Connect hose assembly (C) to solenoid valve assembly (D) as shown in Illustration 227.
5. Connect wiring harness (E) from pump to corresponding connector on the chassis wiring harness at the front of the steering hydraulic tank.
6. Connect to Electronic Technician (ET) and access "Chassis Configuration". Locate "Auto Lube System Configuration Code" and set to "1".
Connect the 418-6494 Lubrication Pump Group (If Equipped)

(A) Lube reservoir
(B) Hose assembly
(C) Hose assembly
(D) Wiring harness
1. Remove the shipping plug from the lower port of lube reservoir (A).
2. Connect hose assembly B (fast fill hose) to lube reservoir (A).
3. Remove the shipping caps from the two ports of lube reservoir (A).
4. Connect hose assemblies (C) to lube reservoir (A) as shown in Illustration 228.
5. Connect wiring harness (D) from pump to corresponding connector on the chassis wiring harness at the front of the steering hydraulic tank.
6. Connect to Electronic Technician (ET) and access "Chassis Configuration". Locate "Auto Lube System Configuration Code" and set to "2".
Install the 461–6944 Fender Group

Required Parts for Installation of the 461–6944 Fender Gp

1 1 340-3605 Guard
2 1 340-3607 Guard
3 1 346-7672 Rubber Guard
5 1 358-9150 Guard
8 1 357-6592 Guard
9 18 8T-4196 Bolt
10 4 8T-4195 Bolt
11 22 7X-7729 Washer
12 1 358-6038 Plate As
13 16 357-0497 Plate
14 1 346-8338 Plate As
20/3/22, 18:47 SIS 2.0
15 1 358-9152 Plate As

16 1 340-3616 Plate
17 4 8T-4136 Bolt
18 1 422-2636 Guard
19 1 567-7041 Mud Flap
20 5 115-6433 Washer
21 7 444-8506 Bolt
Table 89
Left-Hand Fender Guards

View of the rear left-hand walkway and cab
(A) Bolt

(B) Washer
1. Remove three bolts (A) and three washers (B). Retain the hardware.

View behind the cab
(C) Plate

(D) Bolt

(E) Washer
2. Remove two plates (C), four bolts (D), and four hard washers (E). Retain the plates and hardware.
20/3/22, 18:47 SIS 2.0
View of the rear left-hand walkway and cab

(A) Bolt

(B) Washer
(12) Plate assembly
3. Install plate assembly (12). Secure plate assembly (12) using three bolts (A) and three washers (B) that were removed in Step 1.

(C) Plate

(D) Bolt

(E) Washer
(3) Rubber guard
(10) Bolt

(11) Washer
(13) Plate
4. Install rubber guard (3) using two plates (13), two plates (C), four bolts (10), four washers (11), four bolts (D), and four washers (E). Two
plates (C), four bolts (D) and four washers (E) were retained in Step 2.

(F) Hydraulic tank

(3) Rubber guard

(10) Bolt

(11) Washer
(13) Plate

(14) Plate
assembly
5. Secure rubber guard (3) to hydraulic tank (F) using plate assembly (14), three plates (13), six bolts (10), and six washers (11).
20/3/22, 18:47 SIS 2.0

(4) Rubber guard

(10) Bolt

(11) Washer
(13) Plate

(14) Plate
assembly
6. Install rubber guard (4). Secure rubber guard (4) onto plate assembly (14) using three plates (13), six bolts (10), and six washers (11).
Right-Hand Fender Guards

(G) Plate

(H) Bolt

(J) Washer
1. Remove three plates (G), six bolts (H), and six washers (J). Retain the plates and hardware.
20/3/22, 18:47 SIS 2.0


2. Install guard (2). Secure guard (2) using three plates (G), six bolts (H), and six washers (J) retained in Step 1.

(K) Plate

(L) Plate

(M) Bolt

(N) Washer
(P) Bolt

(R) Washer
3. Remove four bolts (M), four washers (N), and two plates (K). Remove four bolts (P), four washers (R), and two plates (L). Retain the plates
and hardware.

(8) Guard

(K) Plate

(L) Plate

(M) Bolt

(N) Washer
(P) Bolt

(R) Washer
4. Install guard (8). Secure guard (8) using two plates (K), four bolts (M), four washers (N), two plates (L), four bolts (P), and four washers (R)
retained in Step 3.
20/3/22, 18:47 SIS 2.0

(S) Plate

(T) Bolt

(U) Washer
5. Remove six bolts (T), six washers (U), and two plates (S). Retain the plates and hardware.

(S) Plate

(T) Bolt

(U) Washer
(1) Guard
6. Install guard (1). Secure guard (1) using two plates (S), six bolts (T), and six washers (U) retained in Step 5.

(Z) Bar

(AB) Bracket
(9) Bolt

(11) Washer
(18) Guard

(17) Bolt

(13) Plate

(16) Plate
20/3/22, 18:47 SIS 2.0
7. Install guard (18). Secure guard (18) using two plates (13), four bolts (9), and four washers (11) onto two bars (Z) Mount one plate (16), and
three bolts (17) and three more washers (11) to bracket (AB).

(AC) Fuel tank
(9) Bolt
(11) Washer
(13) Plate
(18) Guard
8. Secure guard (18) to fuel tank (AC) using two plates (13), two bolts (9), and two washers (11).

View of rear of the hood
(6) Guard
(16) Plate
(13) Bolt
(11) Washer
9. Install guard (6) to the rear of top platform.

Use three plates (16), six bolts (13), and six hard washers (11) to attach guard (6) to the rear of the hood assembly.
20/3/22, 18:47 SIS 2.0
View of underside of the cab mud flap

(19) Mud flap
(20) Washer
(21) Bolt
10. Install mud flap (19) to the front cab support bosses using four washers (20) and two bolts (21).
Note: Be sure to have mud flap (19) between two washers (20) before attaching each bolt (21) to the each of the bosses.
11. Attach the other side of mud flap (19) to the underside of the cab using three more bolts (21) and three more washers (20).
Install the Front Tires

Required Parts for Installation of the Front Tires

1 40 339-3284 Hex Nut
Table 90
1. Make sure that all the paint, debris, and, shipping grease have been removed from the wheel studs and from 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.
3. Use a tire handler to install a tire and rim on the wheel at each side of the truck.
4. Remove paint and clean the mounting surfaces. Make sure that all paint, shipping grease, and burrs have been removed from the wheel
studs and the mating surfaces.
20/3/22, 18:47 SIS 2.0
5. Install rim (A) with 20 hard washers (2), and 20 hex nuts (1).
a. Apply 4C-5592 Anti-Seize Compound to the hard washer face, and the threads of the hex nuts, tighten the hex nuts to a torque of
1700 ± 200 N·m (1254 ± 148 lb ft).
6. Use Tooling (DD) to inflate the front tires. Refer to Special Instruction, SMHS7867, "Use of 6V-4040 Nitrogen Tire Inflation Group".
7. Repeat Step 1 through Step 6 for the other front tire and rim.
Install the Rear Tires

Required Parts for Installation of the Rear Wheels

1 2 420-0526 Tire Valve Gp
2 80 339-3284 Hex Nut
4 2 329-8262(1) Stem Extension Gp
Table 91
(1)
Remove and reuse a valve cap from rear rims to protect the core on extension group.
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: Remove paint and clean the mating surfaces.

View of the left-hand rear wheel

1. Mark the final drives to locate the extension cover for the valve stem. Mark the inner tire and rim to locate the valve stem.
2. Remove four bolts (A), four hard washers (B), and plate (C).
20/3/22, 18:47 SIS 2.0
3. Use a tire handler to install an inner tire and rim on the truck.
Note: Before installing the rear inner rim, locate the valve stem extension guard on the wheel and use the valve stem extension to determine
the proper orientation of the rim’s valve stem port relative to the wheel.
4. Align the marks to install the inner rear tire and rim on the truck.

(2) Hex nut
(3) Hard washer
6. Use 20 hard washers (3), and 20 hex nuts (2) to secure the inner rear tire and rim to the final drive.
a. Apply 4C-5592 Anti-Seize Compound to the hard washer face and the threads of the full nuts, tighten the full nuts to a torque of
1700 ± 200 N·m (1254 ± 148 lb ft).

(A) Bolt
(B) Hard washer
(C) Plate
(4) Stem extension group
7. Install stem extension group (4) on the inner rear rim. Reinstall plate (C), two hard washers (B), and two bolts (A) over tire valve (1).
8. Use Tooling (DD) to inflate the inner rear tire. Refer to Special Instruction, SMHS7867, "Use of 6V-4040 Nitrogen Tire Inflation Group".
9. Repeat Step 1 through Step 8 for the other inner rear tire.
Outer Rear Tires

Note: Remove paint and clean the mating surfaces.

(1) Tire valve group
20/3/22, 18:47 SIS 2.0
1. Mark the outer tire and rim to locate the valve stem.
2. Install tire valve group (1) on the outer rear rim.
3. Use a tire handler to install an outer tire and rim on the truck.

(2) Hex nut
(3) Hard washer
4. Align the marks to install the inner rear tire and rim on the truck.
6. Use 20 hard washers (3), and 20 hex nuts (2) to secure the outer rear tire and rim to the rear wheel assembly.
a. Apply 4C-5592 Anti-Seize Compound to the hard washer face and the threads of the hex nuts, tighten the full nuts to a torque of
1700 ± 200 N·m (1254 ± 148 lb ft)
7. Use Tooling (DD) to inflate the outer rear tire. Refer to Special Instruction, SMHS7867, "Use of 6V-4040 Nitrogen Tire Inflation Group".
8. Loosen bracket assembly (A) to secure tire valve group (2).
9. Repeat Step 1 through Step 7 for the other outer rear tire and rim.
Front Wheel Alignment

20/3/22, 18:47 SIS 2.0
Note: The front wheels must be off the ground. Ensure that the suspension cylinders are fully extended.
NOTICE
The tie rods must be tightened to a torque of 285 N·m (210 lb ft).
The tie rods must be tightened regardless of whether an
adjustment has been made.
1. Move the wheels until the wheels face straight ahead.
2. Measure the distance (D) between the front tires.
3. Mark location (D) on each front tire. Rotate the tires until the marks are 180 degrees from point (D).
4. Measure the distance (E) between the marks on the tires.
5. Subtract distance (E) from distance (D). This value will be 62.3 mm (2.45 inch) when the toe-out is correct.
6. If necessary, adjust the tie rods to set the toe-out. Loosen clamps (F) on the left side. Loosen clamps (G) 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 (F) and clamps (G) 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 377-6260 Truck Body Mounting Group to Install the Truck Body
Required Parts for Installation of the 377-6260 Truck Body Mounting Gp

1 16 1D-0503 Washer
2 4 5D-3887 Rod
3 2 5T-5528 Plate
4 2 5T-9266 Pin As
5 4 6F-8499 Spring
6 2 6G-7773 Pin
7 2 8W-8454 Pin As
8 2 8W-8456 Plate
9 4 9D-2316 Spacer
10 4 054-3788 Washer
11 2 253-7490 Ejector
12 2 270-7034 Pin As
13 2 322-5067 Mud Guard
14 2 322-5068 Plate
20/3/22, 18:47 SIS 2.0
15 2 331-5956 Plate

16 8 3B-4615 Cotter Pin
17 4 3B-4647 Cotter Pin
18 8 5P-2566 Bolt
19 20 6V-8801 Nut
20 28 8T-4183 Bolt
22 8 8T-4244 Nut
23 20 9B-7237 Bolt
Thrust Washer
24 1 8W-2897 (1)
25 2 9D-3432 Thrust Washer(1)

26 20 106-8227 Shim
27 6 229-6177 Pad As
326-3097
Baffle As(2)
28 1
113-1218
Baffle As
29 2 031-9831 Bolt
Table 92
(1)
(2) Use thrust washers if necessary and as required to shim between the body and frame assemblies at outside pivot pin areas to reduce gaps to less than 3 mm (0.12 inch).
Part of the 321-6518 Rear View Mirror Gp
Installing the Truck Body

1. Remove the paint from the mating surfaces of the truck body and the frame. Remove all lifting eyes and lugs prior to installation.

View of the bottom of the truck body
(7) Pin assembly
2. Insert one-pin assembly (7) into the outer pivot pin bore on each side of the truck body.
20/3/22, 18:47 SIS 2.0
3. Use a suitable lifting device 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.

View truck body and frame
(25) Thrust washer
5. At each side of the machine, insert one thrust washer (25) between the outer ear of the truck body and the truck frame.
Note: If thrust washer (25) does not fit, insert one thrust washer (24). Thrust washer (24) is 2.0 mm (0.079 inch) thinner than thrust washer
(3).

View truck body and frame
(7) Pin assembly
(8) Plate
(18) Bolt
(21) Hard washer
6. Manually grease the pins and the pin bores of the truck body and of the truck frame.
Drive pin assemblies (7) through the pivot pin bores of the truck body and of the truck frame.
7. Secure pin assemblies (7) in place using two plates (8), four bolts (18), and four hard washers (21).
Secure the Hoist Cylinder to the Truck Body

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 to stabilize the hoist cylinders.
20/3/22, 18:47 SIS 2.0
NOTICE
Do not grind into the parent material of the frame.
3. Remove the shipping brackets being careful not to gouge or grind into the parent material underneath the shipping bracket.
4. Sand the excess weld material flush with the surrounding parent material using a 36 grit minimum sanding disk.
5. Use a suitable lifting device to align the pin bores of the truck body and the hoist cylinders.

View of the left-hand side hoist cylinder
(3) Plate

(4) Pin assembly
(9) Spacer

(18) Bolt

(21) Hard
washer
6. Place one spacer (9) on each side of the hoist cylinder bearing. At each side of the machine, insert one-pin assembly (4) through the truck
body and through the hoist cylinder bearing.
Note: Before you install pins (4), apply grease to both the upper and lower the pins.
7. Secure each pin assembly (4) using one plate (3), two bolts (18), and two hard washers (21).
Install the Mud Guards
20/3/22, 18:47 SIS 2.0

(13) Mud guard
(14) Plate

(15) Plate
(19) Nut

(23) Bolt
1. Secure two mud guards (13) to two plates (14) and two plates (15) by using 20 bolts (23) and 20 nuts (12).

View of the bottom of the body
(A) Plate assembly

(13) Mud guard

(20) Bolt

(21) Hard
washer
(22) Nut
2. Install two mud guards (13) onto plate assemblies (A) using eight bolts (20), eight hard washers (21), and eight nuts (22).
Note: Tighten eight bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
Install the Body Retaining Pins
20/3/22, 18:47 SIS 2.0
1. Install two rods (2) on the right-hand side and left-hand side of the truck body. Secure rods (2) using two cotter pins (16), one spring (5), and
one washer (10). Refer to Illustration 265 for installation locations.
2. Install two pins (12) to the truck body. Secure the pins with rods (2).
Installing the Rock Ejectors

View of the right-hand side ejector

1. Install one ejector (11) in each plate assembly using one pin (6), eight washers (1). and two cotter pins (17).
Note: Use washers (1) to center ejectors (11) between the two rear tires on each side of the machine.
Install the Visual Body Down Indicator

Note: Machine equipped with the 341-5471 Rear View Mirror Gp or the 328-9834 Rear View Mirror Gp should use the 326-3097 Baffle As. The
326-3097 Baffle As is used on coal bodies. Machines without coal bodies should use the 113-1218 Baffle As.
20/3/22, 18:47 SIS 2.0

Typical view
(28) 113-1218
Baffle As or 326-3097 Baffle As
(29) 031-9831 Bolt
1. Use two bolts (29) to install baffle assembly (28) on the canopy.
Install the 309-1212 Central Lubrication Lines Group (If Equipped)

Required Parts for Installation of the 309-1212 Central Lubrication Lines Gp (If Equipped)

1 14 5P-9085 Clip
3 12 8T-4191 Bolt
5 2 5M-3062 Bolt
Table 93
20/3/22, 18:47 SIS 2.0
Rear view

(A) Hose assembly
(B) Hose assembly
(C) Hose assembly
(D) Hose assembly
(E) Hose assembly

(F) Hose assembly

(G) Hose assembly
(H) Hose assembly

(J) Hose assembly

(K) Hose assembly
(1) Clip

(2) Hard
washer
(3) Bolt

(4) Hard washer
(5) Bolt
1. Connect hose assembly (D) to the fitting on the bottom of the left-hand rear suspension cylinder. Secure hose assembly (D) using clip (1),
hard washer (4), and bolt (5).
2. Connect hose assembly (H) to the fitting on the bottom of the right-hand rear suspension cylinder. Secure hose assembly (H) using clip (1),
3. Connect hose assembly (C) to the fitting on the top of the left-hand rear suspension cylinder.
4. Connect hose assembly (G) to the fitting on the top of the right-hand rear suspension cylinder.
5. Route hose assembly (B) and hose assembly (F) to the body pivot pins. Connect hose assembly (B) and hose assembly (F) to the fittings on
the body pivot pins.
6. Secure hose assembly (A) and hose assembly (E) using two clips (1), two hard washers (2), and two bolts (3).

(K) Hose assembly
7. Connect hose assembly (K) to the fitting on the inward sway bar.

(J) Hose assembly
8. Route hose assembly (J) to the fitting on the end of the inward sway bar. Connect hose assembly (J) to the fitting on the end of the inward
sway bar.
20/3/22, 18:47 SIS 2.0

(A) Hose assembly

(1) Clip

(2) Hard
washer
(3) Bolt
9. Route hose assembly (A) to the head end of the hoist cylinder. Connect hose assembly (A) to the fitting on the top of the hoist cylinder.
10. Secure hose assembly (A) in five locations using five clips (1), five hard washers (2), and five bolts (3).

(E) Hose assembly

(1) Clip

(2) Hard
washer
(3) Bolt
11. Route hose assembly (E) to the head end of the hoist cylinder. Connect hose assembly (E) to the fitting on the top of the hoist cylinder.
12. Secure hose assembly (E) in five locations using five clips (1), five hard washers (2), and five bolts (3).
Install the 309-1213 Automatic Lubrication Group (If Equipped)

Required Parts for Installation of the 309-1213 Automatic Lubrication Gp (If Equipped)

1 2 5M-3062 Bolt
3 14 5P-9085 Clip
5 12 8T-4191 Bolt
Table 94
20/3/22, 18:47 SIS 2.0

Rear view

(A) Hose assembly
(B) Hose assembly
(C) Hose assembly
(D) Hose assembly
(E) Hose assembly

(F) Hose assembly

(G) Hose assembly
(H) Hose assembly

(J) Hose assembly

(K) Hose assembly
(L) Hose assembly

(1) Bolt

(2) Hard washer
(3) Clip

(4) Hard
washer
(5) Bolt
1. Connect hose assembly (F) to the fitting on the bottom of the left-hand rear suspension cylinder. Secure hose assembly (F) using clip (3),
2. Connect hose assembly (L) to the fitting on the bottom of the left-hand rear suspension cylinder. Secure hose assembly (L) using clip (3),
3. Connect hose assembly (C) to the fitting on the top of the left-hand rear suspension cylinder.
4. Connect hose assembly (J) to the fitting on the top of the left-hand rear suspension cylinder.
5. Route hose assembly (B) and hose assembly (H) to the body pivot pins. Connect hose assembly (B) and hose assembly (H) to the fittings on
the body pivot pins.
6. Secure hose assembly (A) and hose assembly (G) using two clips (3), two hard washers (4), and two bolts (5).
20/3/22, 18:47 SIS 2.0

(D) Hose assembly
7. Connect hose assembly (D) to the fitting on the inboard sway bar.

(K) Hose assembly
8. Route hose assembly (K) to the fitting on the end of the inward sway bar. Connect hose assembly (K) to the fitting on the end of the inward
sway bar.

(A) Hose assembly

(3) Clip

(4) Hard
washer
(5) Bolt
9. Route hose assembly (A) to the head end of the hoist cylinder. Connect hose assembly (A) to the fitting on the top of the hoist cylinder.
10. Secure hose assembly (A) in five locations using five clips (3), five hard washers (4), and five bolts (5).
20/3/22, 18:47 SIS 2.0

(G) Hose assembly

(3) Clip

(4) Hard
washer
(5) Bolt
11. Route hose assembly (G) to the head end of the hoist cylinder. Connect hose assembly (G) to the fitting on the top of the hoist cylinder.
12. Secure hose assembly (G) in five locations using five clips (3), five hard washers (4), and five bolts (5).
Installation of the Rear Axle Lubrication Kit (If Equipped)

For the assembly instructions, refer to Special Instruction, SEHS0030, "Field Procedure to Install the Rear Axle Lubrication Kit (If Equipped) on
Certain 777G Off-Highway Trucks".
The 486-0544 Rear Axle Lubrication Kit is adaptable to S/N:RDR1-499, ; S/N:T5A1-299, ; S/N:TNM1-999, ; S/N:T4Y1-499, and ; S/N:GT71-UP.
The 510-5059 Rear Axle Lubrication Kit is adaptable to S/N:RDR500-UP, ; S/N:T5A300-UP, ; S/N:TNM1000-UP, ; S/N:T4Y500-UP, and ;
S/N:GT71-UP.
Installation of the Engine Oil Metering Group (If Equipped)

For the assembly instructions, refer to Special Instruction, SEHS0031, "Field Instructions to Install the Engine Oil Metering Group (If Equipped) on
Certain 777G Off-Highway Trucks".
Installation of the Cold-Weather Group (If Equipped)

For the assembly instructions, refer to Special Instruction, REHS9320, "Procedure to Install the Cold-Weather Cover Group onto Certain Tier IV
773G, 775Gand 777G Off-Highway Trucks".
Installation of the Cat Detect

The following will cover the installation of the following arrangements:
461-6862 Camera Ar (2 camera system)
461-6863 Camera Ar (4 camera system)
461-6864 Camera Ar (4 camera system with radar)
Reference: Refer to Testing and Adjusting, UENR1274 for the orientation of the radar. The radar orientation is critical for the operation of the object
detection system.
20/3/22, 18:47 SIS 2.0
Install the Front and Rear camera in the 461-6862 and 461-6863 Camera
Arrangement (If Equipped)
Required Parts for Installing the 461-6862 Camera Ar
2 1 271-6768 Plate
3 1 347-3568 Plate
4 1 348-9226 Grommet Assembly
5 1 2V-8260 Grommet
6 2 347-1668 Camera Gp
7 1 4P-8134 Clip
8 4 5C-2890 Nut
9 1 5P-7468 Clip
10 1 5P-7469 Clip
13 2 8T-4136 Bolt
14 1 8T-4183 Bolt
16 1 8T-4244 Nut
17 4 9X-8256 Washer
18 1 315-5391 Nut
Table 95
Camera Cable Color Codes

Camera 1 Red
Camera 2 Blue
Camera 3 Green
Camera 4 Yellow
Table 96
Assemble the Camera Groups
20/3/22, 18:47 SIS 2.0

Typical view of the front camera
(3) Plate

(6) Camera
group
(8) Nut

(17) Washer
1. Install camera group (6) onto plate (3) using two nuts (8) and two washers (17).

Typical view of the rear camera
(2) Plate

(6) Camera
group
(8) Nut

(17) Washer
2. Install camera group (6) onto plate (2) using two nuts (8) and two washers (17).
Installation of the Camera Groups

Install the Rear Camera Group
20/3/22, 18:47 SIS 2.0
Typical view of the rear camera group

(A) Bracket assembly

(B) Cable assembly

(1) Cable strap

(6) Camera group
(7) Clip

(12) Hard
washer
(13) Bolt
1. Install camera group (6) onto bracket assembly (A) using two bolts (13) and two hard washers (12).
2. Remove protective caps from cable assembly (B) and the camera harness.
3. Connect camera cable to cable assembly (B).
4. Secure camera cable and cable assembly (B) using clip (7) and cable strap (1).
Install the Front Camera Group

View of the top of the cowling group
(C) Handrail assembly

(6) Camera group

(9) Clip

(10) Clip
(11) Grommet
(14) Bolt

(15) Hard washer
(16) Nut
1. Install clip (9), clip (10), and grommet (11) onto handrail assembly (C).
2. Secure camera group (6) onto clip (9) using bolt (14), two hard washers (15), and nut (16).

View between the hood and front of the cab
(D) Cable assembly

(5) Grommet
3. Install grommet (5), and route cable assembly (D) up through grommet (5).
20/3/22, 18:47 SIS 2.0

View of camera group mounted on the handrail group
(C) Handrail group

(D) Cable assembly
(1) Cable strap

(6) Camera group
4. Route cable assembly (D) up handrail group (C) to camera group (6).
5. Remove protective caps from cable assembly (D) and the camera cable.
6. Connect camera cable to cable assembly (D).
7. Secure cable assembly (D) onto handrail group (C) in eight locations using eight cable straps (1).
Installing the Left side and Right side cameras in the 461-6863 and 461-
6864 Camera Arrangement (4 Camera System)(If Equipped)
Note: For instructions on assembling and installing the front and rear camera groups Refer to Section "Install the Front and Rear camera in the
461-6862 and 461-6863 Camera Arrangement (If Equipped)".
Required Parts to Install the 461-6863 Camera Ar- Detect (If Equipped)
2 2 478-5939 Camera and Mounting Gp
3 2 336-6684 Camera Gp
4 2 7G-3228 Grommet
5 2 132-5789 Clip
6 2 8T-4137 Bolt
Table 97
Camera Cable Color Codes

Camera 1 Red
Camera 2 Blue
Camera 3 Green
Camera 4 Yellow
Table 98
Installation of the Camera Groups

Install the Right-Hand Side Camera Group
20/3/22, 18:47 SIS 2.0

View of right-hand side mount
(3) Camera assembly
1. Route the harness from camera (3) up from the bottom of the existing bracket. Secure the harness with grommet on the harness.
Note: Flood lamp assemblies removed for clarity.

View of right-hand side mount
(3) Camera assembly
2. Use the two supplied screws to mount camera (3) to the inside of the existing bracket.
3. Using three cable straps (1) secure the cable from camera assembly (3) to the top of the mounting bracket and the upright tie off.
20/3/22, 18:47 SIS 2.0

View of right-side
(1) Cable strap

(2) Camera and

mounting group
(3) Camera assembly

(5) Clip

(6) Bolt
(7) Hard
washer
4. Connect the cable from camera assembly (3) to the cable from camera and mounting group (2) and secure both cables to the bracket
assembly with one clip (5), one bolt (6), one washer (7) and one cable strap (1).
Install the Left-Hand Side Camera Group

View of left-side mounting bracket
(3) Camera assembly
1. Route the harness from camera assembly (3) up from the bottom of the existing bracket. Secure the harness with grommet on the harness.
2. Use the two supplied screws to mount camera assembly (3) to the inside of the existing bracket.
20/3/22, 18:47 SIS 2.0

Left-side camera mount
(1) Cable straps

(3) Camera assembly
3. Using two cable straps (1) secure the cable from camera assembly (3) to the top of the mounting bracket and the upright tie off.
4. Connect the cable from camera assembly (3) to the cable from camera and mounting group (2) and secure both cables to the bracket
assembly with one clip (5), one bolt (6), one washer (7) and one cable strap (1).
Install the 461-6864 Object Detection Installation Arrangement (If

Equipped)
Note: For instructions on assembling and installing the front camera group. Refer to Section "Install the Front and Rear camera in the 461-6862
and 461-6863 Camera Arrangement (If Equipped)".
Note: For instructions on assembling and installing the left-hand side and right-hand side camera groups Refer to Section "Installing the Left side
and Right side cameras in the 461-6863 and 461-6864 Camera Arrangement (4 Camera System)(If Equipped)" (.
Reference: System Operation, Testing and Adjusting, KENR8668, "Integrated Object Detection System for Off-Highway Trucks".
Required Parts to Install the 461-6864 Camera Ar (If Equipped)

1 24 8T-9655 Isolation Mount
2 12 8T-9658 Spacer
3 12 9N-0869 Hard Washer
4 1 359-7444 Bracket As
5 2 359-7850 Bracket As
6 1 360-3919 Bracket As
7 2 364-5738 Bracket As
8 4 430-8391 Object Detection Box Gp
9 1 381-4174 Bracket As
20/3/22, 18:47 SIS 2.0
10 1 392-4618 Plate

11 4 344-5674 Nut
13 8 6V-3964 Hard Washer
14 16 6V-7357 Bolt
15 8 7X-0818 Bolt
16 2 7Y-5262 U-Bolt
19 11 8T-4195 Bolt
21 4 8T-6912 Bolt
22 2 4P-7581 Clip
23 7 8T-4137 Bolt
25 2 7X-7729 Washer
26 1 347-3568 Plate
28 2 5C-2890 Nut
29 1 5P-7468 Clip
30 1 5P-7469 Clip
31 2 336-6684 Camera Gp
33 1 8T-4133 Nut
34 1 8T-4183 Bolt
36 2 9X-8256 Washer
Table 99
Secure the Object Detection Box Groups to the Brackets

Typical view of the front object detection box group

(8) Object detection box group
(12) Hard washer

(14) Bolt
1. Install object detection box group (8) onto bracket assembly (4) using four bolts (14) and four hard washers (12).
20/3/22, 18:47 SIS 2.0

Typical view of the right and left-side object detection box groups

group
(8) Object detection box

(12) Hard washer

(13) Hard washer

(14) Bolt
2. Install sensor and mounting (8) onto bracket assembly (7).
3. Secure sensor and mounting (8) onto bracket assembly (7) using four bolts (14) four hard washers (12), and four hard washers 13.
Installation of the Object Detection Box Groups

Installation of the Box Group for the Object Detection (Front)

Typical view of the front object detection box group
(1) Isolation mount

(2) Spacer

(3) Hard washer
(8) Sensor and mounting
(10) Plate

(21) Bolt
1. Install sensor and mounting (8) onto plate (10) using eight isolation mounts (1), four spacers (2), four hard washers (3), and four bolts (21).
20/3/22, 18:48 SIS 2.0

View of the front handrail assembly
(A) Handrail assembly

(8) Object detection box group
(10) Plate

(16) U-Bolt
(17) Locknut
(18) Hard washer
(22) Clip
2. Install sensor and mounting (8) and plate (10) onto handrail assembly (B) using two U-bolts (16), four hard washers (18), one clip (22) and
four locknuts (17).

Typical view of the front sensor and mounting
(B) Front harness assembly

(18) Hard washer

(22) Clip

(23) Bolt
(24) Cable
strap
3. Connect front harness assembly (B) to sensor and mounting (8).
4. Secure front harness assembly (B) using two clips (22), bolt (23), hard washer (18), and two cable straps (24).
Installation of the Box Group for the Object Detection (Rear)

(29) 501-8246 Bracket
20/3/22, 18:48 SIS 2.0

(12) 5P-4115 Hard Washer
(26) 8T-4971 Bolt
1. Attach the radar box to the bracket using four hard washers (12) and four bolts (26).

(19) 8T-4195 Bolt
(25) 7X-7729 Washer
2. Attach Bracket (29) to block (28) using two bolts (19) and two washer (25).

(30) 501-8250 Rear Harness As
3. Connect Rear Harness As (30) to radar connector. Secure harness using Cable Strap (24) as shown in Illustration 302 and 303.
Note: Allow adequate slack, so that no curves in the harness are near sharp corners and that the harness has rounded curves as it is routed
around the bracket.
20/3/22, 18:48 SIS 2.0

(31) 336-6684 Camera Gp
4. Mount Camera Gp (31) using the hardware provided with the camera. Connect camera cable to harness as shown in Illustration 304.
5. Use Cable Strap (24) to secure slack from camera harness as shown in Illustration 305.
6. Tighten the cable strap to hold harness in place, but not tight enough to pinch the harness.
Installation of the Box Group for the Object Detection (Right-Hand Side)

Typical view of the right-hand side sensor and mounting
(1) Isolation mount

(2) Spacer

(3) Hard washer
(18) Hard washer

(19) Bolt
20/3/22, 18:48 SIS 2.0
1. Install bracket assembly (5) onto bracket assembly (6) using two bolts (19) and two hard washers (18).
2. Install sensor and mounting (8) onto bracket assembly (5) using eight isolation mounts (1), four spacers (2), four hard washers (3), and four
bolts (15).

(D) Right -side platform
(18) Hard washer
(19) Bolt
3. Install sensor and mounting (8) onto right-hand platform assembly (D) using four bolts (19) and eight hard washers (18).

(E) Right-hand harness assembly
(F) Grommet
4. Route right-hand harness assembly (E) through grommet (F) and connect to sensor and mounting (8).
Installation of the Box Group for the Object Detection (Left-Hand Side)
20/3/22, 18:48 SIS 2.0

View of the left-hand catwalk assembly

Measurement System (TPMS)
(G) Lamp assembly for the Truck Payload
Note: If the machine is equipped with lamp (G) for the Truck Payload Measurement System (TPMS), complete Step 1 that follows.
1. If equipped, remove lamp (G) for the Truck Payload Measurement System (TPMS). Retain lamp (G) and the hardware that secures lamp (G)
to the catwalk assembly.

(18) Hard washer

(19) Bolt
2. Install bracket assembly (5) onto bracket assembly (9) using two bolts (19) and two hard washers (18).

(1) Isolation mount

(2) Spacer

(3) Hard washer
3. Install sensor and mounting (8) onto bracket assembly (5) using eight isolation mount (1), four spacers (2), four hard washers (3), and four
bolts (15).
20/3/22, 18:48 SIS 2.0

Typical view of the left-hand side sensor and mounting
(G) Lamp assembly for the Truck Payload Measurement
System (TPMS)
(H) left-hand harness assembly



(24) Cable strap
4. Install sensor and mounting (8) bracket assembly (9), and lamp (G). Secure using the mounting hardware retained in Step 1.
5. Secure left-hand harness assembly (H) using two cable straps (24).

View of the backside of the cab
(J) Covers
6. Remove covers (J). Retain covers and hardware.

View of the backside of the cab
(K) Harness assembly
7. Route harness assembly (K) and connect to existing harness connections on the rear of the cab.
Note: The wiring harness may ship already attached to the cab assembly. If so, verify that harness assembly (K) is connected to the correct
terminal.
8. Re-install cover (J) which were removed and retained in Step 6.
Installing the 320-5104 Wheel Chock Group

Required Parts for Installation of the 320-5104 Wheel Chock Gp
1 2 7D-7496 Pin As
2 2 155-3597 Wheel Chock
3 1 336-3744 Bracket As
4 1 336-3745 Bracket As
20/3/22, 18:48 SIS 2.0
6 4 8T-4195 Bolt
Table 100

View of the front of the machine

(5) Hard washer

(6) Bolt
1. Install bracket assembly (3) and bracket assembly (4) onto the bumper assembly using four hard washers (5) and four bolts (6).

View of the front of the machine
(1) Pin assembly

(2) Chock
2. Install chocks (2) and secure using pin assemblies (2).
Install the 380-6903 Film Gp

Required Parts for Installation of the 380-6903 Film Gp

1 1 380-6904 Film
2 1 380-6905 Film
3 1 380-6906 Film
Table 101
Locations for the Installation of the Films
20/3/22, 18:48 SIS 2.0

Typical front view
(3) Film

Typical left-hand side view
(2) Film

Typical right-hand side view
(1) Film
1. Install film (3) on the front of the canopy.

Note: Center the films in the available space.
2. Install film (2) on the left side of the truck body.

Note: Center the films in the available spaces.
3. Install film (1) on the right side of the truck body.

Note: Center the films in the available spaces.
Install the 461-6865 Fire Suppression Arrangement (If Equipped)

Fire Suppression Ready (FSR) is designed to accommodate the basic components of a typical fire suppression system post factory. FSR includes
a designated surface on the right-hand side platform for suppressant tanks, clipping points for detection lines, bulkhead plates, and space claim for
mounting hoses and nozzles.
After installation of the 461-6865 Fire Suppression Ar, a review of the field assembly must be part of the system manufacture’s final inspection of
the fire suppression system.
Note: The final inspection, working condition and certification of the fire suppression system is the sole responsibility of the manufacture.
20/3/22, 18:48 SIS 2.0
The 461-6865 Fire Suppression Ar is a stand-alone system. The system has no communications with the Caterpillar Vital Information Management
System (VIMS).
All proprietary parts of the fire suppression system belonging to the manufacture are not serviced through the Caterpillar parts system. These parts
if required must be replaced through the manufacture.
Reference the following group part numbers of the 461-6865 Fire Suppression Ar for Caterpillar parts serviced:
461-6979 Fire Suppression Lines Gp
477-1300 Fire Suppression Group
486-3730 Front Wiring Gp
497-2244 Film Gp
Any questions regarding the functionality, working condition or maintenance of the fire suppression system should be directed to the manufacture,
or a representative authorized to service the manufacture’s system.
Required Parts for Installation of the 461-6865 Fire Suppression Ar

1 2 488-7131(1)(2)(3) Cartridge As
2 2 488-7064(1)(2)(3) Actuator
3 2 488-7089(2)(4) Cable
4 1 290-5562(4) Mount
5 18 7K-1181(4) Cable Strap
6 1 488-7063(2)(4) Controller As
7 4 8T-4136(4) Bolt
8 4 9X-8256(4) Washer
9 1 488-7066(2)(4) Bracket
10 2 8T-4136(4) Bolt
12 1 488-7065(2)(4) Actuator As
13 1 488-7140(5) Film
14 2 148-8337(1) Connector As
Table 102
(1)
(2) From the 461-6979 Fire Suppression Lines Gp
(3) Cat part number for reference only. Part is not serviced through the Cat parts system
(4) Part supplied by representative authorized to service the manufacture's system.
(5) From the 486-3730 Front Wiring Gp
From the 497-2244 Film Gp
Note: Do not adjust the nozzle positions. The nozzle positions have been preset at the factory following manufacturer’s guidelines.
20/3/22, 18:48 SIS 2.0

View of the locations to install the 461-6865 Fire Suppression Ar
(A-A) Location at the rear of the cab
(B-B) Location at the rear of the right-hand platform
(C-C) Location on the right-hand platform
(D-D) Location at the front of the right-hand platform
(E-E) Location on the left-hand side of the right-hand platform
(F-F) Location on the front left-hand side of the bumper

View of the rear of the cab at location A-A of Illustration 320
(A) Cable
(B) Bulkhead fitting
1. Remove the cover plate from the rear of the machine cab and Connect cable (A) to bulkhead fitting (B).
Note: Remove the caps from the end of cable (A) and bulkhead fitting (B) prior to connection.
2. Route cable (A) towards the right side of the cab and use cable straps as needed to secure to the existing harness.
20/3/22, 18:48 SIS 2.0

View of the rear of the right-hand rear corner of the hood at location B-B of Illustration 320
(C) Hose assembly
(D) Adapter
(E) Hose assembly
(F) Adapter
3. Connect hose assembly (C) to adapter (D). Connect hose assembly (E) to adapter (F). Tighten the nut on the hose assemblies to 75 ± 8 N·m
(55 ± 6 lb ft).

View of location C-C of Illustration 320
(1) 488-7131 Cartridge As
(2) 488-7064 Actuator

Note: A representative authorized to service the manufacture's system will supply and install cartridge assemblies (1) and actuators (2).

(G) Hose assembly
(H) Adapter assembly
(J) Hose assembly
4. Remove and discard the plugs from actuators (2). Insert connector assemblies (14) to actuators (2) where the plugs were removed. Tighten
connector assemblies (14) to 25 N·m (220 lb in).
20/3/22, 18:48 SIS 2.0

(G) Hose assembly
(J) Hose assembly
5. Remove and discard the shipping caps from the end of hose assembly (G) and hose assembly (J). Connect hose assembly (G) and hose
assembly (J) to connector assemblies (14). Tighten the nut on the hose assemblies to 15 ± 2 N·m (130 ± 18 lb in).

(K) Tee assembly
(2) 488-7064 Actuator
(3) 488-7089 Cable
6. Connect two cables (3) to two actuators (2) and to tee assembly (K).
Note: All connections must be finger tightened only.

(G) Hose assembly
(3) 488-7089 Cable
(4) 290-5562 Mount
7. Secure hose assembly (G) to two cables (3) by using mount (4) and two cable straps (5).
20/3/22, 18:48 SIS 2.0

View of location D-D of Illustration 320
(6) 488-7063 Controller As
(7) 8T-4138 Bolt
(8) 9X-8256 Washer
8. Secure controller assembly (6) to the right front corner of the hood by using four bolts (7) and four washers (8).

View of location D-D of Illustration 320
(L) Cable
9. Connect six cables (L) that are coiled up in a bundle on the outside of the cowling to controller assembly (6).
Note: All connections must be finger tight only.
Note: The end of each cable (L) is color coded and must be connected to controller assembly (6) correctly. Refer to the Illustration above and
the list below.
POS G = Black (Remote Display
POS H = Green (Power)
POS J = Yellow (Relay #1 and #2)
POS K = Blue (Release)
POS L = Red (Detection #1)
POS M = Red (Detection #2)
10. Secure cables (L) to the existing ladder clips by using four cable straps (5).
20/3/22, 18:48 SIS 2.0

View of location E-E of Illustration 320
(L) Cable
(M) Cable
11. Connect the other end of cable (L) POS K of controller assembly (6) to existing cable (M) on the right-hand side of the platform.

View of location F-F of Illustration 320
(9) 488-7066 Bracket
(10) 8T-4136 Bolt
(11) 8T-4121 Hard Washer
(12) 488-7065 Actuator As
12. Secure bracket (9) to the backside of the left-hand side stairway by using two bolts (10) and two hard washers (11). Tighten bolts (10) to
55 ± 10 N·m (40 ± 7 lb ft).
Secure actuator assembly (12) to bracket (9). Tighten the retaining nut for actuator assembly (12) to 2.8 ± 0.6 N·m (25 ± 5 lb in).

(N) Cable
13. Unbundle red cable (N) from the bundle of cables and harness assemblies on the left-hand side of the cowling.
20/3/22, 18:48 SIS 2.0

(N) Cable

(N) Cable

(N) Cable
(12) 488-7065 Actuator As
14. Route cable (N) along the tie-off points on the frame, fender, and the backside of the left-hand stairway. Use 12 cable straps (5) to secure
cable (N). Refer the Illustrations above. Connect cable (N) to actuator assembly (12).
Note: Remove the caps from the end of the cable and the actuator assembly before connecting the cable.
Note: Cable (N) routes along the same path as the wiring harness to the engine shutdown and stairway lamp switches.
20/3/22, 18:48 SIS 2.0

(13) 488-7140 Film
15. Attache film (13) to the left-hand stairway as shown in the Illustration above.
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.
Check the Fluid Levels
NOTICE
An improper hydraulic oil level can result in machine damage.
Refer to Operation and Maintenance Manual, M0106094, "777G Off-Highway Truck S/N:RDR" or Operation and Maintenance Manual, M0109096,
"777G Off-Highway Truck S/N:TNM" for additional information on fluid capacities and level check procedures.
Fluid Level Checklist

Description Fluid Full Yes or No
Engine Coolant System(1)
Transmission and Torque Converter
Hydraulic Tank
Steering Hydraulic Tank
Engine Crankcase
Left Rear Final Drive
Right Rear Final Drive
Rear Axle
Auto Lube Grease (if equipped)
Left Front Wheel Station
Right Front Wheel Station
Window Washer Reservoir
Fuel
Table 103
(1)
Check the jacket water level
Tire Inflation - Check

Measure the tire pressure of each tire. Adjust the tire pressure, if necessary. Consult your tire supplier for the correct tire operating pressures and
load ratings.
Refer to Operation and Maintenance Manual, M0106094, "777G Off-Highway Truck S/N:RDR", "Tire Inflation Information" and Operation and
Maintenance Manual, M0106096, "777G Off-Highway Truck S/N:TNM", "Tire Inflation Information" for more information.
Suspension Cylinder Charging Procedure

Refer to Special Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks".
20/3/22, 18:48 SIS 2.0
Electrical System Power Up Procedure

To power the electrical system of the truck, perform the steps that follow:
1. Ensure that all electrical circuits, wiring, and connections are fitted and connected correctly.
2. Make sure that the machine battery disconnect switch and the ignition key are both in the OFF position.
3. Connect the machine batteries at the battery compartment.

Typical view of the battery master disconnect switch

4. Turn the battery master disconnect switch to the ON position.
5. Turn the ignition key to the ON position.
6. Check and make sure that the machine cab and components are powering up correctly.
Do not start the truck.
Check the Configuration of the Electronic Control Modules (ECM)
1. Connect a laptop computer to ET service connector (A) and VIMS service connector (B).
2. Start ET, ET will list all the electronic control modules for the machine.
20/3/22, 18:48 SIS 2.0

Highlighted area is ECM type


Highlighted area is truck serial number

3. ET should also display the truck model and serial number for each control. Ensure that the model and serial number are correct for each
control.
20/3/22, 18:48 SIS 2.0

Highlighted area is active codes


Highlighted area is logged codes

4. Select "ACTIVE CODES" from the ET menu. Click the button at 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. Select "LOGGED CODES" from the ET menu. Click the button at the bottom of the screen that reads "INCLUDE ALL ECM's". Clear all
logged codes.
6. Select "DIAGNOSTICS" and choose "EVENTS" from the ET menu. Click the button that reads "INCLUDE ALL ECM's". Clear all logged
events.
7. From ET menu, select "C32 777 Engine ECM". Reconfigure any adjustable parameters to the specific application as required.
8. In the ET menu select "BRAKE 777 Brake ECM". Reconfigure any adjustable parameters to the specific application as required.
9. In the ET menu select "MONITOR 777G". Reconfigure any adjustable parameters to the specific application as required.
10. In the ET menu select "PLE(VIMS)". is enabled if required. Re-configure any adjustable parameters to the specific application as required.
Configurable "Payload Control System Settings" parameters are as follows:
Machine payload control system installation status
Target payload
Payload overload limit
Green TPMS lamp installation configuration
Red TPMS lamp installation configuration
Truck payload last pass indicator enable status
External payload indicator configuration
OHT payload reweigh
Front axle strut pressure to payload weight ratio configuration
Service lamp installation configuration

Note: Road Analysis Control (if equipped) will come with a factory setting of "3". If the setting is otherwise, It is recommended that the Road
Analysis Control be changed to "3" before truck operation.
11. In the ET menu select "CHASSIS ECM". Reconfigure any adjustable parameters to the specific application as required.
Note: Configure transmission settings as needed to comply with site-specific requirements.
Configurable Transmission parameters are as follows:

20/3/22, 18:48 SIS 2.0
Transmission maximum forward gear
Machine body up speed limit
Loaded machine speed limit
Maximum reverse ground speed
Maximum forward ground speed
Throttle lock enable gear limit
Transmission second gear forward start enable
Transmission neutral idle enable status

Configurable Hoist parameters are as follows:
Hoist system enable status
Hoist lower valve adjustment status

Configurable Auto Lube parameters are as follows:
Auto Lube system installation status
Auto Lube interval
Auto Lube duration

Machine configuration menu parameters should be configured to the specific application as required.
12. In ET menu select "VIMS MAIN MODULE". Reconfigure any adjustable parameters to the specific application as required.
13. In ET menu select "OBJECT DETECTION SYSTEM 777". Reconfigure any adjustable parameters to the specific application as required.
Check ECM Software Status

Highlighted area is current software

Utilizing Cat ET, verify that all the ECM's and controllers which the truck is equipped with, all have the latest version of software installed. To check
on the latest software available access SIS and under "Service Software Files" tab, enter "Flash Files" section. Enter the serial number of the
machine that being commissioned. The latest controller software version will be displayed and can be downloaded.
Electronic Control Module (ECM) - Flash Program

1. Locate the version of software that you require from SIS in the "Service Software Files" menu.
2. Enter the "Flash Files" menu and enter the serial number of the truck requiring the software flash.
3. Select which version of software required from the list, and download the software to a laptop computer in a file where the software can easily
be found. Downloading the software to the "Desktop" is the preferred location.
20/3/22, 18:48 SIS 2.0
Procedure for Connecting Electronic Technician (ET) to the Electronic Control Module (ECM)
1. Connect a data link cable between the 171-4400 Communication Adapter Gp and the ET.
2. Connect a data link cable between the 171-4400 Communication Adapter Gp and the diagnostic connector of the machine (rear most
connector).
3. Start ET, and allow ET to connect to all available ECM's on the truck.

Highlighted area is winflash tab

4. Select the "Winflash" tab at the top of the ET screen to open the software flash utility screen.
5. Select the ECM required.
6. Click on the "Select a flash file" tab, then browse and select the file which was saved to in Step 3. Ensure that the flash file is correct for the
ECM selected.

Flash button

7. Click the "Begin Flash" tab at the lower left of the screen to begin the software upload.
20/3/22, 18:48 SIS 2.0

Highlighted area flash file

8. Follow the prompts on the screen to complete the software upload to the ECM.
Activation of the Hoist Controls for the Truck Body

Highlighted area is hoist system enable

The activation of the hoist controls may be required on the 777G Off-Highway Truck upon delivery to enable the hoist system to function.
Note: The software for ET must be used to set the following parameters. Use the latest version of the ET software. Enable the Hoist System (an
adjustable parameter).
Verify that the hoist system is enabled by selecting "CONFIGURATION TOOL", then select "CHASSIS ECM". Click the hoist enable tab to
enable/disable the hoist control settings.
Vital Information Management System (VIMS) Setup

Refer to Testing and Adjusting, KENR9941, "777G Off-Highway Truck VIMS, 3G, and Payload".
Refer to Special Instruction, REHS7412, "Software Installation Guide for Large Off-Highway Trucks" for information regarding the software update
and installation procedure for the 777G Off-Highway Trucks.
1. Connect a laptop computer to the Caterpillar "VIMS" service connector. The "VIMS" service connector is located to the left rear of the
operator seat (forward connector).
Note: When the key is in the ON position, VIMS will perform a four to six second self-tests. Disregard the "VIMS" self-test at this time.
20/3/22, 18:48 SIS 2.0
2. Use a laptop computer to open up "VIMSpc."
3. Enter "STATUS" to verify that the system is functioning correctly.
4. Verify that the "Product ID" matches the machine serial number.
5. Verify that all the settings are correct to the application.

Refer to System Operation, Testing and Adjusting, KENR9941, "777G Off-Highway Truck VIMS, 3G, and Payload" for system setup
guidelines.
Information Display Monitor Setup

Refer to Service Manual, KENR9938, "770G, 772G, and 777G Off-Highway Trucks and 773G and 775G Quarry Trucks Monitoring System" to
perform the setup for the Advisor Monitoring System.
Setup Scoreboard in the PLE Webpage

1. In Cat ET select "Utilities".

Cat ET screen

2. Browse "Network Devices" and click "Detect".

20/3/22, 18:48 SIS 2.0

Cat ET screen

3. Select "PL Elite Monitoring System" and click "Launch".

Cat ET screen

4. Select "Settings".
20/3/22, 18:48 SIS 2.0

Cat ET screen

5. Select "Serial Ports Configuration".

Selection screen

6. For "RS-232 #3", Change "Feature" to "Scoreboard" and select "Save Changes."
7. Reboot the Device.
Prepare to Start the Engine

1. Verify that all the fluid levels are at an acceptable level.
Note: Refer to Operation and Maintenance Manual, M0106394, "777G Off-Highway TruckS/N:RDR", "Capacities (Refill)" or Operation and
Maintenance Manual, M0106096, "777G Off-Highway Truck S/N:TNM", "Capacities (Refill)" for fluid capacities.
20/3/22, 18:48 SIS 2.0

View of the manual engine shutdown switch

2. Move the manual engine shutdown switch to the OFF position.

Note: The engine should be disabled allowing the engine to crank, but the engine will not start.
3. Chock the wheels.
4. Engage the parking brake.
5. Prime the pump drive housing and the hoist pump with the recommended oil or crank the engine. Crank the engine over two times for 15
seconds to fully prime and pre-lube all hydraulic and engine components.
NOTICE
Low brake pressure condition will cause the alert indicator to
flash. The VIMS message center should provide the following
instruction: DO NOT MOVE THE MACHINE
6. Verify that the fluids are at an acceptable level.

Note: Refer to Operation and Maintenance Manual, SEBU8095, "777G Off-Highway Truck S/N:RDR", "Capacities (Refill)" or Operation and
Maintenance Manual, SEBU8227, "777G Off-Highway Truck S/N:TNM", "Capacities (Refill)" for fluid capacities.
Engine Start-Up

View of the manual engine shutdown switch

1. Move the manual engine shutdown switch to the ON position to prepare to start the engine.
2. Start the engine. Refer to Operation and Maintenance Manual, M0106094, "777G Off-Highway Truck S/N:RDR", "Engine Starting" or
Operation and Maintenance Manual, M0106096, "777G Off-Highway Truck S/N:TNM", "Engine Starting" for additional instructions on starting
the engine.
Note: The Information screen may instruct the operator to shutdown the engine to resolve any issues. All issues must be resolved before
restarting the engine.
20/3/22, 18:48 SIS 2.0
3. Start the engine and run the engine for 30 seconds.
4. Turn the key to the OFF position.
6. Check for leaks.
7. As needed, check the following systems and fill the following systems:
Transmission and Torque Converter
Engine oil
Steering Circuit
Brake and Hoist
Engine coolant system
8. Move the manual engine shutdown switch to the ON position.
9. Start the engine and run the engine for 60 seconds.
10. With the engine running, turn the steering wheel from the center position three rotations to the left. Then turn the steering wheel back to the
center position.
11. With the engine running, turn the steering wheel from the center position three rotations to the right. Then turn the steering wheel back to the
center position.
Note: If improper steering function is noticed. Refer to Service Manual, KENR9935, "777G Off-Highway Truck Steering System
Troubleshooting".
12. Turn the key to the OFF position.
14. Check for leaks.
15. Move the manual engine shutdown switch to the ON position.
16. Restart the engine.
17. Operate the engine until normal operation temperatures are reached.
18. Check for leaks.
19. Adjust all the fluid levels, as required.
Install the Pad Assembly (Dump Body)

Note: This step cannot be done until commissioning of the engine and the enabling of the hoist has been initiated in Cat ET.
1. Raise and secure the dump body.
20/3/22, 18:48 SIS 2.0

(B) Pad assembly
(C) Plate
2. Remove two pad assemblies (b) and two plates (C) from the two shoes on the frame. Retain pad assemblies (B), plates (C), and the
hardware.
Note: Pad assemblies (B) and plates (C) are shipped attached to the two shoes.

(26) Shim
(27) Pad assembly
3. Stack one pad assembly (27) and one shim (26) at each pad mounting location on the frame rails.
20/3/22, 18:48 SIS 2.0

(26) Shim
(27) Pad assembly
4. Remove the safety devices and slowly lower the dump body until the body touches the pad assemblies and shims.
5. Add shims (26) one at a time, until there are no gaps between pad assemblies (27) and the dump body.
6. Raise the dump body. Secure the dump body.
20/3/22, 18:48 SIS 2.0

(20) Bolt
(21) Hard
washer
(26) Shim

(27) Pad assembly
7. Secure pad assemblies (27) and shims (26) to the dump body by using 20 bolts (20) and 20 hard washers (21). Tighten bolts (20) to a torque
of 100 ± 20 N·m (74 ± 15 lb ft).

(B) Pad assembly
(C) Plate

(26) Shim
8. Return two pad assemblies (B) and two plates (C) to the shoes.
9. Remove the safety devices and slowly lower the dump body until the pad assemblies contact the frame rails.
10. Add shims (26) one at a time, until there are no gaps between pad assemblies (b) and the dump body.
Note: Each shim (26) is 2 mm (0.079 inch) thick.
20/3/22, 18:48 SIS 2.0
11. Raise the dump body. Secure the dump body.
12. Add one more shim (26) beneath each pad assembly (B).
13. Secure pad assemblies (B) to the shoes with the hardware that was removed in Step 2. Tighten the bolts to a torque of 100 ± 20 N·m
(74 ± 15 lb ft).
14. Remove the safety devices and lower the body to make sure that all mounted pad assemblies have even contact with the frame. Add shims
(26) as needed.
Purge the Air from the Hydraulic Brake System

Refer to Service Manual, KENR9933, "777G Off-Highway Truck Hydraulic and Braking System Testing and Adjusting Brake System Air - Purge".

View of the service brake port and the parking brake port

1. Attach a gauge hose from the service brake tap to the parking brake tap. The service brake tap is indicated by a "S" and the parking brake
tap is indicated by a "P".
2. Chock the wheels, start the engine, and wait for the brake charge indicator on the control panel to turn off.
3. Pull the retarder lever. Leave the retarder lever in this position for 2 minutes and then release the retarder lever.
4. Depress the service brake pedal. Leave the service brake pedal depressed for 2 minutes and then release the service brake pedal.
5. Position the transmission control lever in the NEUTRAL position. Leave the transmission control lever in the NEUTRAL for 2 minutes.
6. Position the transmission control in the PARK position.
7. Repeat Step 1 through Step 6 for the other three wheels.
8. When finished, remove the gauge hose from the service brake tap and the parking brake tap.
9. Engage the various brakes and ensure that the low brake accumulator pressure warning does not come on.
10. If low brake accumulator pressure warning comes on, repeat this procedure until the low brake accumulator pressure warning does not come
on.
Variable Speed Fan Test (If Equipped)

Machine Model: Date:
Machine Serial Number: Machine Hours:
Engine Software Part Number: Software Release Date:
Table 104
Fan speed is controlled by modulating current to the cooling fan solenoid based on temperatures and brake status. If any of the temperatures are
unknown because the temperature sensors fail, the fan will run at full speed (minimum current).
20/3/22, 18:48 SIS 2.0
1. At start-up, with retarder released and the engine at low idle the desired fan speed is 200 rpm.
Control pressure starts at 69 kPa (10 psi) and slowly drops to 62.75 kPa (9.1 psi) as actual fan speed decreases to 200rpm. Control pressure
eventually stabilizes at 64 kPa (9.3 psi). Lube pressure quickly goes to 414 kPa (60 psi) and slowly stabilizes around 345 kPa (50 psi).
2. With the retarder engaged and the engine at high idle the desired fan speed is 1088 rpm. Control pressure starts at 117 kPa (17 psi) and
slowly drops and stabilizes around 110 kPa (16 psi) as actual fan speed slowly increases to 1088 rpm. Lube pressure continuously stays at
about 345 kPa (50 psi).
3. At high idle, with the retarder released, desired fan speed drops to 200 rpm. Control pressure drops to around 28 kPa (4 psi) and stabilizes at
24 kPa (3.5 psi) as actual fan speed slowly decreases to 200 rpm. Lube pressure continuously stays at about 345 kPa (50 psi).
Observe the desired and actual fans speeds. The engine fan bypass percent (current to fan control solenoid) will change gradually until the actual
engine fan speed becomes close to the desired engine fan speed. The fan bypass percent changes gradually so that there are no abrupt changes
in the fan speed.
Test Desired Fan Speed Actual Fan Speed Control Pressure Fan Bypass %
Retarder OFF at Low Idle 200 rpm
Retarder ON at Low Idle 1088 rpm
Retarder ON at High Idle 1088 rpm
Table 105
Use ET and observe the variable speed fan status. Add additional parameters as desired.

ET screen with retarder OFF at low idle
20/3/22, 18:48 SIS 2.0

ET screen with retarder ON at high idle
Transmission Clutch Engagement Pressure Calibration (Using Caterpillar Electronic

Technician) and Calibrate the Transmission
Use the ET to calibrate the transmission clutch pressures. The procedures are performed to compensate for variations in the transmission
components.
Note: The torque converter lockup clutch calibration procedure is performed during the calibration procedure for the seven transmission clutches.
When it is necessary to work under the machine with the body

(bed) raised, attach the body (bed) retaining cables to the body
retaining pins. Install the body retaining pins through the ends
of the retaining cables. Always use both retaining cables.
Failure to properly secure the body (bed) may result in personal

injury or death.
Incorrect transmission clutch pressure adversely affects the life of the transmission. In this process, the service technician adjusts the electrical
current sent to the transmission solenoid valve to obtain the specified pressure for the transmission clutch. The transmission main relief valve must
be set to the specification.
Refer to Testing and Adjusting, KENR9927, "Transmission Pressures - Test and Adjust" for information about setting the relief valve.
20/3/22, 18:48 SIS 2.0
Calibration is required in the following situations:
Before dealer delivery to the customer.
After replacing the transmission ECM
After replacing or servicing any of the ECPC valves or the main relief valve
After replacing or rebuilding the transmission or torque converter
After replacing the transmission control charge pump
Degradation in shift quality
The transmission ECM must detect the following conditions before starting the calibration procedure:
1. The parking brakes are ENGAGED.
2. The service brakes are RELEASED.
3. The engine speed is at low idle (approximately 700 rpm).
4. The gear selector is in the PARK position.
5. The transmission oil temperature is above 70 °C (158 °F) and below 85 °C (185 °F).
Note: After the test begins, temperature must stay at 65° C (149° F) to 105° C (221° F)
6. The transmission output speed (TOS) is 0 rpm.
7. There are no active clutch solenoid diagnostic codes.
8. There are no active transmission or torque converter speed sensor diagnostic codes.
9. There are no active transmission or torque converter temperature sensor diagnostic codes.
If any of these conditions are not met during the calibration, the procedure is aborted immediately.
20/3/22, 18:48 SIS 2.0
Rear view of torque convertor

(10) Temperature sensor (torque convertor outlet)
(11) Liquid level sensor (transmission and torque convertor oil)
(29) Relief valve (torque convertor inlet)
(31) Modulating valve (torque convertor lockup clutch)
(34) Pressure tap for the torque convertor inlet pressure
(36) Pressure tap for the torque convertor outlet pressure

Top view of the transmission
(1) Number 1 clutch modulating valve
(8) Main relief valve
(9) Lubrication relief valve (transmission)
The sustain pressure calibration requires pressure gauges to measure the actual pressure in the clutch. The Data View diagnostic tool should be
used when possible. Eight pressure gauges should be installed before the calibration procedure begins. The transmission ECPC valve pressure
taps are under the cover of the transmission and the lockup clutch (LUC) ECPC is on the torque converter case.
20/3/22, 18:48 SIS 2.0

ET Calibration Screen
Use the Cat ET to calibrate the transmission clutch pressures. Select the “CALIBRATION” option from the Service Menu in Cat ET. Follow the
instructions that are provided. Use the Cat ET to increase the individual pressure of the clutch. Use the Cat ET to decrease the individual pressure
of the clutch. The pressure changes can be viewed on the pressure gauge.
Reference: To calibrate the transmission. Refer to Service Manual, M0106099, "Testing and Adjusting Transmission Fill".
1. Connect the communication cable between a laptop computer, equipped with a current version of Cat ET software, and the service connector
of the truck.
2. Open ET and select "Chassis ECM". On the top tool bar, click the tab labeled "Service". At the bottom of the drop-down box, click
"Calibrations" and select "Transmission Fill Calibration". A "Setup Conditions" box will appear. When conditions are met, click "Next".
3. Follow the instructions provided. Approximately 15 minutes are required to complete the fill calibration.
Note: During calibration, engine speed will be set automatically. Calibration will abort and error codes will appear on the ET display screen if
any of the listed calibration conditions are not met.
20/3/22, 18:48 SIS 2.0
4. When finished, a dialog box in ET will show whether the calibration was successful or unsuccessful.
Power Train Test

777G Off-Highway Truck Power Train Test
Machine Model ________________________________________ Date: _________________________________
Machine Serial No. _____________________________________ Machine Hours: _________________________
Transmission Serial No. _________________________________ Transmission Hours: _____________________
Converter Serial No. ____________________________________ Converter Hours: ________________________
Chassis ECM Part No. __________________________________ Chassis ECM Serial No. __________________
Software Part No. ______________________________________ Software Release Date: __________________
Visual Checks
Oil Brand and Viscosity: _________________________________ Oil Level: _____________________________
Suction Screen Debris: __________________________________ Oil Leaks: ____________________________
Oil Filter Examination: ___________________________________ Air/Water In Oil: ________________________
Table 106
NOTICE
The wheels must be chocked during all Power Train Tests
Transmission Pump, Lube, and Converter Pressure Tests

Transmission Pump, Lube, and Converter Pressure Tests
Specifications Actual
Description Low High
Low Idle High Idle
Idle Idle
Minimum
Maximum 2895 ± 137 kPa
Transmission Pump Pressure (Tap Number 8) 2585 ± 172 kPa
(420 ± 20 psi)
(375 ± 25 psi)
7 kPa (1.0 psi) to
Lube Pressure (RH side of Transmission) 170 kPa (25psi) to 275 kPa (40 psi)
55 kPa (8.0 psi)
Torque Converter Inlet Pressure at Low Idle and High Idle (top Maximum at High Idle with Cold Oil
103 kPa (15 psi)
valve on LH side of Torque Converter) 955 ± 95 kPa (138 ± 15 psi)
Torque Converter Outlet Pressure at Stall RPM (lower tap on
No Specification 380 kPa (55 psi) to 520 kPa (75 psi)
LH side of Torque Converter)
Torque Converter Stall RPM 1525 to 1655 rpm
Transmission Oil Temperature (during tests) 69° C (156 ° F) to 100° C (212 ° F)
Torque Converter Oil Temperature (during tests) 80° C (176 ° F) to 121° C (250 ° F)
Table 107
Note: Transmission taps are numbered 1,2,3,4,5,6,7,8 from front to rear.
Note: Use information display "Transmission Test" to run "Converter Outlet Pressure" and "Stall RPM Test."
Transmission Pump Pressure (Main relief)
20/3/22, 18:48 SIS 2.0
1. Use two 6V-4143 Quick Connect Couplers and 177-7862 Hose As to connect 8T-0855 Pressure Gauge to the nipple at pressure tap number
8.
2. Start the engine. Run the engine at low idle rpm while the transmission is in the PARK position. The pressure on the gauge should be a
minimum of 2280 kPa (330 psi) while the lockup clutch solenoid is deactivated.
3. Run the engine at high idle rpm while the transmission is in the PARK position. The maximum pressure on the gauge should be 2830 kPa
(410 psi) while the lockup clutch is deactivated.
4. When this test is complete, stop the engine and remove the test equipment.
Lube Pressure Test Procedure

View of lube pressure tap

1. Connect tooling to pressure tap.
2. Ensure that the transmission control is in the PARK position and start the engine.
3. Increase the engine speed to high idle. Check the pressure and record.
4. When this test is complete, stop the engine and remove the test equipment.
Torque Converter Inlet Pressure - Test Procedure
20/3/22, 18:48 SIS 2.0
1. Use two 6V-4143 Quick Connect Coupler and 177-7862 Hose As to connect 8T-0855 Pressure Gauge to the nipple at pressure tap number 3.
2. Start the engine while the parking brakes are engaged.
3. Run the engine at low idle rpm while the transmission is in the NEUTRAL position. The pressure on the gauge should be a minimum of
103 kPa (15 psi) while the lockup clutch solenoid is deactivated.
4. Run the engine at high idle rpm while the transmission is in the NEUTRAL position. The maximum pressure on the gauge should be 955 kPa
(138 psi) while the lockup clutch is deactivated.
5. When the test is complete, stop the engine and remove the test equipment.
For additional information on Testing and Adjusting the torque converter and transmission pressures refer to Service Manual, KENR9927, "777G
Off-Highway Truck Power Train - Testing and Adjusting".
Transmission Fill Calibration Procedure

ET conducts this test automatically.
Note: Remove all test equipment from the transmission before performing transmission fill calibration.
1. On the ET toolbar, click "Service - Calibration - Transmission Fill Calibration".
2. When set-up conditions are met, choose "Next" to continue.
20/3/22, 18:48 SIS 2.0
3. Engine speed will increase. Each clutch will be selected for calibration. Another clutch will be engaged to provide a load to the clutch being
calibrated. The clutch being calibrated will engage and disengage until the ECM is satisfied that the clutch Fill calibration is complete.
The calibration will continue until all the clutches have been calibrated or until the user aborts the procedure by selecting "Cancel" or any of
the required conditions are changed or out of range. An example would be if the transmission oil temperature drops below the minimum limit.
Clutch Fill Calibration Completed Successfully: Yes NO
Table 108
777G Off-Highway Truck Brake System Tests
NOTICE
The wheels must be chocked for all brake tests

Using the ET screens, ECM summary, logged diagnostic codes, and the configuration screen, fill in the information requested.
777G Off-Highway Truck Brake System Tests

Machine Model: _________________________ Date: ______________________
Machine Serial Number: ___________________ Machine Hours: ______________
ECM Part Number: _______________________ ECM Serial Number: _____________
Equipment ID: ___________________________ Brake ECM Software Part Number and Date: _______________
Table 109
Brake Pump Test

Brake Pump Test
Test Specification Actual
Brake Oil Temperature (during tests) 71° C (160° F) to 94° C (201° F)
5512 kPa (800 psi) at 70° C
Parking Brake Accumulator (Front) Nitrogen Pressure
(158° F)
5512 kPa (800 psi) at 70° C
Service Brake Accumulator (Rear) Nitrogen Pressure
(158° F)
18890 kPa (2740 psi) to 20270 kPa
Service Brake Cut-Out Pressure at LI (tap below brake accumulators)
(2940 psi)
20/3/22, 18:48 SIS 2.0
15410 kPa (2235 psi) to 16790 kPa

Service Brake Cut-In Pressure at LI (tap below brake accumulators)
(2435 psi)
Pump Standby Pressure at LI (tap before brake filter) Less than 1375 kPa (200 psi)
1.
____________________
2.
Cycle time from Cut-In to Cut-Out at Low Idle, Service Brake Released, and ____________________
Less than 5 seconds
Parking Brake Engaged 3.

____________________
Average:
_______________
1.
_____________________
2.
Cycle time from Cut-Out to Cut-In at Low Idle, Service Brake Released, and _____________________
15 to 120 seconds
Parking Brake Engaged 3.
_____________________
Average:
_______________
Table 110
Accumulator Pressure Bleed-Down

Accumulator Pressure Bleed-Down
1. ____________________
2. ____________________
Accumulator Pressure Bleed-Down Time after Engine

Less than 30 seconds 3. ____________________
Shutdown with Key Switch
Average:
_______________
start
:______________________
psi
after 30 seconds:
____________ psi
after 1 minute:
_______________ psi
after 1.5 minutes:
Accumulator Pressure Bleed-Down Time after Engine No Specification Previous Tests Approximately
_____________ psi
Shutdown with Ground Level Shutdown Switch 10340 kPa (1500 psi) after 5 minutes
after 2 minutes:
______________ psi
after 3 minutes:
______________ psi
after 4 minutes:
______________ psi
after 5 minutes:
______________ psi
Table 111
Service Brake Application Test

Note: Conditions: Engine at low idle, transmission control lever in the NEUTRAL position, and apply the service brake.
Service Brake Application Test

Left Wheel:
5380 kPa (780 psi) to 6760 kPa ____________________
Rear Brake Pressure (pressure taps at wheels)
(980 psi) Right Wheel:

___________________
Left Wheel:
Rear Brake Pressure - Brakes Released (pressure taps at ____________________
less than 140 kPa (20 psi)
wheels) Right Wheel:

___________________
Left Wheel:
5380 kPa (780 psi) to 6760 kPa ____________________
Front Brake Pressure (pressure taps at wheels)

___________________
20/3/22, 18:48 SIS 2.0
Left Wheel:
Front Brake Pressure - Brakes Released (pressure tap at ____________________

___________________
Table 112
Manual Retarder Brake Application Test

Note: Conditions: Engine at low idle, transmission control lever in the NEUTRAL position, apply the retarder lever. The retarder indicator should be
ON.
Manual Retarder Brake Application Test

Left Wheel:
4275 kPa (620 psi) to 5655 kPa ____________________
Rear Brake Pressure (pressure taps at wheels)

___________________
Left Wheel:
Rear Brake Pressure - Brakes Released (pressure taps at ____________________

___________________
Left Wheel:
4275 kPa (620 psi) to 5655 kPa ____________________
Front Brake Pressure (pressure taps at wheels)

___________________
Left Wheel:
Front Brake Pressure - Brakes Released (pressure tap at ____________________

___________________
Table 113
Secondary/Parking Brake Application Test

1. With the engine running at low idle, the secondary brake pedal RELEASED, and the transmission control lever in the PARK position the
parking brake pressure will be the following:
Specification
Less than 140 kPa (20 psi)
Table 114
Note: The parking brake indicator should be ON.
2. With the secondary brake pedal RELEASED. Apply the service brakes and move the transmission control lever into the NEUTRAL position.
The parking brake pressure will be the following:
Specification
4340 kPa (630 psi) to 5720 kPa (830 psi)
Table 115
Note: The parking brake indicator should be OFF.
3. With the transmission control lever in the NEUTRAL position. Depress the secondary pedal to "FULL" travel. The parking brake pressure will
be the following:
Specification
Table 116
4. With the transmission lever in the NEUTRAL position. Release the secondary brake pedal. The parking brake pressure will be the following:
Specification
4340 kPa (630 psi) to 5720 kPa (830 psi)
Table 117
20/3/22, 18:48 SIS 2.0
5. Using the ground level shutoff switch, stop the engine. The parking brake pressure will remain above the following pressure for at least 60
seconds.
Specification
Table 118
6. Depress the secondary brake pedal to "FULL" travel. The parking brake pressure will be the following:
Specification
Table 119
Auto Retarder Control (ARC) Functional Test

1. Record the brake configuration desired engine retard speed 1750 to 2000 rpm: Programmed rpm __________________.
2. Connect a 0 to 6895 kPa (1000 psi) gauge to a slack adjuster.
3. Run the engine at low idle.
4. Turn ON the ARC On/Off switch located in the cab.
5. Using ET, choose "Brake ECM".
6. On the ET screen toolbar, select "Diagnostics - Diagnostics Tests - Auto Retard Test".
7. Click the start button and the auto retarder test will be turned ON.
8. The ARC control solenoid current will sweep from 0 to 48 percent.
9. Observe the front and rear slack adjuster pressure increase and decrease accordingly.
Auto Retarder Control (ARC) Functional Test

Rear Brake Pressure with 48 percent ARC Control (pressure tap at rear slack adjuster) Approximately 1965 kPa (285 psi)
Front Brake Pressure with 48 percent ARC Control (pressure tap at front slack adjuster) 1965 kPa (285 psi)
Table 120
20/3/22, 18:48 SIS 2.0
Note: Pressure starts to increase at 30 percent ARC Control.
Towing Pump Functional Test

1. Start the engine and put the transmission control lever in the NEUTRAL position.
2. Shut down the engine and allow at least 30 seconds for the accumulators to reduce pressure.
3. Turn the keyswitch to the ON position.
4. Move the manual valve toggle handle on the tow valve to the TOWING position. Check that the park brake pressure drops to within 140
(−5 psi) and that the park brake is engaged.
5. Hold the secondary steering pump switch and verify that the park brake pressure is greater than or equal to 4700 kPa (680 psi) and that the
parking brake is dis-engaged.
6. Put the transmission control lever in the PARK position. Move the manual valve toggle handle on the tow valve to the OPERATION position.
7. Start the engine and put the transmission control lever in the NEUTRAL position.
8. At low idle, check that the park brake pressure is greater than or equal to 4700 kPa (680 psi) and that the park brake is dis-engaged.
Towing Pump Functional Test

Park Brake Pressure in TOWING position 140 kPa (20 psi)
Park Brake Pressure with Secondary Steering Pump engaged 4700 kPa (680 psi)
Park Brake Pressure at Low Idle 4700 kPa (680 psi)
Table 121
Brake Holding Capacity Test

1. Start the engine and let the brake accumulators charge to operating pressure (approximately 30 seconds).
2. Apply the desired brake (engage and hold).
3. Move the transmission control lever to the FIRST SPEED FORWARD position. Placing the transmission control lever in gear will release the
parking brake.
4. Gradually increase the engine speed to 1200 rpm. The machine should not move.
5. Engine rpm at the beginning of machine movement, with the brakes engaged, should be compared against the engine rpm the machine was
able to hold on a prior test, as an indication of system deterioration.
6. Reduce the engine speed to low idle and move the transmission control lever into the PARK position. The parking brake will engage.
Brake Holding Capacity Test

Service Brake: _______________________________________ rpm
Secondary Brake: ____________________________________ rpm
Retarder Brake: ______________________________________ rpm
Table 122
Note: Truck must not move below 1200 rpm.
Brake Cooling Test

1. Connect a 20685 kPa (3000 psi) gauge to the hoist pump and 345 kPa (50 psi) gauge to the brake cooling lines at the front and rear wheels.
2. Record the "Hoist System Configuration" hoist lower valve adjustment status in ET (-5 to 5) “0” is default.
Brake Cooling Test

Brake Oil Temperature 71° C (160° F) to 94° C (201° F)
Brake Cooling Oil Pressure (hoist output in SNUB)
(Tap at Hoist Pump)
Low Idle: _______________________
Relief Valve Setting: 585 ± 15 kPa (85 ± 2 psi)

Maximum 1725 kPa (250
psi) High Idle: _______________________
Table 123
20/3/22, 18:48 SIS 2.0
Brake Cooling Oil Pressure at Rear Wheels (Hoist Output in SNUB)

Test Inlet Outlet
Low Idle: _____________
Low Idle: ____________
Left Rear Wheel

High Idle: _____________ High Idle: ____________
Low Idle: _____________
Low Idle: ____________
Right Rear Wheel

High Idle: _____________ High Idle: ____________
Table 124
Primary Steering System Hydraulic - Test

Note: Test the primary steering system hydraulic system pressures prior to the initial field operation of the machine.
Refer to Testing and Adjusting, KENR9935, "Piston Pump (Steering) Pressure - Test and Adjust".
Steering System Pressure Testing Procedure

Locate the steering system pressure port. The steering control manifold is mounted on right frame behind the right front suspension cylinder. The
steering system pressure test port is located to one of the larger tubes connected to the front of the steering control manifold. Attach pressure test
equipment 0 to 41369 kPa (6000 psi) to the steering system pressure test port.
Note: Low Idle is 700 rpm +/- 30 rpm and High Idle is 1935 rpm +/- 30 rpm.
Primary Steering Pressure

1. Start the engine.
2. Operate the engine at High Idle.
3. Turn the steering wheel to the right or left until the steering cylinder stop is reached. Hold the steering wheel in this position for 3 seconds and
then release the steering wheel. Continue this step until the oil in the steering system reaches at least 38° C (100° F) to 93° C (200° F).
Note: The pressure gauge needs to withstand the maximum pressure from the steering piston pump.
4. Operate the engine at High Idle. Turn the wheels to the right or left until the steering cylinder stop is reached. Check the pressure while the
turning the steering wheel against the stop. The pressure setting of the high-pressure cutoff valve at zero flow is 20685 kPa (3000 psi) to
22065 kPa (3200 psi).
Standby Steering Pressure Test

1. Start the engine.
2. Turn the steering wheel to the right or left until the steering cylinder stop is reached. Hold the steering wheel in this position for 3 seconds and
then release the steering wheel. Continue this step until the oil in the steering system reaches at least 38° C (100° F) to 93° C (200° F).
Note: The steering system pressure will drop to low-pressure standby when the steering wheel is not turned.
3. Check the standby pressure at the pressure tap for the steering system. The pressure tap is part of the steering control manifold. The
steering control manifold is mounted on the outside of the right frame behind the suspension cylinder.
Note: The pressure gauge needs to withstand the maximum pressure from the steering piston pump.
4. Operate the engine at High Idle. Check the pressure without turning the steering wheel. The pressure setting of the flow compensator valve is
2000 kPa (290 psi) to 3620 kPa (525 psi). Do not turn the steering wheel.
5. If pressure needs adjusted, stop the engine.
Primary Steering System Hydraulic Test

Steering Oil Temperature (during tests) 38° C (100° F) to 93° C (200° F)
1._____________________
Cycle time at High Idle

2._____________________
6 to 7 Seconds
From left to right and right to left on hard surface
with all brakes released 3._____________________
Average:_______________
Left:___________________
Primary Steering at Low Idle (steer hard against stops) 21200 to 700 kPa (3075 to 102 psi)
Right:___________________
Low-Pressure Standby at Low Idle Max 3620 kPa (525 psi)
Table 125
Secondary Steering - Test

20/3/22, 18:48 SIS 2.0
NOTICE
Personal injury or death can occur if steering is lost completely
during operation. Do not continue to operate the machine using
the secondary steering. If the secondary steering activates
during operation, immediately park the machine in a safe
location. Inspect the machine and correct the condition which
caused the use of the secondary steering.
NOTICE
Extended operation of the secondary steering motor could
damage the motor and result in loss of emergency steering
capability, which could cause injury or death. The secondary
steering system should not be used for towing the machine or
for other service procedures lasting longer than 5 minutes. The
motor should be allowed to cool to ambient temperatures before
reuse.
NOTICE
The secondary steering switch should always be in the AUTO
position during normal operation, ensuring that secondary
steering capability is immediately available if the primary
steering system fails.
NOTICE
To minimize battery drain, leave the switch in the MANUAL
position long enough to test the secondary steering. Return the
switch to the AUTO position immediately after testing.

l
Typical view of the brake release/secondary steering switch on the overhead switch panel
(1) Brake secondary switch
Note: Brake release/ Secondary steering switch (1) is on the overhead switch panel.
1. With engine running and machine lockout NOT active, park the machine on a level hard surface. Chock the rear wheels.
2. Place the hoist control in the HOLD position.
3. Place the transmission control in the NEUTRAL position. Confirm that the park brake indicator light on the dash is not illuminated(park brake
is released).
4. Stop the engine with the ground level switch on the front bumper.
20/3/22, 18:48 SIS 2.0
Note: After the engine is stopped, there is limited time to perform Step 5 and Step 6 before the parking brake engages due to the brake
accumulators bleeding down.

View of secondary steering pump
5. Push the top of brake release/secondary steering switch (1) and hold the switch to manually activate the brake release and secondary
steering pump.
6. Turn the steering wheel to one side. Confirm that the wheels turn.
7. Turn the steering wheel to one side. Confirm that the wheels turn.
8. Release the switch to return the switch to the AUTO position.
Note: The secondary steering response should be similar to the primary steering response. If the secondary steering does not function properly,
consult your Cat dealer
Traction Control System (TCS) - Test

Refer to Operation and Maintenance Manual, M0106094, "Traction Control System (TCS) - Test"
This test is used to verify the operation of the traction control system (TCS). The machine must be stationary with the parking brake engaged.
Service personnel should monitor the hydraulic brake oil pressure for the correct operation.
1. Chock the tires and engage the park brakes.
2. Install two 0 to 6895 kPa (1000 psi) pressure gauges on the rear service brake test ports (1 gauge per side of the truck).
3. Simultaneously release the retarder lever and the service brake pedal, and press the TCS test switch.
4. Watch for an increase in the right brake pressure and a decrease in the left brake pressure. After a short pause, watch for an increase in the
right brake pressure and a decrease in the left brake pressure. The test will repeat while the TCS test is in the ENGAGED position.
Note: The test of the TCS will terminate if a fault is detected during the test. Follow the instructions that are displayed on the Cat ET screen to
complete this procedure.
Alternate Traction Control System (TCS) - Test

1. Connect two 0 to 6895 kPa (1000 psi) pressure gauges to the service brake pressure taps on the rear axle.
2. Using ET, select the Chassis ECM.
20/3/22, 18:48 SIS 2.0
3. Select the "Traction Control Status Group".
4. Run the engine at Low Idle.
5. Run the test with the wheels turned to the right and repeat the test with the wheels turned to the left. Run the test in "FIRST GEAR" with the
TCS test switch depressed. The brakes will engage and release intermittently.
Duo-Cone Break- In Procedure

The break-in procedure must be performed as a continuous section. The time that is required to carry out the break-in procedure is 25 minutes.
This procedure should be performed when the wheels turn for the first time. This procedure may also be done after you purge the air from the
brake system as long as the wheels are not turned before the air is purged from the brake system. Follow the break-in procedure in the sequence
below:
Note: If test is performed on stand instead of tires, do not exceed SECOND GEAR.
1. Operate the machine at low idle rpm in FIRST GEAR for 5 minutes.
2. Operate the machine at high idle rpm in FIRST GEAR for 5 minutes.
3. Operate the machine at high idle rpm in SECOND GEAR for 5 minutes.
4. Operate the machine at high idle rpm in THIRD GEAR for 5 minutes.
5. Operate the machine at high idle rpm in FOURTH GEAR for 5 minutes.
Adjustment for Hoist Lower Valve

The command for the hoist lower valve is adjustable. An adjustable command can compensate for the differences between 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 pressure causes the
body to come down harder. A negative adjustment factor will decrease the lower valve command. This pressure 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 for 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. Too much oil 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.
20/3/22, 18:48 SIS 2.0
4. Enter the configure parameter screen through the pull-down 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 pressure causes too much oil to be diverted to the
hoist valve. Too much oil 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. Lower 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.
Body Down Snub Function

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. When the body is too close to the rail, the ECM will command the hoist valve
to go into snub mode.
Adjust the Position Sensor for the Dump Body (Magnetic Switch)
1. Raise the dump body and install the body retaining pins to secure the dump body in the UP position.
20/3/22, 18:48 SIS 2.0

View of the position sensor for the dump body
(1) Body up switch

(2) Magnet

(3) Plate

View of the position sensor for the dump body
(A) 10 mm (0.40 inch)

(1) Body up switch

(2) Magnet
2. Adjust plate (3) so the gap between switch (1) and magnet (2) is 10 mm (0.40 inch).
3. Remove the body retaining pins and lower the dump body into the DOWN position.
4. To adjust the snub position of the dump body to approximately 200 mm (8 inch) to 300 mm (12 inch) between the front of the body pads and
the frame rail, cycle the dump body and observe the SNUB position. If the dump body reaches the SNUB position too early, move magnet (2)
upward. If the dump body reaches the SNUB position too late, move magnet (2) downward.
5. Repeat Step 4 until the desired SNUB position of the dump body is obtained.
Hoist System Test

777G Truck Hoist Test
Machine Model: Date:
Machine Serial Number: Machine Hours:
Hoist Valve Part/Serial Number: Hoist LOWER Adjustment:
Setting:
Chassis ECM Flash File (Software Group Part Number) Date:
Visual Inspection
Oil Level: Oil Viscosity:
Air/Water in Oil: Oil Filter Examination:
Table 126
20/3/22, 18:48 SIS 2.0
The hoist system can be enabled or disabled in the Chassis ECM using ET. All trucks shipped from the factory without bodies installed are set at
the Hoist Disabled Status. The Hoist Disabled Status is a test mode only and will prevent the hoist cylinders from accidentally being moved. After
the body is installed, enable the Hoist Status for the hoist system to function properly.
777G Truck Hoist Test

Hoist Oil Temperature (Brake Cooling Oil during test) 71° C (160° F) to 94° C (201° F)
PILOT PRESSURE at Low Idle (taps on hoist valve) (from towing valve) (fluctuates with brake
3450 kPa (500 psi)
charge pressure)
18475 kPa (2680 psi) to 19960 kPa
RAISE PRESSURE at High Idle (tap on hoist pump)
(2895 psi)
FLOAT PRESSURE at High Idle (tap on hoist pump) body switch in the RAISED position 1720 kPa (250 psi)
LOWER PRESSURE at High Idle (tap on hoist pump) body switch in the RAISED position 3450 ± 350 kPa (500 ± 50 psi)
Table 127
Relief Valve (Hoist Raise, Hoist Lower) - Test and Adjust

Required Tools
Part Number Description Required Amount

6V-3079 Pressure Hose Assembly 1
6V-4143 Coupler Assembly 2
198-4240 Digital Pressure Indicator 1
Table 128
Note: Make sure that the filters and the screens are clean before you test any pressures. Make sure that the oil is at operating temperature before
you perform this test.
Note: Before you perform any tests, visually inspect the entire hydraulic system for oil leaks and for damaged components.
20/3/22, 18:48 SIS 2.0
Personal injury or death can result from sudden machine

movement.
Sudden movement of the machine or the release of oil under

pressure can cause injury to persons on or near the machine. To
prevent possible injury before testing and adjusting the
hydraulic system, perform the procedure in the Testing and
Adjusting, "General Information" section.
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, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.
Dispose of all fluids according to local regulations and

mandates.

(1) High-pressure relief valve
(2) Low-pressure relief valve

(3) Hoist dual stage relief valve
(4) Hoist control valve
Hoist dual stage relief valve (3) is part of the hoist control valve (4). The relief pressure for the RAISE position is controlled by high-pressure relief
valve (1). The relief pressure for the LOWER position is controlled by low-pressure relief valve (2).
Relief Valve Test (High Pressure)
20/3/22, 18:48 SIS 2.0

View of the tube on the rear support assembly
(5) Pressure tap for high-pressure oil
1. Lower the dump body. Stop the engine.
2. Connect a hose assembly with an 8T-0860 Pressure Gauge ( 0 to 40000 kPa (0 to 5800 psi)) to pressure taps (5).
3. Start the engine. Operate the dump body repeatedly until the temperature of the hydraulic oil is above 38°C (100°F).
4. Run the engine at high idle and move the hoist control to the RAISE position.
5. After the dump body is fully raised, look at the gauge. Hold the hoist control in the RAISE position. The high-pressure gauge reading is the
relief valve pressure setting of high-pressure relief valve (1). The correct pressure setting for the 777G machines is 18950 ± 520 kPa
(2750 ± 75 psi).


(6) Nut

(7) Retainer
6. Loosen nut (6). Turn retainer (7) to adjust the setting of high-pressure relief valve (1).
7. When high-pressure relief valve (1) is correctly set, tighten nut (6).
20/3/22, 18:48 SIS 2.0
Relief Valve Test (Low Pressure)

View of the tube on the rear support assembly
(8) Pressure tap for low-pressure oil
1. Lower the dump body. Stop the engine.
2. Connect a hose assembly with an 8T-0856 Pressure Gauge ( 0 to 6000 kPa (0 to 870 psi)) to pressure tap (8).
3. Start the engine. Operate the dump body repeatedly until the temperature of the hydraulic oil is above 38°C (100°F).
4. Lower the dump body onto the truck frame.

Note: The body down or up switch must be in the RAISE position before low-pressure relief valve (2) can be measured. If the body down or
up switch is in the LOWER position, the Power Train Electronic Control Module will keep the hoist control valve in the SNUB position. Low-
pressure relief valve (2) cannot be measured in this condition.
5. Remove the magnet from the body. When the magnet is removed and the body is in the down position, the indicator light on the dash turns
on.
6. Run the engine at high idle and move the hoist control to the LOWER position.
7. Look at the gauge and hold the hoist control in the LOWER position. The low-pressure gauge reading is the relief valve pressure setting of
low-pressure relief valve (2). The correct pressure setting is 3450 ± 350 kPa (500 ± 50 psi).
20/3/22, 18:48 SIS 2.0


(9) Retainer

(10) Nut
8. Loosen nut (10). Turn retainer (9) to adjust the setting of low-pressure relief valve (2).
9. When low-pressure relief valve (2) is correctly set, tighten nut (10).
Auto-lube System Check - type 1 (If Equipped)

View of the left-hand side grease injectors


View of the right-hand side grease injectors


View of the rear grease injectors

Note: Verify that all locations to be greased are receiving the correct supply of grease to the joint or component.
Adjust the grease injectors, as required. Refer to Service Manual, KENR9937, "Off-Highway Truck Automatic Lubrication".
1. Turn the key to the ON position. Do not start the truck.
2. Using Cat ET, select "CHASSIS ECM" and then select "CONFIGURATION".
20/3/22, 18:48 SIS 2.0
3. Click on the "AUTO LUBE" setup section.
4. Verify auto lube interval. If necessary, change the settings to achieve the correct interval.
CAT Integrated Object Detection System for Off-Highway Trucks (If Equipped)
Refer to Service Manual, KENR8668, "CAT Integrated Object Detection System (CIODS)" for system setup information and calibration.
Payload System Calibration (If Equipped)

The following information describes the calibration for the truck payload.
Note: The TPMS will not operate until a successful payload calibration has been completed.
Note: For security, this service program code will only function while Cat ET is connected or the service mode in the Advisor is enabled.
Calibrate the Payload System

1. Ensure that the truck body is empty. Carryback weight of the material that is stuck in the body can affect the payload measurements.
2. Operate the empty truck to a minimum ground speed of 4 MPH on hard level ground.
3. Move the transmission control to the NEUTRAL position and allow the truck to coast to a complete stop. DO NOT use the service brakes or
the retarder to stop the truck.
4. After the truck has stopped, calibrate the payload system. The information display will show a "Calibration Complete" message when the
calibration is successful.
Refer to Service Manual, M0109037, "777G OFF-Highway Truck VIMS 3G and Payload" for system setup and calibration procedures.
Ton Mile Per Hour (TMPH)/Tonne Kilometer Per Hour (TKPH) Configuration
1. Verify that TPMS is applicable (MSO), installed, and calibrated.
2. Configure the TMPH/TKPH. Refer to Service Manual, KENR8744, "773G, 775G, 777G Off-Highway Trucks VIMS ™Truck Payload
Measurement System".
Transmission and Torque Converter Filters

The transmission system uses 337-5270 Oil Filter Elements, which have to be replaced by a service filter element after 8 hours of
machine operation. Failure to change to a service element may result in clogging of the filter.
Replace the 337-5270 Oil Filter Element with a 337-5270 Oil Filter Element.
Note: The 337-5270 Oil Filter Element is for power train use only and not approved for hydraulic applications.
Contamination is one of the major causes of transmission control system failure. Some power train oil systems were cleaned with fine clean out
filters, which frequently caused oil to bypass the filter. The use of clean out filters in power train oil systems is no longer recommended. A new line
of advanced efficiencyCaterpillartransmission filters have been introduced for use in power train application.
20/3/22, 18:48 SIS 2.0
Replacing the Cleanout Filters

Cleanout filters are installed on some of the 777G hydraulic systems at the factory. Replace all cleanout filters with the standard filters that have
been provided with the truck after the truck has been continuously operated for 8 hours. Failureto replace clean out filters can cause a plugged filter
condition causing contaminated oil to enter the transmission, torque converter, steering, hoist, or brake hydraulic systems.
Use the following chart for replacing the filters.
Hydraulic System Qty Cleanout Filter Standard Filter

Brake accumulator charge 1 293-3645 293-3645
Steering case drain 1 126-1813 (5µ max.) 4I-3948 (25µ max.)
Steering 1 144-0832 (5µ max.) 4T-6788 (27µ max.)
Torque Converter 1 337-5270 337-5270
Transmission 1 343-4465 337-5270
Table 129
Cab Instrumentation and Functional Checks

Operators Seat
Check for Seat Adjustability Check if OK
Check the range of the light to heavy dampening for the seat
Full range of the back reclining positions
Full range of the seat suspension travel
Table 130
Operators Seat Belt

Check Seat Belt Latch and Seat Belt Adjustability Check if OK
Adjust the length of the seat belt
Fasten the seat belt catch into the buckle
The seat belt must not be able to slip after adjusting
The seat belt catch should unlatch from the buckle when required
Table 131
Engine Start
Check the Ignition Switch, Horn, and Engine Start Check if OK
Turn the ignition key to the ON position(1)
Sound the horn for all clear
Turn the key to the START position to activate the starting motor.
After the diesel engine starts, release the key. The key should return to the ON position
Turn the ignition key to the OFF position. The engine should stop
Table 132
(1)
The key in the ON position will enable the electrical circuits in the cab and activate the VIMS self test
Pressurize the Cab

Check the Operation of the Blower Motor to Pressurize the Cab(1) Check if OK
Turn the ignition key to the ON position
Check the four settings for the blower speed(2)
Turn the ignition key to the OFF position
Table 133
(1)
(2) Pressurizing the Cab helps to eliminate dust in the operators compartment
There should be an audible sound between the different settings
Climate Control
Check the operation of the Heater and the Air Conditioner Check if OK
20/3/22, 18:48 SIS 2.0
The lines for the heater valves should be open

Sound the horn for all clear
Start the engine
Turn the climate control to cool
Push the top of the A/C switch to activate
Air from the dash vents should be cold(1)
Push the top of the A/C switch to deactivate
Turn the climate control to warm
Air from the dash vents should be warm (1)
Table 134
(1)
When the engine is at operating temperature
Window Wipers
Check the Operation of the Window Wiper and Washer Check if OK
From the OFF position, turn the window wipers to the LOW setting
Turn the window wiper to the HIGH setting
Press the button to activate the window washer fluid
Turn the window wiper to the first INTERMITTENT setting
Turn the window wiper to the second INTERMITTENT setting
Turn the window wiper to the third INTERMITTENT setting
Turn the window wipers to the OFF position
Table 135
Panel and Running Lights

View of the left-hand side of the operator control panel
(1) Switch for headlights, parking lights, and taillights

(2) Panel light switch
20/3/22, 18:48 SIS 2.0

(3) Multifunction switch
Check the operation of the Panel Lights and the Headlights(1) Check if OK
Push switch (1) to activate low beam headlights
Push the top half of switch (2) to the first detent to activate the instrument panel lights, marker lights, and the tail lights
Use multifunction switch (3) to toggle between low beam lights and high beam lights
Push the bottom half of switch (1) to the OFF position to deactivate the headlights
Table 136
(1)
The tail lights should be on any time a light switch is activated
Hazard Lights

(4) Hazard flasher switch
Check the Operation of the Hazard Lights Check if OK
Push the top half of switch (4) to activate the hazard lights
Push the bottom half of switch (4) to deactivate the hazard lights
Table 137
Access Lights
20/3/22, 18:48 SIS 2.0

(5) Switch for the access lights in the cab

(6) Switch for the access lights at ground level
Check the operation of the Access Lights(1) Check if OK
Push the top half of switch (5) or switch (6) to activate the access lights
If necessary, adjust the access light to provide light for the steps
Push the bottom half of switch (5) or switch (6) to deactivate the access lights
Table 138
(1)
The access lights can be activated from two places on the machine. The position of one switch will determine whether the other switch is in the ON position or in the OFF position.
Engine Shutdown Switch

(7) Engine shutdown switch
Check the operation of the Engine Shutdown Switch Check if OK
Start the engine
20/3/22, 18:48 SIS 2.0
Activate engine shutdown switch (7)

Engine shuts down
Deactivate engine shutdown switch (7)
Table 139
Cab Dome Light

Check the operation of the Cab Dome Light Switch(1) Check if OK
Turn the ignition key to the OFF position and close the door
Push dome light switch to the ON position to turn on the light
Push dome light switch to the OFF position to turn the light OFF
Open the door to turn on the light
Close the door to turn off the light
Table 140
(1)
The dome light and switch are located above the operator in the cab
Map Light
Check the operation of the Map Light Switch(1) Check if OK
Turn the ignition key to the OFF position.
Push map light switch to the ON position to turn on the light
Push map light switch to the OFF position to turn the light OFF
Table 141
(1)
The mape light and switch are located above the operator in the cab
Cigar Lighter
Check the operation of the Cigar Lighter(1) Check if OK
Push the lighter inward and release the lighter
When the lighter is ready to use, the lighter will move outward.
Table 142
(1)
The lighter can also be used as a 12 V power receptacle
Backup Alarm
Check the operation of the backup alarm(1) Check if OK
Move the transmission direction and the speed control lever to the REVERSE position
The backup alarm should sound immediately(2)
Table 143
(1)
(2) Make sure that the area behind the machine is clear of personnel and clear of obstacles
The backup alarm should sound until the transmission direction and speed control lever are moved to the NEUTRAL position or the FORWARD
Product Link Setup

Note: Caterpillar highly recommends registering and subscribing to Product Link. Product link enables remote monitoring of customer
equipment helping keep jobs on schedule, maintain machine health, and reduce the cost of owning and operating a customer fleet. First
year subscription to Product Link is at no charge to the customer. Contact a Caterpillar representative with questions.
Product link is set up using the latest version of Caterpillar Electronic Technician.
The Communications Adapter II hardware is connected between the service connector of the machine and the PC serial port of the PC parallel
port. The Cat ET "Communications Interface Device" is found under the "Utilities" menu, "Preferences" drop-down menu.
PL121SR/PL321SR, Satellite PL Setup (If Equipped)

Refer to Service Manual, RENR7911, "Product Link 121S/300" for information and procedures regarding the setup and configuration for the
PL121SR/PL321SR, Satellite-based Product Link systems.
Configuration
20/3/22, 18:48 SIS 2.0
Connecting a Computer to the Product Link System

Verify that Product Link has installed the latest flash file.
Supported Connections for Hardware

The PL121SR Radio and PL300 ECM are configured with CAT ET by using the following communications interfaces:
PL121SR Installations Only - The 245-7310 Control Harness Assembly (Serial Service Cable) is connected between the PC serial port and the
serial service connector on the radio legacy harness or the conversion harness. The CAT ET "Communications Interface Device" is configured for
"Embedded Communications Adapter".
PL121SR plus the PL300 Installations Only - The 171-4400 Communication Adapter Group hardware is connected between the machine service
connector and the PC serial port or parallel port. The CAT ET "Communications Interface Device" is configured for the "Caterpillar Communications
Adapter II (RP1210)".
Note: The configuration parameters for the "Communications Interface Device" are found in CAT ET under "Utilities" menu, "Preferences" drop-
down menu.
Configure Computer Interface Communications for CAT ET

The following examples of screens show configuring communications for the computer to use CAT ET.
1. Use the 245-7310 Serial Service cable to connect a computer with the required CAT ET software to the serial service connector of the wiring
harness.
2. Select "Utility" on the tool bar.

"Preference" Section for CAT ET

3. From the drop-down menu, select "Preference".
20/3/22, 18:48 SIS 2.0

"Preference" Section for CAT ET

4. From the "Communications" tab, click the drop-down menu and select "Caterpillar Embedded Communication Adaptor".
Configure Product Link PL121SR Radio and PL300 ECM

This section provides information for the user to configure the parameters required for the Product Link system during installation. After the
"Machine Serial Number","Machine Make Code", and the "Dealer ID" are set, the unit will auto-register the Product Link system.
There are some parameters that need configured for the Product Link. There are default values that are loaded. Many of the default values are
acceptable in most applications. However, care must be followed in setting these parameters to ensure proper operation. Also, care will help avoid
increased costs for messaging. Enter the "Product Link Module (PLM) Installation Parameters" last to ensure proper registration. Select the
configuration screen by selecting the icon on the tool bar or by using the pull-down menus from the menu bar.
Two communications adapters are available to flash program the electronic control modules. The 7X-1700 Communications Adapter can be used,
or the 171-4400 Communication Adapter II can be used.
After the Product Link has been configured, the radio must be registered with the Equipment Manager system. If installing only the PL121SR Radio
(no PL300 ECM), configure the radio as described in PL121SR "Installation Parameters Configure - Radio Only" section. If installing the PL121SR
and the PL300 ECM, configure the radio and ECM as described in the "Installation Parameters Configure for PL321SR System (PL121SR Radio
and PL300 ECM)".
1. There are three ways to access the configuration screen. Select one of the following options:
Select "Service" and select "Configure" on the menu bar.
Press the "F5" key.
Select "ECM Configuration Icon" on the tool bar.
2. Ensure that steps have been taken to connect the computer with CAT ET software properly to the Product Link system.
3. Click the "Connect" icon or click "File" on the menu bar. Click "Connect" from the pull-down menu to establish communication with the
PL121SR radio.
4. After the computer has connected to the PL121SR radio, click the "Configuration Tool" icon. Select the "Service" menu, "Configuration" drop-
down menu to view the Configuration screen.
5. Double-click the desired parameter or select the desired parameter. Click "Change". A dialog box will appear with a scroll down list that will
show all the possible parameter values.
6. Click "OK" after changing each parameter to return to the Configuration screen.
Refer to the Systems Operation, Troubleshooting, Testing and Adjusting, "Commands" for information about registering the Product Link system.
Commands
"Synchronize Service Hour Meters" for PL321
20/3/22, 18:48 SIS 2.0
To perform the "Synchronize Service Hour Meters" function, select the "Service" menu, and "Synchronize Service Hour Meters" from the drop-down
menu.
The machine maintains a function that is called "Sync Clock". In a PL321 system, the Product Link clock can be the master or the slave. This
criteria is automatically determined by the priority that is provided to each ECM when the machine is designed. Usually, Product Link will not be the
master ECM. If Product Link is not the master, the user must use the "Synchronize" button to synchronize the Product Link SMH to the master
ECM SMH. Product Link could be the master ECM if the following scenarios occur:
No other ECM on the machine is SYNC clock capable/enabled.
No other ECM on the machine has a priority higher than Product Link.
If Product Link is the master ECM, the user should select the "Set Master Hours" button. Once the master hours have been set, click
the"Synchronize" button to synchronize any other sync-clock capable/enabled ECM. Refer to Illustration 399.
Note: To change the SMH to a value lower than the current value, a factory password will be required.
Note: In a PL321 system using sync-clock where Product Link is not the master ECM, the Product Link module will automatically sync to the
master ECM hours if the difference is not greater than 50 hours. If the difference is greater than 50 hours, a diagnostic will be generated in Cat ET
that indicates that a manual sync is required. In that instance, sync the hours (Service/Synchronize Service Meter Hours) unless the master ECM
hours are incorrect.
If Product Link is not the master ECM, and the master ECM hours are not correct, troubleshoot on machine side. Do not replace the Product Link
module.

"Synchronize Service Hour Meters" Screen
"PLM Commands"

"PLM Commands" Menu for Cat ET

There are ten commands that can be completed by selecting "Service/PLM Commands" from the menu bar in Cat ET.
20/3/22, 18:48 SIS 2.0
Registration - This command automatically queues a registration message and an administration message. The registration message will queue
up and wait for the next available satellite to complete the process. The parameters "Queued Registration Messages"and "Queued Administration
Messages" in "Message Queue" will show a value of "1". When the registration message and administration messages has been successfully
transmitted, the value will change back to "0". This registration process can take from 15 minutes to 1 hour. The time frame depends on the
performance of the communications network.
Note: Performing the registration process will activate the installed system. Complete the configuration process prior to performing the registration
process.
Note: To register Product Link, the Product Link antenna must have a clear view of the sky for detecting satellites. Therefore, if the machine is
inside a building or another structure that would prevent a clear view of the sky, the machine will need to be moved outside. The yellow LED and
the orange LED on the PL121SR radio should be solid to ensure that a lock has been established with the satellite. If the LED indicators for the
radio cannot be observed, then the user can look in Cat ET at "Satellite Information" and "Satellite Communication Status" to determine that
satellite communication has been established.
De-registration - This command de-registers the Product Link before removing the unit for installation on another machine. This command will set
all of the fields back to the default values. This command will clear the memory of the unit. All the Fence settings and diagnostics in the memory
are erased. After the message is "queued", the message should enter the Message Queue. This message can be viewed by observing "Message
Queue" for the Product Link ECM. After the message has been transmitted, the unit can be removed. The unit can be reinstalled on another
machine.
Status Message - This command queues the following status descriptions: SMH, location, and fuel.
Fuel Report - This command queues a fuel report.
Position Report - This command queues a position report.
Time and Geo-Fencing Report - This command queues a "Time and Geo-Fencing Report" report.
SMH Report - This command queues a "SMH" report.
Empty Message Queue - This command clears all messages out of the message queue. This command can be used to clear messages that are
inadvertently added to the queue.
ECM List - This command queues up an "ECM List Report" after a wait of a few minutes. The "ECM List Report" includes a list of all ECM modules
(and the associated serial numbers, software part numbers, and sync-clock status) detected by the Product Linkthat are connected to the Cat
Datalink. The "ECM List" is automatically sent at the time of registration. The "ECM List" contains a unique identifier for each ECM that is detected
by the Cat Datalink
Administration Message - This command queues an Administration message. This message contains data from the "Configuration"screen. The
following examples are data examples: "PLM Report Configuration Parameters", "System Settings",and "Digital Input Configurations".
Note: Once these entries have been entered, the Product Link Module will automatically queue an Administration message after 15 minutes. The
Product Link can be forced to queue a message sooner by using this command.
To register a module for the first time, follow the procedure that is listed below.
20/3/22, 18:48 SIS 2.0
"Registration" Screen
1. Click "Service" on the toolbar. Select "Product Link Registration". Refer to Illustration 401.
2. Enter information in the following fields: "Machine Make Code", "Machine Serial Number", "Dealer Code", "Confirmation Email Address"
(optional), and "Service Meter Hours". Refer to Illustration 401.
Note: In a PL321 system, the machine serial number will be auto filled via information from the other ECMs on the CDL. The user will have
the option to "Synchronize Service Meter Hours" if the PL321 is considered a "slave". The user will have the option to "Set Master Hours" if
the PL321 is considered the "master". Refer to Illustration 401.
Note: This will not change the SMH on other ECMs. Only the SMH on Product Link will be modified.
3. Click "Register".
4. After "Registration" is selected, a dialog box will appear. The message will ask "Are you sure?". Click "Yes" or click "No". Clicking "Yes" will
queue the registration messages and administration messages.
5. A confirmation message will be displayed. Click "OK"

Note: After receiving a confirmation, you will be returned to the "Registration" screen.

PL321 "Registration Configuration" Screen

PL121 "Registration Configuration" Screen
To register the system again, follow the procedure that is listed below.
1. Click "Service" on the tool bar. Select "PLM Commands". Click "Registration" on the pull-down menu to start the registration process.
20/3/22, 18:48 SIS 2.0
2. After "Registration" is selected, a dialog box will appear. The message will ask "Are you sure?". Click "Yes" or click "No".
3. The registration message and administration message will "queue up".The parameters "Queued Registration Messages" and "Queued
Administration Messages" in "Message Queue" will show a value of "1". When the registration message has been successfully transmitted,
the value will change back to "0". This registration process can take from 15 minutes to 1 hour. This time frame depends on performance of
the communications network.
Note: The "Status Parameters" PLM Registration Status will change immediately to "Confirmation Pending". The "PLM Registration Status"
will change to "Registered" once the module receives the confirmation that "the message was received and processed successfully in the
backoffice (EM)". If the message was not processed successfully in the BackOffice, the "PLM Registration Status" will change to "Failed". If
this occurs, the parameters should be verified for accuracy. If changes are required, repeat the original registration process via "Service",
"Product Link Registration".

"Queue Status" Screen (PL121SR)
Note: The "Queued Registration Messages" and the "Queued Administration Messages" value will be "1" while the messages are still in the queue.

"Queue Status" Screen (PL321SR)
PL522/PL523, Cellular (GSM) PL Setup ( If Equipped)

Refer to Service Manual, RENR8143, "Product Link PL522/523" for information and procedures regarding the setup and configuration for the
PL522/PL523, Cellular based Product Link systems.
Installation Parameters Configured for PL522 and 523
20/3/22, 18:48 SIS 2.0
1. Ensure that the correct steps have been taken to connect the computer with Cat ET software to the Product Link system. Refer to Systems
Operation, "Configuration".
2. Click the "Connect" icon or click "File" on the menu bar. Click "Connect" from the selections on the pull-down menu to establish
communication with the PL522 or 523.

"Select an ECM" Screen
3. The PL523 device is listed as "Vital Information Management System (VIMS) Main Module" as the Cat Data Link connection is made with the
gateway board within the device. Select "VIMS Main Module"or "Product Link" from the list of available ECMs. Refer to Illustration 406.
4. Click "OK".
5. Once you are connected, click the "Configuration Tool" icon or select "Service" from the menu. Click "Configuration" from the drop-down
menu to view the configuration screen.
20/3/22, 18:48 SIS 2.0

PL522 and 523 Configuration Screen
6. Highlight "VIMS Main Module" and then click "Expand All". Refer to Illustration 408.
Note: Internet Protocol parameters should NOT be modified.
7. Double click the desired parameter or select the desired parameter and click "Change". A dialog box will appear. Also, a list will appear that
will show all of the possible parameter values.
8. Click "OK" after changing each parameter to return to the configuration screen.
Reference: Refer to the "Machine Serial Number" section that follows for information about the "Product ID" that is used in the PL522 and 523
system. Refer to Illustration 409 for an example of a machine serial number.
Machine Serial Number

The Machine Serial Number is used by the PL522 and 523 system for routing information by the machine and displaying information by the
machine.
Note: The serial number for a non-Caterpillar machine can be any alphanumeric characters up to 17 characters long such as "147433789DBS".

(1) Caterpillars World Manufacturing Code (characters 1 - 3)
(2) Machine description (characters 4 - 8)

(3) Check character (character 9)

or Product Sequence Number (characters 10 - 17). These characters were previously referred to as the Serial Number.
(4) Machine Indicator Section (MIS)
For Caterpillar machines, enter only the last eight characters of the "Machine Serial Number". Refer to Illustration 399 for an example of a machine
serial number. For Non-Caterpillar machines, enter the entire machine serial number.
First Quarter 2001, the Caterpillar Product Identification Number (PIN) changed from 8 characters to 17 characters. The "Product ID" that is
required by the PL522 and 523 system is the last eight digits. Do not start the serial number with a space. Do not abbreviate the serial number. For
example, "1AA00123"should not be shortened to "1AA123". Do not use uppercase "O" instead of zero "0". Refer to Item (4) in Illustration 399.
"Machine Maintenance Mode" Screen
20/3/22, 18:48 SIS 2.0

"Machine Maintenance Mode" Screen

The maintenance mode is used to prevent diagnostic and event messages from being reported when performing maintenance on the machine.
This value should be reverted to "Off" after the servicing is complete. This value also reverts to "Off" after 12 calendar hours to ensure proper
operation (long term) of the system. If an event or diagnostic does occur when the maintenance mode is active, the event is ignored until the
maintenance mode is turned off. Remember to clear any diagnostic codes that were created during maintenance. If you do not remember, the
diagnostic codes will be transmitted once the maintenance mode is turned off.
To disable the PLM from sending any diagnostic or event messages while performing maintenance, select the "On" value. To continue normal
operation of the system after maintenance is done, select the "Off" (default) value.
"Synchronize Service Hour Meters" for PL522 and 523

The machine maintains a function that is called "Sync Clock". In a PL522 or 523 system, the PL522 or 523 clock can be the master or the slave.
This criteria is automatically determined by the priority that is provided to each ECM when the machine is designed. In most cases, the PL522 and
523 will not be the master ECM. If PL522 or 523 is not the master, use the "Synchronize" button to synchronize the PL522 or 523 SMH to the
master ECM SMH. The PL522 or 523 can be the master ECM if the following scenarios occur:
No other ECM on the machine is SYNC clock capable/enabled as displayed in Cat ET.
No other ECM on the machine has a priority higher than Product Link. This priority cannot be changed and is automatically determined when
the machine is first powered.

"Synchronize Service Hour Meters" Screen

To perform the "Synchronize Service Hour Meters" function, select the "Service" menu, and "Synchronize Service Hour Meters" from the drop-down
menu. When the PL522 or 523 is the master ECM, select the "Set Master Hours" button. Once the master hours have been set, click
the"Synchronize" button to synchronize any other sync-clock capable/enabled ECM. Refer to Illustration 411.
20/3/22, 18:48 SIS 2.0
Note: To change the SMH to a value lower than the current value, a factory password will be required.
Note: When a PL522 or a 523 is not the master ECM, the PL522 or 523 module will automatically sync to the master ECM hours if the difference is
not greater than 50 hours. If the difference is greater than 50 hours, a MID 122 - EID 0861 - WCI 01 diagnostic will be generated in Cat ET
indicating that a manual sync is required. In that instance, sync the hours (Service/Synchronize Service Meter Hours) unless the master ECM
hours are incorrect.
If a PL522 or a 523 is not the master ECM, and the master ECMs hours are not correct, troubleshoot on machine side. Do not replace the PL522 or
523 module.
Commands
Product Link Module(PLM) Commands

There are five commands that can be completed by selecting "Service" from the menu bar and "PLM Commands" from the drop-down menu in Cat
ET . Refer to Illustration 412.
Fuel Report - This command sends a fuel report.
ECM List - This command sends up an "ECM List Report" after waiting a few minutes. The "ECM List Report" includes a list of all ECM modules
connected to the Cat Data Link. The report also lists the associated serial numbers, software part numbers, and sync-clock status detected by the
PL522 and 523. The "ECM List" is automatically sent at the time of registration. The "ECM List" contains a unique identifier for each ECM that is
detected by the Cat Data Link.
Administration Message - This command sends an Administration message.
Body Serial Number

Record the body serial number in SIMS. Refer to Special Instruction, SEHS0046, "A Procedure to Link a Body Serial Number to Product
Configuration in SIMS for Certain Off-Highway Trucks" for the procedure.
Commissioning Checklist
Use the Service Manual and use the Operation and Maintenance Manual to correct any system problems before you deliver the truck.
Note: After 10 hours of continuous operation, replace the cleanout filter elements with standard filter elements for the systems that follow:parking
brake filter, steering system filter, torque converter charge filter and transmission charge filter. See "Replacing the Cleanout Filters" section of this
document. Record a SIMS entry for the initial cleanout filter replacements using PD Code 38 (General Info), F Code 357 (Filter) and DT Code 901
(Predelivery Inspection).
After you complete the final check, sign your name and the name of the dealer.
Make copies of all completed systems tests, commissioning check list, and predelivery work sheet and mail copies to the following
address:
Caterpillar Inc.

Attention: Quentin Burt

777G Truck

N. 27th and Pershing Road

Decatur, IL 62525

USA

Dealer:____________________
Customer:____________________
20/3/22, 18:48 SIS 2.0
Product Identification Number:____________________
777G Commissioning Checklist

Check that all fluid levels are correct Yes No Page 130
Verify that air cleaners are installed Yes No Refer to Operation and Maintenance Manual
Check tire inflation pressures Yes No Page 130
Verify suspension strut charge pressures Yes No Page 131
Check battery cables and connections Yes No Refer to Operation and Maintenance Manual
Verify electrical system functions correctly Yes No Page 132
Verify that ECM configurations are correct Yes No Page 133
Verify that all configurations are set up Yes No Page 136
Verify that ECM software versions are correct Yes No Page 137
Verify that VIMS is set up correctly Yes No Page 141
Verify that information display is set up correctly Yes No Page 142
Check that the engine starts correctly Yes No Page 143
Verify Variable Fan Tests Yes No Page 144
Check that the transmission is calibrated correctly Yes No Page 146
Verify transmission pressures Yes No Page 148
Verify torque converter pressures Yes No Page 149
Verify that the ARC system operates Yes No Page 154
Verify that the brakes are purged of air Yes No Page 157
Verify that the service brakes test correctly Yes No Page 157
Verify that park brakes test correctly Yes No Page 158
Verify that the retarder operates correctly Yes No Page158
Verify correct steering system operation Yes No Page 158
Verify correct secondary steering operation Yes No Page 159
Verify Traction Control System operation Yes No Page 160
Verify that Duo Cone Seal break-in has been performed Yes No Page 161
Verify hoist lower valve settings Yes No Page 162
Verify body hoist system operation(1) Yes No Refer to Operation and Maintenance Manual
Check body position sensor adjustment Yes No Page 163
Verify body SNUB adjustment settings Yes No Page 163
Verify Hoist System Test Yes No Page 165
Verify Auto Lube system operation(1) Yes No Page 168
Verify CIODS operation and settings(1) Yes No Page 169
Verify Payload system calibration(1) Yes No Page 169
Check all cab controls and functions Yes No Page 170
Check operation of all lights and the horn Yes No Refer to Operation and Maintenance Manual
Verify Product Link setup and operation Yes No Page 174
Check machine drives and operates correctly Yes No Refer to Operation and Maintenance Manual
Table 144
(1)
If equipped
Predelivery Worksheet
Date Employee I.D. Model Serial Number Hours Inspector Name

Table 145
Note: All safety product improvement programs (PIP) must be completed.
Visual Inspection Service Points and Fluid Levels Operation After Operation
20/3/22, 18:48 SIS 2.0
_ Oil

_ Air Cleaner Indicator
_ Coolant

_ V-Belt Tension
_ Fuel

_ Leaks (Oil, Air, Fuel,
_ Batteries OVC > (12.45) _ VDC1
Coolant)
_ Paint
_ VDC2
_ Smoke Color
Engine (1) (2)

Damage

_ Friction
on Hoses
_ Outside _ Air Filters

_ Unusual Noise

_ Friction on Wires

_ Drain Water from Fuel Tank

_ Loose Wire Connections
_ Drain Water Separator

Valves
_ Loose or Lost
_ Open Coolant conditioner

Fasteners
_ Grease Fittings
_ Transmission
_ Differential

_ Transmission - Each Gear
_ Paint
_ Final Drives
_ Neutral Start

Damage

_ Leaks (Oil)
_ Outside _ Tire Pressure

_ Transmission
Lever Lock

Fasteners
Power Train

_ Loose or lost
_ Tires - Cuts, _ Grease Fittings
_ Back - Up Alarm

Bolt Torques

_ Tires - Cuts, Gouges
gouges _ Front & Rear Axle _ Neutralizer Valve
_ Front & Rear Universal Torques
_ Unusual Noise
_ Wheel to Rim Torques
_ Steering
_ Brake Fluid
_ Retarder
_ Leaks - Oil, Air
Steering and _ Paint

Damage _ Drain Water
from Air Tank

_ Service Brakes
_ Loose or Lost
Brakes _ Outside
_ Grease Fittings _ Parking Brakes
Fasteners
_ Unusual Noise
_ Sheet Metal

_ Enclosure Doors - Locks and _ Loose or Lost Fasteners
Chassis _ Paint
_ Grease Fittings

Latches _ Welds
_ Damage
_ Controls
_ Leaks - Oil
_ Hydraulic Tank
Hydraulic _ Cylinder Rods _ Too much

Drift

_ Friction or Lost
_ Grease Fittings
_ Unusual Noise
Fasteners
_ Paint
_ Grease Fittings
_ Welds
Truck Body
_ Damage
_ Body Pads

_ Body Positions
Lost Fasteners
_ Loose or
_ Liners

_ Retention Cable _ Damage

_ Disconnect Switch
_ VIMS

_ Hoist Control
_ Horn

_Seat Belts
_ Seat Adjustments
_ Operation Guide
_ All Switches & Controls

_ Maintenance Guide
_ Front Window Washer

_ Doors and Windows

_ Parts Book

_ Sheet Metal

_ Air Filters
_ Locks and Latches

_ Seat Cover

Cab _ Paint

_ Grease Fittings
_ Mirror Adjustment

_ Steps & Grab
Irons
_ Glass
Support

_ Torque on ROPS _ Front Window Wipers

_ Loose or Lost Fasteners
_ Front Window Washers

_ Loose Wire Connections
_ Heater

_ Leaks - Water

_ (Air Conditioner/Pressurizer)
Lights - Outside and Cab

_ Gauges

_ Unusual Noise
_ Steering Column
Adjustment
_ Special Assembly
Parts
_ Attachment Fluid Levels
_ Warning Plates
_ S/N
Plates

_ Charge for Fire Suppression _ Attachments

_ Films

Misc. and

Fire
_ Correct System
_ Test Switch for _ Leaks
Attachments
Fittings
Attachments
_ Grease Suppression _ Loose
or Lost
_ Hand Tools
_ Automatic Lubrication System Fasteners

_ Paint
Table 146
(1)
(2) If the machine was in storage, refer to Special Instruction, SEHS9031, "Storage Procedure For Caterpillar Products"
For cold-weather operation, refer to Operation and Maintenance Manual, M0106094 and M0106096.
PPT-0100237E

2022/03/20

23:45:16-05:00

i07764572

© 2022 Caterpillar Inc.

Caterpillar:

Confidential Green

TNM 777G

Uploaded by

Copyright:

Available Formats

TNM 777G

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TNM 777G

Uploaded by

Copyright:

Available Formats

20/3/22, 18:47 SIS 2.

SMCS - 1000, 7000, 7960 i08644657

Check for parts and for information in the following locations:

Personal injury or death can result from improper assembly

Do not attempt any assembly until you have read and

Refer to Special Publication, PERJ1017, "Dealer Service Tool

Dispose of all fluids according to local regulations and

Weights and Specifications

Sales Model Empty Weight

Approximate Weight of Body Assembly

321-5410 Body and Canopy As 17826 kg (39300 lb)

Approximate Weights of Components

Tool Part Number Description

Qty Part Number Description

32 217-9902 Washer(1)

Required Parts for Installation of the Front Suspension Cylinders

Qty Part Number Description

2 Front Suspension Gp

Qty Part Number Description

Required Parts for Installation of the Fuel Tank

Qty Part Number Description

Required Parts for Installation of the Ladder Gp

Qty Part Number Description

Qty Part Number Description

Item Qty Part Number Description

Required Parts for Installation of the Steering Lines Gp

Item Qty Part Number Description

Required Parts for Installation of the Exhaust Pipe Group

Qty Part Number Description

Required Parts for the Installation of the Muffler Group

Required Parts for Installation of the Right-Hand Platform Group

Qty Part Number Description

Required Parts for Installation of the Left-Hand Walkway Group

Qty Part Number Description

Required Parts for Installation of the Platform Assembly

Qty Part Number Description

Required Parts for Installation of the Ladder Group

Qty Part Number Description

Required Parts for Installation of the Ladder Group

Qty Part Number Description

Required Parts for Installation of the Handrail Group

Qty Part Number Description

Required parts for Installation of the 310-7621 Platform Wiring Gp

Required Parts for Installation of the 354-8040 Mirror Gp

Required Parts for the Installation of the 336-4450 Mirror Gp

Required Parts for the Installation of the 342-8700 Mirror Gp

1 7X-7468 Convex Mirror

Required Parts for Installation of the Fender Group

Qty Part Number Description

Required Parts for Installation of the 347-5894 Chassis Harness As

Required Parts for Installation of the 308-3212 Front Wheel

Qty Part Number Description

Required Parts for Installation of the Rear Wheels

Qty Part Number Description

Qty Part Number Description

20 9B-7237 Bolt

Qty Part Number Description

Required Parts for Installation of the 309-1213 Automatic Lubrication Gp

Qty Part Number Description