Techdoc - Print - Page Rear Invert Process

777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engi...
Page 1 of 17
Shutdown SIS
Previous Screen
Product: TRUCK
Model: 777D TRUCK AGC
Configuration: 777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engine
Special Instruction
Procedure to Invert the Rear Suspension Group on Certain 777 Off-Highway Trucks{0679,
0756, 7200, 7201, 7213}
Media Number -SEHS0027-00 Publication Date -28/04/2015 Date Updated -28/04/2015
i06066973
Procedure to Invert the Rear Suspension Group on Certain 777

Off-Highway Trucks{0679, 0756, 7200, 7201, 7213}
SMCS - 0679; 0756; 7200; 7201; 7213
Off-Highway Truck:
777D (S/N: AGC1-UP; FKR1-UP)
777F (S/N: JRP1-UP; JXP1-UP)
Introduction
ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"
ReferenceSpecial Instruction, REHS4445, "Servicing the Suspension Cylinders for Off-Highway Trucks"
ReferenceDisassembly and Assembly, RENR3365
ReferenceDisassembly and Assembly, RENR8311
The following instructions provide the needed information to invert the rear suspension cylinders on
certain 777 Off-Highway Trucks.
Note: If needed, the following procedure can be completed on only one rear suspension cylinder. A
configuration of one cylinder installed "rod up" and the other cylinder installed "rod down" is acceptable.
The following manuals will be referenced in the procedure:
• 777D Disassembly and Assembly, RENR3365
• 777F Disassembly and Assembly, RENR8311
Safety
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
safety information in this document and the safety information on the machine are not all inclusive.
You must determine that the tools, procedures, work methods, and operating techniques are safe.
You must determine that the operation, lubrication, maintenance, and repair procedures will not
damage the machine. Also, you must determine that the operation, lubrication, maintenance, and
repair procedures will not make the machine unsafe.
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis... 12/31/2019
777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engi... Page 2 of 17
Personal injury or death can result from sudden suspension cylinder

movement.
Sudden movement, up or down, can cause the clearance above your

head to change rapidly.
Read all warning labels on the suspension cylinders before servicing. Do

not check the oil in the suspension cylinder until all the nitrogen
pressure has been released.
Do not, under any condition, remove valves, cover or plugs from the
cylinder unless the rod is fully retracted and all the nitrogen pressure is
released.
Do not stand under the machine when testing or adjusting the

suspension cylinders.
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.
Improper operation, lubrication, maintenance or repair of this product

can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on

this product, until you have read and understood the operation,
lubrication, maintenance and repair information.
High Pressure Cylinder. Do not remove any grease fitting, valve or plug
until the truck is supported and pressure is relieved or the truck may
drop suddenly, resulting in personal injury.
Suspension groups should only be serviced by properly trained

personnel who have read and understand the service manual procedure
to relieve pressure and to charge cylinders.
Dry nitrogen is the only gas approved for use in the suspension
cylinders. Charging the suspension cylinders with oxygen gas will cause
an explosion. This danger will not happen if nitrogen cylinders with
standard CGA (Compressed Gas Association, Inc.) Number 580
Connections are used.
When you order nitrogen gas, be sure that the cylinders are equipped
with CGA No. 580 Connections. Do not use color codes or other
methods of identification to tell the difference between nitrogen
cylinders and oxygen cylinders.
Never use an adapter to connect your nitrogen charging group to a

valve outlet used on both nitrogen, oxygen or other gas cylinders. Be
sure you use dry nitrogen (99.8% purity).
NOTICE
Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Machine Preparation
1. Move the machine to a hard level surface.
2. Avoid sudden steering inputs when you are parking the machine.
3. Apply the service brakes in order to stop the machine.
4. Move the transmission control lever to the PARK position.
5. Turn the engine start switch to the OFF position in order to stop the engine.
6. Turn the battery disconnect switch to the OFF position.
7. Disconnect the battery. Refer to Operation and Maintenance Manual, "Battery or Battery Cable -
Inspect/Replace" for additional information disconnecting the battery.
8. Chock the front wheels and the rear wheels. Refer to Disassembly and Assembly, "Wheel Chock
(Front and Rear) - Remove and Install".
9. Release the pressure from the system. Refer to Operations and Maintenance Manual, "System
Pressure Release".
Procedure
Table 1
Required Parts
Item Qty Part Number Description
1 1 469-6517 Valve Block
2 1 8M-4435 O-Ring Seal
3 2 8T-5005 Bolt
4 2 8T-4121 Hard Washer
3 (1)
5 372-1181 Valve As
4 (2)
6 1 114-3361 O-Ring Seal
7 1 (1) 129-1029 Check Valve Gp
8 1 (1) 033-6039 O-Ring Seal
9 1 (1) 030-0167 Backup Ring
10 1 (1) 228-4929 Block
11 2 (1) 4L-7124 Bolt
12 2 (1) 5P-0537 Hard Washer
13 1 (1) 3J-1907 O-Ring Seal
14 1 (1) 221-3416 Pressure Sensor Gp
15 6 N/A Plug 3/8 - 18 Thread (3)
16 2 2H-5001 (4) O-Ring Seal
17 1 3J-1907 (4) O-Ring Seal
18 1 4J-1151 (4) Backup Ring
19 1 8J-8900 (4) Wear Ring
20 1 9X-7354 (4) Lip Type Seal
21 1 243-4567 (4) Backup Ring
22 1 243-4572 (4) O-Ring Seal

23 1 330-6822 (4) (5) Buffer Seal As
24 1 433-5904 (4) U-Cup Seal
25 1 279-2269 Film
26 1 279-2271 Film
(1)
If the machine is equipped with TPMS
(2)
If the machine is not equipped with TPMS
(3)
Fabricated
(4)
Part of the 451-5832 Hydraulic Cylinder Seal Kit
(5)
If head design allows use
Illustration 1 g03795690
Typical view of the rear of the 777
1. Remove the rear suspension group from the machine and completely disassembly the suspension
cylinders.
Note: Refer to Disassembly and Assembly, "Rear Suspension (Cylinder) - Remove" and
Disassembly and Assembly, "Rear Suspension (Cylinder) - Disassemble" for information to remove
and disassemble the rear suspension cylinders.
2. Clean and inspect the condition of all the parts. Thoroughly inspect the finish on the cylinder bores
and the rod surfaces. If there are any visible signs of damage or wear to the rod finish, the part must
be reworked.
Note: Refer to Reuse And Salvage Guidelines, SEBF8194, "Specifications for Rear Suspension
Cylinder Components Used in Off-Highway Trucks" for specification information for the rear
suspension cylinders.
View of the holes in the center cap
(A) 30 mm (1.18 inch) diameter spotface
(B) 11 mm (0.433 inch) diameter hole
(C) 14.5 mm (0.571 inch) diameter hole 18 mm (0.708 inch) deep. 5/8-18-2B thread 15 mm (0.591 inch) deep.
(D) 5 mm (0.197 inch) radius
(E) 8.7 mm (0.342 inch) diameter hole 22 mm (0.866 inch) deep (two places). M10 X 1.5-6G thread 18 mm (0.708
inch) deep. Use a bottom tap to cut threads.
(F) 12.7 mm (0.5 inch) diameter hole
(G) 5 mm (0.197 inch) radius (two places)
(H) Spot face until full cleanup on hole (A)
(J) 64 mm (2.51 inch) (maximum)
(K) 75 mm (2.95 inch) (minimum)
(L) 95 mm (3.74 inch)
(M) 120 mm (4.72 inch) (minimum)
(N) 25 mm (0.98 inch)
(P) 50 mm (1.96 inch) (minimum)
(R) 60 mm (2.36 inch) (maximum)
(S) 185 mm (7.28 inch) and not to exceed 190 mm (7.48 inch)
(T) 95 mm (3.74 inch)
3. Machine the center cap according to the specifications in Illustration 3.
(1) 469-6517 Valve Block
(2) 8M-4435 O-Ring Seal
(3) 8T-5005 Bolt
(4) 8T-4121 Hard Washer
4. Secure block (1) and O-Ring seal (2) to the center cap by using two bolts (3) and two hard washers
(4) .
(5) 372-1181 Valve As
(7) 129-1029 Check Valve Gp
(8) 033-6039 O-Ring Seal
(9) 030-0167 Backup Ring
(5) 372-1181 Valve As
5. If the machine Is Equipped with a Truck Payload Measurement System (TPMS), secure two valve
assemblies (5), check valve group (7), O-Ring seal (8), and backup ring (9) onto valve block (1).
Refer to Illustration 5.
777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B En... Page 10 of 17
If the machine is Not Equipped with a Truck Payload Measurement System (TPMS), secure three
valve assemblies (5) onto valve block (1). Refer to Illustration 6.
Note: Installation torque on valve assemblies (5) is 13.6 ± 0.6 N·m (120 ± 5 lb in).
(10) 228-4929 Block
(11) 4L-7124 Bolt
(12) 5P-0537 Hard Washer
(13) 3J-1907 O-Ring Seal
(14) 221-3416 Pressure Sensor Gp
6. If the machine Is Equipped with a Truck Payload Measurement System (TPMS), secure block (10)
to valve block (1) by using two bolts (11) and two hard washers (12). Secure pressure sensor group
(14) with O-Ring seal (13) to block (10) .
(5) 372-1181 Valve As
(6) 114-3361 O-Ring Seal
7. Secure valve assembly (5) with O-Ring seal (6) to the top of the cap.
Note: Installation torque on valve assembly (5) is 13.6 ± 0.6 N·m (120 ± 5 lb in).
Plug (15)
3/8-18 Thread
(A) 12 mm (0.472 inch)
(B) 3 mm (0.118 inch)
(C) 3 mm (0.118 inch)
8. Using low strength bolts, fabricate six plugs (15) .
Note: Cut the bolt to the correct length and add a slot for a flat-head screwdriver.
(15) Plug
(A) 90 Degrees (six places)
(B) 15 mm (0.59 inch) Diameter hole (six places)
Note: Machining and rework to the four outside holes is optional. Machining and rework to the two
inside holes must be completed. Refer to Illustration 10 for the machining dimensions.
9. Machine and rework the rod assembly.
(15) Plug
10. Insert six plugs (15) into the rod assembly.
11. Prepare the area for welding.
Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" prior to performing
any welding on the machine.
Fill the remainder of the six holes with plug weld.
Note: Preheat to 232° C (450° F). Use "GMAW" or Low Hydrogen 7018. Grind the area flush.
Remove any weld splatter.
12. Thoroughly clean the parts again and repaint, as needed.
(16) 2H-5001 O-Ring Seal
(17) 3J-1907 O-Ring Seal
(18) 4J-1151 Backup Ring
(19) 8J-8900 Wear Ring
(20) 9X-7354 Lip Type Seal
(21) 243-4567 Backup Ring
(22) 243-4572 O-Ring Seal
(23) 330-6822 Buffer Seal As (If head design allows use)
(24) 433-5904 U-Cup Seal
NOTICE
Do not reuse old seals.
13. Using all new seals, reassemble the reworked suspension cylinders.
Note: Refer to Disassembly and Assembly, "Rear Suspension (Cylinder) - Assemble" for
information to assemble the rear suspension cylinders.
Typical view
NOTICE
Ensure that the blocks on the suspension cylinders face away from the
tires when installed.
14. Install the reworked suspension cylinders with the rod down.
Note: Refer to Disassembly and Assembly, "Rear Suspension (Cylinder) - Install" for information to
install the rear suspension cylinders.
Note: Each suspension cylinder has two holes for grease fittings. The grease fittings may require
relocation.
View of the inverted rear suspension with cover
NOTICE
Do not secure the cover to the bottom (rod end) of the suspension
cylinders.
15. Reinstall the cover onto the bottom of the suspension cylinders without a clamp on the bottom (rod
end).
(25) 279-2269 Film
(26) 279-2271 Film
16. Remove the existing film, and replace with film (25) and film (26) .
17. Charge the suspension cylinders. Refer to Special Instruction, REHS4445, "Servicing the Suspension
Cylinders for Off-Highway Trucks" for instructions.
Copyright 1993 - 2019 Caterpillar Inc. Tue Dec 31 10:23:19 UTC+0800 2019
All Rights Reserved.
Private Network For SIS Licensees.

Techdoc - Print - Page Rear Invert Process

Uploaded by

Copyright:

Available Formats

Techdoc - Print - Page Rear Invert Process

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

Techdoc - Print - Page Rear Invert Process

Uploaded by

Copyright:

Available Formats

777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engi...

Procedure to Invert the Rear Suspension Group on Certain 777

ReferenceDisassembly and Assembly, RENR3365

ReferenceDisassembly and Assembly, RENR8311

The following manuals will be referenced in the procedure:

• 777D Disassembly and Assembly, RENR3365

• 777F Disassembly and Assembly, RENR8311

Personal injury or death can result from sudden suspension cylinder

Sudden movement, up or down, can cause the clearance above your

Read all warning labels on the suspension cylinders before servicing. Do

Do not stand under the machine when testing or adjusting the

Personal injury or death can result from improper lifting or blocking.

Approximate weights of the components are shown. Clean all surfaces

Improper operation, lubrication, maintenance or repair of this product

Do not operate or perform any lubrication, maintenance or repair on

Suspension groups should only be serviced by properly trained

Never use an adapter to connect your nitrogen charging group to a

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

3. Apply the service brakes in order to stop the machine.

4. Move the transmission control lever to the PARK position.

6. Turn the battery disconnect switch to the OFF position.

22 1 243-4572 (4) O-Ring Seal

Typical view of the rear of the 777

View of the holes in the center cap

(A) 30 mm (1.18 inch) diameter spotface

(B) 11 mm (0.433 inch) diameter hole

(D) 5 mm (0.197 inch) radius

(F) 12.7 mm (0.5 inch) diameter hole

(G) 5 mm (0.197 inch) radius (two places)

(H) Spot face until full cleanup on hole (A)

(J) 64 mm (2.51 inch) (maximum)

(K) 75 mm (2.95 inch) (minimum)

(L) 95 mm (3.74 inch)

(M) 120 mm (4.72 inch) (minimum)

(N) 25 mm (0.98 inch)

(P) 50 mm (1.96 inch) (minimum)

(R) 60 mm (2.36 inch) (maximum)

(T) 95 mm (3.74 inch)

3. Machine the center cap according to the specifications in Illustration 3.

(1) 469-6517 Valve Block

(2) 8M-4435 O-Ring Seal

(3) 8T-5005 Bolt

(4) 8T-4121 Hard Washer

(1) 469-6517 Valve Block

(5) 372-1181 Valve As

(7) 129-1029 Check Valve Gp

(8) 033-6039 O-Ring Seal

(9) 030-0167 Backup Ring

(1) 469-6517 Valve Block

(5) 372-1181 Valve As

(1) 469-6517 Valve Block

(10) 228-4929 Block

(11) 4L-7124 Bolt

(12) 5P-0537 Hard Washer

(13) 3J-1907 O-Ring Seal

(14) 221-3416 Pressure Sensor Gp

(5) 372-1181 Valve As