11/7/2020 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 126)/Basic Search

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Product: TRUCK
Model: 777D TRUCK FKR
Configuration: 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED
BY 3508B Engine

Disassembly and Assembly

777D Off-Highway Truck Power Train
Media Number -RENR8428-02 Publication Date -01/04/2007 Date Updated -29/04/2019

i07711501

Differential and Bevel Gear - Install

SMCS - 3254-012-WH ; 3256-012; 3258-012-GE ; 3258-012

Installation Procedure
Table 1
Required Tools

Tool Part Number Part Description Qty

A 132-1203 Lifting Bracket 1

B 6V-2012 Depth Micrometer 1

C 5P-7373 Axle Installer 1

D 2P-8312 Retaining Ring Pliers 1

E 439-3938 Link Bracket 1
9U-7536 Lift Stand 2

F(1) 447-0910 Electric Hydraulic Pump Gp (115V) 1

447-0911 Electric Hydraulic Pump Gp (230V) 1
OR

F1 504-9826 Lift Gp (50/60 Hz)(2) 2

504-9827 Lift Gp (50/60 Hz)(3) 2

(1) Use Tooling (F) or (F1) based on requirements.
(2) Operating Voltage (380-500V)
(3) Operating Voltage (180-300V)

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

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11/7/2020 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 126)/Basic Search

Illustration 1 g00647585

1. Install O-ring seal (2) onto differential and bevel gear (1).

2. Four of the bolts that hold bearing cage (3) must be removed to attach Tool (A). Attach Tool (A) to
differential and bevel gear (1), as shown. Position a suitable lifting device on Tool (A). Secure the
suitable lifting device to a hoist. The weight of differential and bevel gear (1) is 590 kg (1300 lb).

Illustration 2 g00647587

Illustration 3 g00700810

3. Install differential and bevel gear (1) into axle housing assembly (4).

4. Install two nuts (5) and the washers. Tighten nuts (5) to a torque of 430 ± 60 N·m (317 ± 44 lb ft).

5. Remove Tool (A) from bearing cage (3). Install the four bolts that hold bearing cage (3) to the
differential carrier assembly. Tighten the bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

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11/7/2020 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 126)/Basic Search

Illustration 4 g00700619

Illustration 5 g00647588

Illustration 6 g00713031

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11/7/2020 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 126)/Basic Search

6. Remove O-ring seal (11) from pin (7). Install pin (7) into the axle housing assembly. Position pin (7)
tightly against bearing cap (6).

7. Use Tool (B) to measure the length of pin (1) that is protruding from the axle housing assembly.

8. Subtract 0.05 ± 0.02 mm (0.0020 ± 0.0008 inch) from the distance that was measured in Step 7. This
dimension is equal to the shim pack thickness.

9. Remove pin (7). Install O-ring seal (11) onto pin (7). Install pin (7), shim pack (9), cover (10), bolts
(8), and the washers.

Illustration 7 g00713055

10. Use Tool (C) (not shown) to install axle shaft (14). Install the spacer and sun gear (13) onto axle shaft
(14). Use Tool (D) (not shown) to install retaining ring (12).

Illustration 8 g06404479

11. Install Tool (E) on cover (15). Position a suitable lifting device on Tool (E). Secure the suitable lifting
device to a hoist.

12. Install nine full nuts (16) and the hard washers. Tighten full nuts (16) to a torque of 65 ± 10 N·m
(48 ± 7 lb ft).

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11/7/2020 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(SEBP4975 - 126)/Basic Search

Illustration 9 g06404481
For Tooling (F)

13. Use Tool (F) to lower the machine.

Illustration 10 g06404480
For Tooling (F1)

14. Use Tool (F1) to lower the machine. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand
- 60 Ton)" for more information on Tooling (F1).

15. Refill the final drives with oil. The capacity of one final drive is 42 L (11 US gal). Refer to the
Operation and Maintenance Manual, "Differential and Final Drive Oil - Change" for the correct
procedure.

16. Refill the axle housing assembly with oil. The capacity of the axle housing assembly is 222 L
(59 US gal). Refer to the Operation and Maintenance Manual, "Differential and Final Drive Oil -
Change" for the correct procedure.

End By:

a. Install the transmission and transfer gears.

Copyright 1993 - 2020 Caterpillar Inc. Sat Nov 07 2020 10:40:30 GMT+0800 (China Standard Time)
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