Usage:
777 (84A1284)
*Turnstops, hitch and rear fenders are shown in Special Instruction FORM SEHS7010.
Reference: Parts Book, Maintenance Guide, Operation Guide, Tool Guide, Service Manual
NOTE: After assembly of the truck is complete, suspension cylinders must be completely charged (see page 18) and the air removed from the braking system (see page 16). Get the machine ready for use as shown in the Maintenance Guide and the Operation Guide. Use the Parts Book and the Service Manual along with this instruction.
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Do not let any dirt or foreign material get into the hydraulic system during assembly, connection of lines, when components are filled with fluid or during any maintenance operation. |
Clean all surfaces and smooth burrs, nicks, etc. where parts are to be installed.
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When a hoist is used to lift any part or assembly, stand clear of the area. Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weights of the components and assemblies are given below. |
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Weights (approximate)
Torque Specifications
REAR AXLE HOUSING MOUNTING NUTS ... 710 ± 25 N·m (525 ± 20 lb-ft)
FRONT SUSPENSION CYLINDER MOUNTING BOLTS/NUTS ... 1180 ± 48 N·m (865 ± 35 lb-ft)
FRONT SUSPENSION CYLINDER CAP MOUNTING BOLTS ... 360 ± 48 N·m (265 ± 35 lb-ft)
FRONT STEERING ARM MOUNTING NUTS ... 1360 ± 163 N·m (1000 ± 120 lb-ft)
TIE ROD ENDS (BALLSTUDS) ... 1360 N·m (1000 lb-ft)
WHEEL (RIM MOUNTING NUTS) ... 1200 ± 55 N·m (890 ± 40 lb-ft)
CAB MOUNTING BOLTS ... 720 ± 25 N·m (530 ± 20 lb-ft)
CAB SUPPORT MOUNTING BOLTS (FINAL) ... 360 ± 48 N·m (265 ± 35 lb-ft)
REAR AXLE HOUSING COVER MOUNTING NUTS ... 102 ± 14 N·m (75 ± 10 lb-ft)
Necessary Tools
- 1-5P7374 LIFTING BRACKET - FRONT SUSPENSION CYLINDERS (both)*1-FT910 HOOK - FRONT SUSPENSION CYLINDER (R.H.)1-6V4085 TORQUE MULTIPLIER (6-1 power ratio)1-6V7915 TORQUE WRENCH1-8H8548 EXTENSION [19 x 203 mm (.75" x 8.0")]1-8H8536 SOCKET - 1 5/16" (Cab mounting bolts)1-8H8537 SOCKET - 1 1/2" (Cab support mounting bolts and rear axle housing mounting nuts)1-8H8538 SOCKET - 1 11/16" (Front suspension mounting nuts)1-5P2964 WRENCH - 1 11/16" (Front suspension mounting bolts)1-2P8285 TUBULAR EXTENSION (Front suspension mounting bolts)1-8H8540 SOCKET - 1 3/4" (Wheel mounting nuts)1-8H8541 SOCKET - 1 7/8" (Steering arm mounting nuts)1-8H8544 SOCKET - 2 3/16" (Tie rod end, ballstud nuts)1-1B7537 ADJUSTABLE WRENCH1-FT1680 STRUT GAUGE1-5P7373 AXLE INSTALLATION TOOL 2P2506 LUBRICANT (Antiseize)
*A lift truck with the capacity to lift approximately 2270 kg (5,000 lb) can be used instead of this hook. A knuckle boom crane (tire truck) can also be used.
Necessary Hoist Capacity
Chassis Assembly
With the differential housing on supports - a hoist of 10 000 kg (22,000 lb) capacity is needed to lift the chassis at the front lifting points.
With the front frame crossmember on supports - a hoist of 8 600 kg (19,000 lb) capacity is needed to lift the chassis at the rear lifting points.
Complete Truck Without Body
With the rear wheels on the ground - a hoist of 17 000 kg (38,000 lb) capacity is needed to lift the front of the chassis.
With the front wheels on the ground - a hoist of 16 000 kg (35,000 lb) capacity is needed to lift the chassis assembly at the rear lifting points.
Distance And Height Necessary To Lift Components
Side of chassis assembly to center of chassis ... 1676 mm (66")
Ground to top of hood (tires installed) ... 3150 mm (124")
Outside of body assembly to center of body ... 2438 mm (96")
Ground to upper edge of body (tires installed) ... 4242 mm (167")
Tire Inflation Pressure
NOTE: The "R" in tire size denotes radial construction.
General Preparation
(1) Remove the boxes, rock reflectors, hand rails, etc. from the chassis.
(2) When lifting the chassis assembly, make lifting connections at locations (A) and (B). Use cables or chains around the rear of the chassis at locations (C) and (D) as shown.
Chassis Support
(1) Put supports under the front and rear of the truck chassis as shown. To install the tires and rims with the front struts completely extended, 1117 mm (44") in height is needed from the ground to the bottom of crossmember (1). To install the strut and wheel assemblies only, with the strut completely retracted, 51 mm (2.0") in height is needed; with the struts completely extended, 368 mm (14.5") is needed. The above dimensions will give approximately 101 mm (4.0") clearance. To install the rear tires and rims, 1092 mm (43") in height is needed, or 254 mm (10") for wheel installation without the tires.
Installation Of Rear Wheel Axle Housings
(1) Remove skid plates (1), spacers and shipping covers (2) and (3). Remove the shipping cover from the axle housings. Clean all mounting surfaces of grease, burrs, nicks, etc., where parts are to be installed (both sides). Install axle housing (4) with an O-ring seal at location (A) [both sides]. Make sure the large brake oil cooling openings on the axle housings are toward the front of the machine and the brake bleed valves are at the top.
(2) Put 2P2506 Lubricant (antiseize) on stud threads and washers. Tighten nuts (5) to a torque of 710 ± 25 N·m (525 ± 20 lb-ft). Remove final drive cover (6) (left side only).
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If the truck is equipped with an AETA (Automatic Electronic Traction Aid), remove the speed sensor from the axle housing at location (B). |
(3) Remove sun gear (7) from axle (8). Install axle (8) [long axle on the left side] using 5P7373 Axle Installation Tool (9). Install spacer, sun gear (7) and snap ring. Install cover (6) with O-ring seal, nuts and lockwashers. Tighten the nuts to a torque of 102 ± 14 N·m (75 ± 10 lb-ft).
NOTE: Do not install the axle on the right side at this time (see page 18). If so equipped, install the speed sensor at location (B).
(4) Connect brake oil cooler lines (8), (9), (10) and (11) to the axle housings with O-ring seals, lockwashers and bolts.
(5) Connect 9D8274 Tube Assembly (12) and 9D8275 Tube Assembly (13) to slack adjuster (14) and to the brake housings at locations (C) and (D) as shown.
(6) Install 9D8363 Tube Assembly (15) and 9D8359 Tube Assembly (16) on brake housings at locations (E) and (F) as shown.
(7) Connect 5T3688 Hose Assembly (17) and 2G3927 Hose Assembly (18) to 9D8363 Tube Assembly (15) as shown. Connect the other end of hose (18) to 9D8359 Tube Assembly (16). Install clips (19). Install the clips on the tubes and install guards (20) and (21) as shown. (See brake bleeding procedure, page 16).
(8) Install clips (22); these were removed for shipment.
Installation Of Rear Tires And Rims
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Remove all grease, burrs, nicks, etc. from the wheel and rim mounting surfaces. |
(1) Put 2P2506 Lubricant on the wheel studs and washers. Install the rear inside tires and rims with washers and nuts (1). Make sure the valve stem is in the position shown when installing the rear inside rims. Install valve stem extension (2) and guard (3) [both sides]. Install valve stem (4). Install the outside tire and rim [both sides]. Tighten nuts (1) to a torque of 1200 ± 55 N·m (890 ± 40 lb-ft). Remove the stands from the rear and lower the truck.
Installation Of Front Suspension Cylinders (Struts)
(1) Remove the spacers and cover (1) and bracket (2). Disconnect grease line (3), and remove strut cap (4) [both sides]. Clean all mounting surfaces of grease, burrs, nicks, etc. where parts are to be installed. Install key (5) as shown [both sides].
NOTE: Use 5P734 Lifting Bracket (6) when installing a suspension cylinder and wheel assembly.
(2) Install the suspension cylinders with steering arm mounting studs (7) towards the rear of the chassis as shown.
NOTE: Before installing the cylinders, install strut cap (4) on the right suspension cylinder (with the lock ring down and the grease fitting to the rear); install the strut cap on the left suspension cylinder (with the lock ring down and the grease fitting to the front).
(3) Install washers and nuts (8) [both sides).
NOTE: Make sure key (5) is in the correct position. Tighten nuts (8) to a torque of 1180 ± 40 N·m (865 ± 35 lb-ft). Tighten strut cap bolts (9) to a torque of 360 ± 48 N·m (265 ± 35 lb-ft), and again connect the grease lines that were disconnected earlier. If the ballstuds for the steering cylinders and tie rod ends were removed, clean the tapers and put 2P2506 Lubricant on the ballstud's tapers. Install nuts (10) and (11) and tighten to a torque of 1360 N·m (1000 lb-ft). If the cotter pin cannot be installed, tighten the nut to the next slot (opening). If the steering cylinder and tie rod ends were removed at the steering arm, install nuts (12) and washers; tighten nuts to a torque of 1360 ± 163 N·m (1000 ± 120 lb-ft).
NOTE: Make sure the spindle and steering arm mounting surfaces are clean before installation of the steering arm on the studs.
(4) Connect front brake line (13) [both sides]. See brake bleeding procedure, page 16.
Installation Of Front Tires And Rims
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Remove all grease, burrs, nicks, etc. from the wheel and rim mounting surfaces. |
(1) Put 2P2506 Lubricant on the wheel studs and washers. Install the front tires and rims with washers and nuts (1). Remove the stand from the front of the truck and lower the front.
Installation Of Cab Assembly
(1) Remove lifting bracket (1). Clean the frame and support mounting surfaces. Install cab supports (2) and (3) as shown. Do not install the center bottom bolts (4) and (5) at this time. Tighten the top center bolts only, on each support, to a torque of 27 N·m (20 lb-ft).
NOTE: Remove ladder assembly (6) before installing the cab. This will make it easier to tighten the cab bolts located in the right front corner.
(2) Clean the cab mounting surfaces and cab support assemblies of all grease, burrs, nicks and etc. Clean the threads in the cab mounting surfaces with a 7/8"-9 tap. Put the cab in position on supports (2) and (3). Install six bolts (7) and washers. Install fourteen bolts (8) and washers. Use a bar (tool) to hold supports (2) and (3) against the cab mounting surfaces so there is no space between the cab mounting surface and supports. Install center bolts (4) and (5). Tighten cab mounting bolts to a torque of 720 ± 25 N·m (530 ± 20 lb-ft), and cab support bolts to a torque of 360 ± 48 N·m (265 ± 35 lb-ft).
Air Hose And Electrical Connections
(1) The plate for the air hose connections is located at the right rear of the cab. Each opening in plate (A) has an identification number as shown. Each air hose also has an identification tag with a number. Connect each air hose to the opening with the same number on the plate. (See hose identification below.)
Plate opening number and hose:
- 1 - From relay valve (service) to air reservoir (service).
- 2 - From brake inversion valve to air reservoir (secondary).
- 3 - From air reservoir (compressor) to air reservoir (service).
- 4 - No connection.
- 5 - From relay valve (service) to brake service control valve.
- 6 - From relay valve (front) to front brake control valve (ON-OFF).
- 7 - No connection.
- 8 - From secondary and park control valve to brake control valve (park).
- 9 - Brake signal line (776 only).
- 10 - From governor to governor override valve (if equipped).
- 11 - From retarder relay valve to retarder brake control valve.
- 12 - From governor control chamber to governor control valve.
- 13 - From brake inversion valve to brake control valve (secondary).
- 2 - From brake inversion valve to air reservoir (secondary).
(2) Connect two battery cables (14) at location (B) and one ground cable (15) at location (C). Connect three cannon plugs (16) as shown. Connect tachometer cable (17) at location (D). Connect body hoist control rod (18) to lever (19). Connect hoist control rod (20) to lever (21) at the hydraulic tank.
Steering Hose Connections
(1) Connect air horn hose (1) and window washer hose (2) as shown. Connect steering hoses (3), (4), (5) and (6) as shown. Connect wiring harness (7) to wiring harness (8). Install hose clips (9) and (10) at location (A) as shown.
Heater And Air Conditioner Hose Connection
| NOTICE |
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Be careful when connecting the heater and air conditioner hoses. The heater and air conditioner parts can be damaged if too much twist is put on hose connections. |
(1) Remove the door from the front of heater and air conditioner assembly (1). Remove the cover from the bottom of the cab. Put the two heater hoses through opening (A).
(2) Connect hose (2) from the lower outlet of the water pump to the heater valve at location (B). Connect hose (3) from the water pump to the heater at location (C). Open heater valves (4).
(3) Put two air conditioner hoses and the electrical wire through opening (A). Connect hose (5) from receiver-dryer (D) to coupling (6) on the evaporator. Connect hose (7) from the compressor to coupling (8) on the evaporator. Connect the plug of electrical wire (9) from the low pressure cutout switch to terminal (10). Install the cover on the front of the air conditioner and cover (11) on the bottom of the cab. (See Service Manual SENR7454 for evacuating and charging the air conditioning system.)
Installation Of Platform, Fenders And Tanks
(1) Install ladder assembly (1). Install left front fender (2) and catwalks (3) with brace (4) as shown.
(2) Connect headlamp wiring harness (5) at location (A). Install bracket assembly (6) and guard assembly (7) as shown. Install headlamps (if removed for shipment).
(3) Install handrail assemblies (8), (9), (10), (11) and mirror assembly (12).
(4) Install right front fender assembly (13) and brace (14). Connect headlamp wiring harness (15) to wiring harness (16). Install headlamps (if removed for shipment). Install 9G9150 Clip (17) as shown. Install handrail assembly (18) and mirror assembly (19).
(5) Install cover assembly (20) and exhaust extension (21). NOTE: Exhaust extension must be adjusted when the truck body is installed. Install four oil pan guards (22) [if removed for shipment].
(6) Install cable steps (23) [if removed for shipment] (both sides). Install flaps (24) [both sides]. Install guards (25) [R.H.] and (26) [L.H.] as shown.
(7) Install hydraulic steering tank (27) [if removed for shipment] with lockwashers and bolts. Connect the oil pressure switch at location (B) with clips. Connect hose (29) from the supplemental steering pump to the steering tank at location (C). Connect hose (30) from hydraulic steering pump (31). Connect hose (32) from the tube on the upper crossbeam.
(8) Install air start tank (32) [if equipped]. Connect hose (33) from the air start motor to the air start tank as shown. Connect hose (34) from the wet tank (or air dryer if equipped) to the air start tank. Connect drain hose (35) to the drain valve as shown.
Brake System Bleeding Procedure (Removing air)
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Put blocks in front of and behind the wheels, to make sure the machine does not move while the parking brakes are OFF. |
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FILL ALL COMPARTMENTS - See the Maintenance Guide.
Before the bleed valves for the hydraulic brakes on each wheel can be used to remove air from the oil in the system, the make-up oil tank for the hydraulic brakes must be full and the air pressure system must have more than 550 kPa (80 psi).
Use a section of hose on the brake bleed valves and a bucket to contain the oil when bleeding the service and parking brakes.
Service brakes
(1) Move parking brake valve (1) to the ON position. With the engine operating, move front brake valve (2) to the OFF position. To make sure the make-up oil tank is full of oil, run the engine at high idle for 20 seconds between each brake application. Hold brake pedal (3) down, and at the same time hold and open bleeder valve (S). Hold the bleed valve open until there is a constant flow of oil. Close bleed valve and release the service brake pedal. Do this procedure for the other rear wheel. Move front brake valve (2) to the ON position and push brake pedal (3) down and hold. Open bleeder valve on the front brake calipers and bleed. Hold the bleed valve open until there is a constant flow of oil. Close the bleed valve and then release the brake pedal. Do this procedure for the other front wheel calipers (two bleeder valves (4) and (5) for each front wheel).
Retarder
(2) Use the same procedure as shown on page 16, except put retarder lever (6) ON and bleed the rear brakes only at bleeder valve (S). Do not bleed the front brakes.
Parking brake
(3) With the engine operating, put service brakes (3) ON and turn parking brake valve (1) OFF. Open bleeder valve (P) on one rear wheel. Close valve (P) when the oil flows free of air. Use the same procedure on the other rear wheel.
(4) Move parking brake valve (1) to the OFF position as shown and put service brake (3) ON. Remove pipe plug (7). Loosen bolts (8). Move towing valve (9) toward the center of the machine.
NOTE: Valve (9) is located on the front of the body hoist L.H. cylinder support. Operate the engine at high idle speed and open one rear wheel bleeder valve (P). Move retarder lever (6) down. Close valve (P) and release the retarder lever. Do this same procedure at 20 second minimum intervals until the oil flows free of air. Move towing valve (9) toward the outside of the machine, install pipe plug (7) and tighten bolts (8).
Installation Of Axle (Right side)
(1) Remove the speed sensor (AETA) from the axle housing at location (A) [if equipped]. Remove sun gear (1) from axle (2). Install axle (2) using 5P7373 Axle Installation Tool (3). Install spacer, sun gear (1) and snap ring. Install cover (4) with O-ring seal, nuts and lockwashers. Tighten nuts to a torque of 102 ± 14 N·m (75 ± 10 lb-ft). Again, install speed sensor at location (A).
Dimensions And Charging Pressures For Front And Rear Suspension Cylinders
| NOTICE |
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Make sure the suspension cylinders are charged with oil before charging the cylinders with nitrogen. |
NOTE: See the Service Manual for the complete charging procedure. (The following procedure can be used before installation of the body.)
(1) Raise the front of the truck until the front suspension cylinders are completely extended 320 mm (12.6").
A) Charge the front cylinders with nitrogen to 1515 kPa (220 psi).
NOTE: This procedure will give the 210-222 mm (8.25"-8.75") dimension with the body installed and machine on level ground.
(2) The rear suspension cylinders are fully extended if the body has not been installed.
A) If the body to be installed is not equipped with liners - charge the rear cylinders with nitrogen to 830 kPa (120 psi).
B) If the body to be installed is equipped with liners - charge the rear cylinders with nitrogen to 1100 kPa (160 psi).
NOTE: This procedure will give the 1016-1029 mm (40.0"-40.5") dimension with the body installed and machine on level ground.
Front Wheel Alignment
(1) Check and adjust front wheel alignment as follows:
A) Lift the front of the truck until the front wheels are off the ground and the suspension cylinders are fully extended.
B) Move the wheels to a straight ahead position.
C) Measure the distance between the front tires at location (F). Mark location (F) each tire and rotate 180°. Again measure distance (G) between the same marks. The correct toe-out for the front wheels (with the wheels off the ground) is when distance (G) at the back of the tires is 64 mm (2.50") less than distance (F) at the front of tires.
D) If it is necessary to adjust the tie rods to get the correct toe-out, loosen clamps (1) on the left side and clamps (2) on the right side. Turn each tie rod the same number of turns to get the correct toe-out measurement. After adjustment, the tie rods must be equal (same) length.
E) When the toe-out measurement is correct, tighten clamps (1) and (2) and lower the front of the truck.
Transmission Neutralizer
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The transmission on this machine will neutralize when the transmission shift lever is in reverse and the hydraulic control lever is in either raise or lower position. The neutralizer will not stop the vehicle from rolling. Use the brakes to stop. |
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(1) If the transmission does not go from REVERSE to NEUTRAL when the control lever for the body is moved to either RAISE or LOWER position, and if the transmission will not go into REVERSE when the body is down, adjustment of hoist control linkage (1) and neutralizer switch (2) [located behind the operator's seat] may be necessary. To adjust the switch, put the yoke in a position so the neutralizer switch is activated only in the raise and lower positions of the hoist control lever. Make sure the hoist control linkage is correctly adjusted before the adjustment of the switch.
Installation Of Body Assembly
(1) Install four pad assemblies (1) without shims (both sides). Lift the body assembly into position on the truck chassis as shown.
(2) Install pivot pins (2), with washers (3) between the body and frame at four locations. Install plate (4) and bolts. Install spacer (5). Install and tighten nut (6). Install the lock pin and cotter pin.
(3) Use a hoist to raise the body assembly. Put blocks (7) between the body rails and the frame.
NOTE: Use a strap and a ratchet puller to help align the cylinder pin bores with the bores in the body. Remove clamps (8). Raise hoist cylinders (9) until the pin bores are in alignment. Install pins (10) with spacers (11) on each side of the cylinder (both sides). Install bolts (12) and lockwashers. Remove straps and ratchet puller. Remove blocks (7). Connect grease fitting lines (both sides).
(4) Put the truck on a level surface. Raise the body to a position where the body rails and the frame are parallel. Install 9D4778 Shims (13), as necessary, under each pad assembly (1) so there is zero clearance between the body rails and pads (1). Move pads (14) into parallel alignment with the front body supports. Measure the clearance dimensions, and install 9D4778 Shims (15) as necessary to make a 1.5 mm (.06") compression on each pad (14).
(5) Tack weld body guide (16) in position on each frame plate (17) with a 25 mm (1.0") space for clearance between the rear surface of the front of the guide and the front of the body rail. Also, leave an 8 mm (.31") clearance between the side of the guide and the body rail as shown. Make a 12 mm (.50") fillet weld at locations (A) [each guide] and 16 mm (.62") bevel groove welds at locations (B) [both guides]. Weld body down indicator (18) on the pad at the dimension shown; use a 5 mm (.19") fillet weld on both sides and the top. Put protection over all glass before welding. Install guard assembly (19) on the left side as shown.
NOTE: If the truck is equipped with an exhaust diverter valve and muffler, install a 2G8003 Guard Assembly on the right side of the canopy.
(6) Install baffles (20) [both sides] with plates (21), bolts, lockwashers and nuts. Install rock ejectors (22) [both sides] with pins and cotter pins. Install body prop pin (23) and lock pin (24) with a spring, washer and cotter pin.
(7) Install four 2D9345 Studs (25) in the truck body at locations (C). Assemble exhaust pipe extension (26) with springs, bolts and locks as shown. Fasten the pipe extension to the body studs with four 7K1270 Washers, 5P8247 Washers and 1D4720 Nuts. With the body in the down position, loosen four bolts (27), and adjust bolts (28) to get the dimension shown at location (D). Tighten bolts (27).
NOTE: See Special Instruction Form SMHS7608 if equipped with an exhaust diverter valve and muffler.
(8) Install rock deflector (29) with two pins (30) and four cotter pins (both sides).
Window Washer Nozzle Adjustment
(1) Use nozzle adjusting wire (1) [taped to the windshield] to adjust window washer nozzle (2) as shown.
Recommendations For Assembly Check Before Delivery Of The Truck
Check to make sure:
a) Seat belt latch is secured with a bolt and nut through the sister hooks.
b) Left and right mirrors are installed.
c) Headlamps and dimmer switch function.
d) Brake lamps function.
e) Turn signals function.
f) With hoist lever held in the raise position, machine will not move in reverse.
g) With hoist lever in float position and shift lever in reverse - backup alarm should sound.
h) Open air tank valves (A) to bleed off any accumulation of water in the air tanks.
j) With the engine operating at 1000 rpm, shift lever in first gear and air pressure at 795-830 kPa (115-120 psi), check to make sure:
Machine does not move with retarder applied.
Machine does not move with service brake pedal applied.
Machine does not move with secondary brake applied.
Machine does not move with park lever applied.
The above procedure confirms brake actuation. With the transmission in gear and parking brake ON, the warning horn will sound; this is normal.
k) With engine OFF, move supplemental steering switch to manual and steer from right to left.
l) With engine and key switch OFF, move supplemental steering switch to automatic; then, turn key switch ON. The supplemental steering pump should turn on for a short test, then shut off.
m) Mud flaps, body down indicator and guard rails are installed.
n) Both right and left doors open and close from the inside of the cab.
o) Operator's Manual is in the literature pouch on the back of the operator's seat.