KENR9932-02

December 2011

Specifications
777G Off-Highway Truck
Hydraulic and Braking System
TNM1-Up (Machine)
RDR1-Up (Machine)

SAFETY.CAT.COM
 i03991620

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
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.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by NOTICE labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR9932-02 3
Table of Contents

Table of Contents
Specifications Section
Hydraulic Tank (Brake, Brake Cooling, Hoist) ....... 4
Pump and Motor (Parking Brake Release, Secondary
Steering) ............................................................. 4
Control Manifold (Parking Brake Release) (For
Towing) ................................................................ 5
Gear Pump (Brake, Brake Cooling, Hoist) ............ 6
Gear Pump (Brake Cooling) ................................. 6
Control Manifold (Brake Accumulator Charge) ..... 7
Pressure Sensor (Brake Oil Accumulator) ............ 7
Brake Accumulator (Parking) ................................ 8
Brake Valve (Parking) ........................................... 8
Pressure Switch (Parking Brake) .......................... 9
Brake Accumulator (Service) ................................ 9
Brake Valve (Front Service Brake) ....................... 10
Position Sensor (Foot Brake Control) ................... 10
Service and Parking Brake (Front) (Extended
Life) ..................................................................... 11
Service and Parking Brake (Front) (Standard) ..... 12
Brake Valve (Rear Service Brake, Retarder Control,
Traction Control) ................................................. 14
Slack Adjuster (Rear Brakes) ............................... 15
Slack Adjuster (Front Brakes) ............................... 15
Service and Parking Brake (Rear) (Standard) ...... 16
Service and Parking Brake (Rear) (Extended
Life) ..................................................................... 17
Oil Filter (Brake System) ....................................... 19
Control Valve (Hoist) ............................................. 20
Position Sensor (Hoist Control) ............................ 22
Hoist Cylinder ...................................................... 23
Hoist Cylinder and Mounting ................................. 24
Cab Mounting ...................................................... 24
Truck Body Mounting ............................................ 25
Limit Switch (Truck Body Up) ................................ 26

Index Section
Index ..................................................................... 28
4 KENR9932-02
Specifications Section

Specifications Section (1) Torque for two bolts .. 30 5 Nm (265 44 lb in)

(2) Torque for two bolts .. 30 5 Nm (265 44 lb in)

i04071173

Hydraulic Tank (Brake, Brake

Cooling, Hoist)
SMCS Code: 5056
Part No.: 331-7060

g02281613
Illustration 3
View of Area C

(3) Torque for plug ............... 68 7 Nm (50 5 lb ft)

(4) 7B-3039 Spring

Length under test force ....... 26.2 mm (1.03 inch)
g02281413
Illustration 1 Test force .............. 15.6 1.2 N (3.51 0.270 lb)
Free length after test .......... 36.6 mm (1.44 inch)
Outside diameter ............ 16.66 mm (0.656 inch)

i04202462

Pump and Motor (Parking

Brake Release, Secondary
Steering)
SMCS Code: 4354-SST; 5927
Part No.: 319-5405

g02281553 g02151707
Illustration 2 Illustration 4
View of Area A
KENR9932-02 5
Specifications Section

Motor speed ......................................... 1800 rpm

i04032036

Control Manifold (Parking

Brake Release)
(For Towing)
SMCS Code: 5264
Part No.: 309-1615

g02151745
Illustration 5
View A-A

(1) Torque for two bolts .. 37 2 Nm (327 18 lb in)

(2) Plug
Torque for two plugs ...... 15 2 Nm (11 1 lb ft)

(3) Torque for plug ............. 102 7 Nm (75 5 lb ft)

(4) Torque for four bolts .. 52 3 Nm (460 27 lb in)

g02157862
Illustration 6
Note: The main relief valve for the secondary
steering is located behind plug (2). Minimum operating temperature ...... 40 C (40 F)
Pressure setting for the main relief valve for the Maximum operating temperature ..... 110 C (230 F)
secondary steering ........................ 20700 517 kPa
(3000 75 psi) (1) 316-0073 Pressure Reducing Valve
(5) Hydraulic pump for secondary steering Installation torque .. 30 3.5 Nm (266 31 lb in)
Regulated pressure setting at 0.95 L/min
Input ..................................... 365 amp at 24 VDC (0.251 US gpm) ......................... 3450 140 kPa
Pressure .......................... 12410 kPa (1800 psi) (500.4 20.3 psi)
Output ....................... 21.6 L/min (5.71 US gpm)
(2) 316-0072 Relief Valve Gp
(6) Hydraulic pump for parking and secondary brake
release Installation torque ........................ 35.4 1.4 Nm
(26.1 1.0 lb ft)
Input ..................................... 170 amp at 24 VDC Relief setting at 0.95 L/min
Pressure ............................... 4136 kPa (600 psi) (0.251 US gpm) ......................... 6207 207 kPa
Output ....................... 18.9 L/min (4.99 US gpm) (900.3 30.0 psi)
(7) Electric motor for pump (3) 318-9742 Manual Valve Gp
Bench test specifications Installation torque ........................ 25.8 1.4 Nm
Current that is required to run the hydraulic pump (228 12 lb in)
for secondary steering (5) ..................... 365 amp
Current that is required to run the hydraulic
pump for parking and secondary brake release
(6) ......................................................... 170 amp
Nominal voltage ........................................... 24 V
6 KENR9932-02
Specifications Section

i04051849 (6) Brake Charging Pump

Gear Pump (Brake, Brake Displacement Per Revolution ............... 0.0496 L
(3.027 in3)
Cooling, Hoist) Maximum Pressure ........ 24800 kPa (3600.0 psi)
Minimum flow rate at 15510 kPa (2249.6 psi) and
SMCS Code: 4268; 5073; 5083
at 2100 RPM ............ 91.1 L/min (24.07 US gpm)
Part No.: 255-5478 Minimum flow rate at 15510 kPa (2249.6 psi) and
at 650 RPM ................ 20.1 L/min (5.31 US gpm)
Max Revolutions Per Minute ....................... 2500

i04125349

Gear Pump (Brake Cooling)

SMCS Code: 5073
Part No.: 350-9966

g01241603
Illustration 7
View of 255-5478 Gear Pump (Brake, Brake Cooling, Hoist)

(1) Torque for four bolts ..... 115 7 Nm (85 5 lb ft) g02322849
Illustration 8
View of Gear Pump (Brake Cooling) with Gear Pump (Power
(2) Torque for four bolts ... 228 7 Nm (170 5 lb ft) Train) sections
(1) Gear Pump (Brake Cooling)
(3) Torque for eight nuts .. 400 7 Nm (295 5 lb ft) (A) Gear Pump (Transmission Charge)
(B) Gear Pump (Torque Converter Charge)
(4) Hoist Pump (C) Gear Pump (Scavenge)

Displacement Per Revolution ................. 0.264 L Before running, lubricate the pump with oil.
(16.11 in3)
Maximum Pressure ........ 19000 kPa (2750.0 psi) The pump must rotate freely by hand.
Minimum flow rate at 17240 kPa (2500.5 psi) and
at 2100 RPM ....... 511.4 L/min (135.10 US gpm) Table 1
Minimum flow rate at 17240 kPa (2500.5 psi) and Pump Test Data for Gear Pump (Brake Cooling)
at 650 RPM ........... 145.5 L/min (38.44 US gpm)
Max Revolutions Per Minute ....................... 2500 Rotation CCW
RPM (Test Stand) 900
(5) Brake Cooling Pump
Pressure 700 kPa (101.5 psi)
Displacement Per Revolution ............... 0.2003 L
Flow (Minimum) 223 L/min (58.9 US gpm)
(12.223 in3)
Maximum Pressure .............. 690 kPa (100.0 psi)
Minimum flow rate at 6900 kPa (1000.8 psi) and
at 2100 RPM ........ 389.1 L/min (102.79 US gpm)
Minimum flow rate at 6900 kPa (1000.8 psi) and
at 650 RPM ............ 109.8 L/min (29.01 US gpm)
Max Revolutions Per Minute ....................... 2500

Note: The brake cooling section of 255-5478 Gear

Pump (Brake, Brake Cooling, Hoist) cools the wet
front brakes.
KENR9932-02 7
Specifications Section

i03924010 i03946809

Control Manifold (Brake Pressure Sensor (Brake Oil

Accumulator Charge) Accumulator)
SMCS Code: 4264; 5264-BRK SMCS Code: 1408-NS; 4263-PXS
Part No.: 320-5075 Part No.: 344-7391

g02152254 g02120759
Illustration 9 Illustration 10

Note: Limits are factory set. Readjustment may result Maximum operating pressure .. 35500 kPa (5150 psi)
in system damage or failure.
Operating voltage ......................... 7 VDC to 14 VDC
Note: Excessive pressure at the tank port may result
in system damage or failure. (1) Final installation torque ...................... 30 3 Nm
(270 27 lb in)
Pressure of cut-in of charging
valve ............... 16100 345 kPa (2335.1 50.0 psi)

Pressure of cut-out of charging

valve ............... 19600 345 kPa (2842.8 50.0 psi)

Relief pressure of system .............. 22100 345 kPa

(3205.4 50.0 psi)

Relief pressure of accumulator ................ 23000 kPa

(3335.9 psi)
8 KENR9932-02
Specifications Section

i04125450 i04034754

Brake Accumulator (Parking) Brake Valve (Parking)

SMCS Code: 4263 SMCS Code: 4282; 4284
Part No.: 330-7828 Part No.: 361-2239

g02322953 g02228433
Illustration 11 Illustration 12
(1) 293-6585 Solenoid Valve
(1) Torque for two end caps ................ 300 15 Nm (2) 342-2410 Solenoid Valve
(221.3 11.1 lb ft)

Internal oil volume ............................ 7.0 L (427.2 in3)

Internal volume of dry nitrogen ........ 7.2 L (439.4 in3)

Precharge pressure at 21 C
(70.0 F) .............. 5517 276 kPa (800.2 40.0 psi)

Maximum operating pressure .................. 25000 kPa

(3626.0 psi)

Minimum burst pressure .... 82800 kPa (12009.3 psi)

Maximum operating temperature ..... 110 C (230 F)

g02231393
Illustration 13
Minimum operating temperature ... 32 C (25.6 F)
(1) 293-6585 Solenoid Valve
(1A) Final installation torque for
cartridge ......................... 35 3 Nm (26 2 lb ft)
(1B) Final installation torque for coil
nut ............................. 20 3 Nm (177 27 lb in)
Duty cycle at rated conditions ........... Continuous
Rated voltage ......................................... 24 VDC
Resistance at 25 C (77.0 F) ..... 5.0 0.3 Ohms
KENR9932-02 9
Specifications Section

Deactuation pressure ................ 1325 170 kPa

(192 25 psi)

i04095894

Brake Accumulator (Service)

SMCS Code: 4263
Part No.: 318-2532

g02231433
Illustration 14

(2) 342-2410 Solenoid Valve

(2A) Final installation torque for
cartridge .............. 27.2 1.4 Nm (241 12 lb in)
(2B) Final installation torque for coil
nut ............................. 6.1 0.7 Nm (54 6 lb in)
Duty cycle at rated conditions ........... Continuous
Rated voltage ......................................... 24 VDC
Resistance at 20 C (68.0 F) ... 33.8 0.5 Ohms

i02505503

Pressure Switch (Parking

Brake) g02152631
Illustration 16
SMCS Code: 1408-ZS; 1435-PX
(1) Torque for two end caps ................ 217 10 Nm
Part No.: 160-2609 (160.1 7.4 lb ft)

Internal oil volume ............................ 5.0 L (305.1 in3)

Internal volume of dry nitrogen ........ 5.2 L (317.3 in3)

Precharge pressure at 21 C
(70.0 F) .............. 5516 250 kPa (800.0 36.3 psi)

Maximum operating pressure .................. 25000 kPa

(3626.0 psi)

Minimum burst pressure .... 82800 kPa (12009.3 psi)

Maximum operating temperature ..... 110 C (230 F)

Minimum operating temperature ... 32 C (25.6 F)

g01254369
Illustration 15

(1) 160-2609 Pressure Switch

Installation torque .......... 48 5 Nm (35 4 lb ft)
Maximum actuation pressure .............. 1724 kPa
(250 psi)
10 KENR9932-02
Specifications Section

i04036325 i04036619

Brake Valve (Front Service Position Sensor (Foot Brake

Brake) Control)
SMCS Code: 4269 SMCS Code: 1408
Part No.: 334-8054 Part No.: 266-1466

g02153266
Illustration 18
Connector Pins
(A) + Battery (red)
(B) Ground (black)
(C) Signal (white)

g02154225 Torque for the two mounting screws (not

Illustration 17
shown) ........................ 2.25 0.25 Nm (20 2 lb in)
(1) Final installation torque for coil nut .... 20 3 Nm Operating temperature .......................... 40 to 85 C
(177 27 lb in) (40 to 185 F)
(2) 293-6585 Solenoid Valve Gp Supply voltage of the position sensor ............. 8 VDC
Nominal voltage ...................................... 24 VDC
Duty .................................................. Continuous Output type ...................................................... PWM
Resistance at 25 C (77.0 F) ......... 5 0.3 ohms
Output frequency of the position sensor ........ 500 Hz
(3) Final installation torque for cartridge .. 35 3 Nm
(26 2 lb ft) Duty cycle ............................................ 3.5 to 94.0 %
KENR9932-02 11
Specifications Section

i04084990 Thickness of one new 196-7866 Friction

Disc ........... 5.08 0.08 mm (0.200 0.003 inch)
Service and Parking Brake Thickness of one new 163-9366 Outer
(Front) Plate .. 2.413 0.064 mm (0.0950 0.0025 inch)
Thickness of one new 7D-3013
(Extended Life) Damper ..... 6.86 0.25 mm (0.270 0.010 inch)

SMCS Code: 4251; 4267 Note: Install one damper assembly so that the facing
material faces toward the endplate. Install the other
Part No.: 330-9471
damper assembly so that the facing material faces
toward the service piston.

Note: At assembly, lubricate the friction discs with

the oil that is used in the brakes. See the Operation
and Maintenance Manual, Lubricant Viscosities for
that information.

(3) 9D-6093 Spring (outer)

Quantity .......................................................... 16
Test length .......................... 90.5 mm (3.56 inch)
Test force .................. 4235 169 N (952 38 lb)
Free length after test ......... 116.5 mm (4.59 inch)
Outside diameter .............. 46.02 mm (1.81 inch)

g02286833
Illustration 19

(1) 330-9471 Service and Parking Brake Gp

g02286975
Illustration 21
Section B-B

g02286977
Illustration 20
Section A-A

(2) Assembled brake pack

Thickness of six new discs, five new plates, and
two new damper assemblies ... 56.26 1.30 mm
(2.215 0.051 inch)
12 KENR9932-02
Specifications Section

Note: Apply blue Loctite 242 removable thread locker

to the threads of studs (7).

(8) Torque for five hat nuts .................. 270 40 Nm

(199 30 lb ft)

Note: Apply blue Loctite 242 removable thread locker

to the threads of hat nuts (8).

Note: Tighten five hat nuts (8) in a crisscross pattern

to the specified torque. Ensure that the piston
housing is seated against the anchor.

(9) Torque for six bolts ........................ 270 40 Nm

(199 30 lb ft)

Note: Tighten six bolts (9) in a crisscross pattern to

the specified torque.

Note: Retighten five hat nuts (8) in a crisscross

pattern to 270 40 Nm (199 30 lb ft).
g02287115
Illustration 22
Section C-C
Note: Retighten six bolts (9) in a crisscross pattern to
270 40 Nm (199 30 lb ft).
(4) 9D-9118 Spring Guide
i04078089
(5) 9D-9121 Spring (return)
Service and Parking Brake
Quantity ............................................................ 4
Test length ........................ 74.90 mm (2.95 inch) (Front)
Test force ........................ 890 27 N (200 6 lb)
Free length after test ...... 91.14 mm (3.588 inch)
(Standard)
Outside diameter .............. 26.59 mm (1.05 inch) SMCS Code: 4251; 4267
Part No.: 355-9679

g02287315
Illustration 23

g02286833
(6) Torque for nine studs ....................... 65 10 Nm Illustration 24
(50.0 7.0 lb ft)
(1) 355-9679 Service and Parking Brake Gp
(7) Torque for five studs ...................... 110 20 Nm
(81 15 lb ft)
KENR9932-02 13
Specifications Section

g02286977
Illustration 25
Section A-A

(2) Assembled brake pack

Thickness of six new discs, five new plates, and
two new damper assemblies ... 56.26 1.60 mm g02286975
(2.215 0.063 inch) Illustration 26
Thickness of one new 9W-7017 Friction Section B-B
Disc ........... 5.08 0.13 mm (0.200 0.005 inch)
Thickness of one new 163-9366 Outer
Plate .. 2.413 0.064 mm (0.0950 0.0025 inch)
Thickness of one new 7D-3013
Damper ..... 6.86 0.25 mm (0.270 0.010 inch)

Note: Install one damper assembly so that the facing

material faces toward the endplate. Install the other
damper assembly so that the facing material faces
toward the service piston.

Note: At assembly, lubricate the friction discs with

the oil that is used in the brakes. See the Operation
and Maintenance Manual, Lubricant Viscosities for
that information.

(3) 9D-6093 Spring (outer)

Quantity .......................................................... 16
Test length .......................... 90.5 mm (3.56 inch)
Test force .................. 4235 169 N (952 38 lb)
Free length after test ......... 116.5 mm (4.59 inch) Illustration 27
g02287115
Outside diameter .............. 46.02 mm (1.81 inch)
Section C-C

(4) 9D-9118 Spring Guide

(5) 9D-9121 Spring (return)

Quantity ............................................................ 4
Test length ........................ 74.90 mm (2.95 inch)
Test force ........................ 890 27 N (200 6 lb)
Free length after test ...... 91.14 mm (3.588 inch)
Outside diameter .............. 26.59 mm (1.05 inch)
14 KENR9932-02
Specifications Section

i04036913

Brake Valve (Rear Service

Brake, Retarder Control,
Traction Control)
SMCS Code: 3123; 4269; 4294; 4801-V4; 4811
Part No.: 340-6409

g02287315
Illustration 28

(6) Torque for nine studs ....................... 65 10 Nm

(50.0 7.0 lb ft)

(7) Torque for five studs ...................... 110 20 Nm

(81 15 lb ft)

Note: Apply blue Loctite 242 removable thread locker

to the threads of studs (7). g02236717
Illustration 29
(8) Torque for five hat nuts .................. 270 40 Nm
(199 30 lb ft) (1) Final installation torque for coil nut .. 9.5 1.5 Nm
(84 13 lb in)
Note: Apply blue Loctite 242 removable thread locker
to the threads of hat nuts (8). (2) Final installation torque for coil nuts .. 20 3 Nm
(177 27 lb in)
Note: Tighten five hat nuts (8) in a crisscross pattern
to the specified torque. Ensure that the piston (3) 285-5628 Solenoid Valve Gp
housing is seated against the anchor. Nominal voltage ...................................... 24 VDC
Duty .................................................. Continuous
(9) Torque for six bolts ........................ 270 40 Nm Resistance at 20 C
(199 30 lb ft) (68.0 F) ................................. 26.96 1.35 ohms
Note: Tighten six bolts (9) in a crisscross pattern to (4) 293-6585 Solenoid Valve Groups
the specified torque.
Nominal voltage ...................................... 24 VDC
Note: Retighten five hat nuts (8) in a crisscross Duty .................................................. Continuous
pattern to 270 40 Nm (199 30 lb ft). Resistance at 25 C (77.0 F) ......... 5 0.3 ohms

Note: Retighten six bolts (9) in a crisscross pattern to (5) Final installation torque for cartridge .. 72 3 Nm
270 40 Nm (199 30 lb ft). (53 2 lb ft)

(6) Final installation torque for

cartridges ....................... 35 3 Nm (26 2 lb ft)
KENR9932-02 15
Specifications Section

i04037088 i02491264

Slack Adjuster (Rear Brakes) Slack Adjuster (Front Brakes)

SMCS Code: 4261-RE SMCS Code: 4261
Part No.: 319-6291 Part No.: 8X-7921
S/N: RDR1-Up

g00990402
Illustration 31

(1) 102-0376 Spring

Test length .......................... 45.5 mm (1.79 inch)
Force at minimum length of 24.1 mm
(0.95 inch) ..................... 56 11 N (12.5 2.5 lb)
Outside diameter ................ 57.2 mm (2.25 inch)

(A) Diameter of new piston ........... 82.27 0.08 mm

(3.239 0.003 inch)

(B) Bore of new housing ............... 82.58 0.05 mm

(3.251 0.002 inch)

g02237354
Illustration 30

(1) 2G-1202 Spring

Test length ............................... 51 mm (2.0 inch)
Test force ........................ 44 2 N (10.0 .50 lb)
Outside diameter ................ 44.5 mm (1.75 inch)
Minimum operating length .. 19.5 mm (0.77 inch)
Load at minimum operating length .............. 98 N
(22.0 lb)

(2) Maximum diameter of piston .............. 82.26 mm

(3.238 inch)

(3) Bore of housing ....................... 82.56 0.04 mm

(3.250 0.002 inch)
16 KENR9932-02
Specifications Section

i04085449 Thickness of one new 9W-7017 Friction

Disc ........... 5.08 0.13 mm (0.200 0.005 inch)
Service and Parking Brake Thickness of one new 163-9366
(Rear) Plate .. 2.413 0.064 mm (0.0950 0.0025 inch)
Thickness of one new 7D-3013 Damper
(Standard) Assembly .. 6.86 0.25 mm (0.270 0.010 inch)

SMCS Code: 4251-RE; 4267-RE Note: Install one damper assembly with the facing
material towards the end plate. Install the other
Part No.: 355-9680
damper assembly with the facing material towards
the service piston.

Note: At assembly, lubricate the friction discs with

the oil that is used in the brakes. See the Operation
and Maintenance Manual, Lubricant Viscosities for
that information.

(3) 9D-6135 Spring (inner)

Quantity .......................................................... 32
Test length ........................ 90.50 mm (3.56 inch)
Test force .................... 1535 44 N (345 10 lb)
Free length after test ....... 115.49 mm (4.55 inch)
Outside diameter .............. 26.59 mm (1.05 inch)

(4) 9D-6093 Spring (outer)

Quantity .......................................................... 36
Test length .......................... 90.5 mm (3.56 inch)
Test force .................. 4235 169 N (952 38 lb)
Free length after test ......... 116.5 mm (4.59 inch)
Illustration 32
g01255147 Outside diameter .............. 46.02 mm (1.81 inch)

(1) 355-9680 Service and Parking Brake Gp

g02294354
Illustration 33
Section A-A

(2) Assembled brake pack

g02294654
Illustration 34
Thickness of 15 new discs, 14 new plates, and Section B-B
two new damper assemblies .. 123.70 3.35 mm
(4.870 0.132 inch)
KENR9932-02 17
Specifications Section

Note: Apply blue Loctite 242 removable thread locker

to the threads of studs (8).

(9) Torque for five hat nuts .................. 270 40 Nm

(199 30 lb ft)

Note: Apply blue Loctite 242 removable thread locker

to the threads of hat nuts (9).

Note: Tighten five hat nuts (9) in a crisscross pattern

to the specified torque. Ensure that the piston
housing is seated against the anchor.

(10) Torque for six bolts ...................... 270 40 Nm

(199 30 lb ft)

Note: Tighten six bolts (10) in a crisscross pattern to

the specified torque.

Note: Retighten five hat nuts (9) in a crisscross

pattern to 270 40 Nm (199 30 lb ft).
g02294715
Illustration 35
Section C-C
Note: Retighten six bolts (10) in a crisscross pattern
to 270 40 Nm (199 30 lb ft).
(5) 9D-9121 Spring (return)
i04086869
Quantity ............................................................ 4
Test length ........................ 74.90 mm (2.95 inch) Service and Parking Brake
Test force ........................ 890 27 N (200 6 lb)
Free length after test ........ 91.13 mm (3.59 inch) (Rear)
Outside diameter .............. 26.59 mm (1.05 inch) (Extended Life)
(6) 9D-9118 Spring Guide SMCS Code: 4251-RE; 4267-RE
Part No.: 308-3208

g02293576
Illustration 36

g01255147
(7) Torque for nine studs ....................... 65 10 Nm Illustration 37
(50.0 7.0 lb ft)
(1) 308-3208 Service and Parking Brake Gp
(8) Torque for five studs ...................... 110 20 Nm
(80 15 lb ft)
18 KENR9932-02
Specifications Section

g02294354
Illustration 38
Section A-A

(2) Assembled brake pack

Thickness of 15 new discs, 14 new plates, and
two new damper assemblies .. 123.70 2.60 mm g02294654
(4.870 0.102 inch) Illustration 39
Thickness of one new 196-7866 Friction Section B-B
Disc ........... 5.08 0.08 mm (0.200 0.003 inch)
Thickness of one new 163-9366
Plate .. 2.413 0.064 mm (0.0950 0.0025 inch)
Thickness of one new 7D-3013 Damper
Assembly .. 6.86 0.25 mm (0.270 0.010 inch)

Note: Install one damper assembly with the facing

material towards the end plate. Install the other
damper assembly with the facing material towards
the service piston.

Note: At assembly, lubricate the friction discs with

the oil that is used in the brakes. See the Operation
and Maintenance Manual, Lubricant Viscosities for
that information.

(3) 9D-6135 Spring (inner)

Quantity .......................................................... 32
Test length ........................ 90.50 mm (3.56 inch)
Test force .................... 1535 44 N (345 10 lb)
Free length after test ....... 115.49 mm (4.55 inch) Illustration 40
g02294715
Outside diameter .............. 26.59 mm (1.05 inch)
Section C-C
(4) 9D-6093 Spring (outer)
(5) 9D-9121 Spring (return)
Quantity .......................................................... 36
Test length .......................... 90.5 mm (3.56 inch) Quantity ............................................................ 4
Test force .................. 4235 169 N (952 38 lb) Test length ........................ 74.90 mm (2.95 inch)
Free length after test ......... 116.5 mm (4.59 inch) Test force ........................ 890 27 N (200 6 lb)
Outside diameter .............. 46.02 mm (1.81 inch) Free length after test ........ 91.13 mm (3.59 inch)
Outside diameter .............. 26.59 mm (1.05 inch)

(6) 9D-9118 Spring Guide

KENR9932-02 19
Specifications Section

i04037273

Oil Filter (Brake System)

SMCS Code: 4295; 5068
Part No.: 335-0980

g02293576
Illustration 41

(7) Torque for nine studs ....................... 65 10 Nm

(50.0 7.0 lb ft)

(8) Torque for five studs ...................... 110 20 Nm

(80 15 lb ft)

Note: Apply blue Loctite 242 removable thread locker

to the threads of studs (8).

(9) Torque for five hat nuts .................. 270 40 Nm

(199 30 lb ft)
g02238335
Illustration 42
Note: Apply blue Loctite 242 removable thread locker
to the threads of hat nuts (9). (1) 156-1382 Switch

Note: Tighten five hat nuts (9) in a crisscross pattern Final installation torque ...................... 30 3 Nm
to the specified torque. Ensure that the piston (266 27 lb in)
housing is seated against the anchor. Maximum actuation pressure at40C to 120C
(40F to 248F) ... 276 28 kPa (40.0 4.0 psi)
(10) Torque for six bolts ...................... 270 40 Nm Deactuation pressure at 40C to 120C
(199 30 lb ft) (40F to 248F) .................... 179 kPa (26.0 psi)
Current draw at 28 VDC ............................. 1.5 A
Note: Tighten six bolts (10) in a crisscross pattern to
the specified torque. The switch is normally closed.

Note: Retighten five hat nuts (9) in a crisscross Bypass valve differential pressure setting at
pattern to 270 40 Nm (199 30 lb ft). 10.4 L/min (2.75 US gpm) .................... 345 17 kPa
(50.0 2.5 psi)
Note: Retighten six bolts (10) in a crisscross pattern
to 270 40 Nm (199 30 lb ft). (2) Torque for housing ....................... 23.5 3.5 Nm
(208 31 lb in)
20 KENR9932-02
Specifications Section

i03798650

Control Valve (Hoist)

SMCS Code: 5051; 5136
Part No.: 245-1668

g01050394
Illustration 44

(2) Torque for two cartridge assemblies .. 35 3 Nm

(25 2 lb ft)

(3) 177-1405 Spring

Length under test force ..... 8.20 mm (0.323 inch)
Test force ............ 18.41 0.55 N (4.14 0.12 lb)
Free length after test ...... 12.29 mm (0.484 inch)
Outside diameter .............. 9.30 mm (0.366 inch)

(4) 177-1403 Spring

g01050243
Illustration 43
Length under test force .... 46.00 mm (1.811 inch)
Test force ............ 21.00 0.63 N (4.72 0.14 lb)
(1) Torque for two nuts ........ 35 3 Nm (25 2 lb ft) Free length after test ...... 53.92 mm (2.123 inch)
Outside diameter ............ 15.24 mm (0.600 inch)

(5) 118-5087 Spring

Length under test force ....... 50.0 mm (1.97 inch)
Test force .......................... 243 19 N (55 4 lb)
Free length after test .......... 63.5 mm (2.50 inch)
Outside diameter ............ 35.56 mm (1.400 inch)

(6) 118-5086 Spring

Length under test force ....... 55.0 mm (2.17 inch)
Test force .......................... 438 35 N (98 8 lb)
KENR9932-02 21
Specifications Section

Free length after test .......... 76.2 mm (3.00 inch) (14) Torque for the nut ...... 60 10 Nm (44 7 lb ft)
Outside diameter ................ 49.2 mm (1.94 inch)

g01050246
Illustration 46
g01053955
Illustration 45 View C-C
View B-B

(7) 5J-4664 Spring

Length under test force ....... 29.0 mm (1.14 inch)
Test force .......................... 38 4 N (8.6 0.9 lb)
Free length after test .......... 36.3 mm (1.43 inch)
Outside diameter ..................... 12.70 0.41 mm
(0.500 0.016 inch)

(8) 1P-6744 Spring

Length under test force ... 20.57 mm (0.810 inch)
Test force .............. 63.5 5.1 N (14.28 1.14 lb)
Free length after test ...... 24.03 mm (0.946 inch)
Outside diameter ............ 14.27 mm (0.562 inch)

(9) Low pressure relief valve

setting ................. 3450 350 kPa (500 51 psi)

(10) High pressure relief valve

setting ............. 18950 520 kPa (2750 75 psi)
g01050427
Illustration 47
(11) 112-4397 Spring Section D-D

Length under test force ... 37.47 mm (1.475 inch) (15) 6J-3380 Spring
Test force ........ 43.34 3.00 N (9.743 0.674 lb)
Free length after test .......... 40.0 mm (1.57 inch) Length under test force ....... 60.5 mm (2.38 inch)
Outside diameter ............ 12.50 mm (0.492 inch) Test force .......... 653.9 51.6 N (147.0 11.6 lb)
Free length after test .......... 86.6 mm (3.41 inch)
(12) 2J-6089 Spring Outside diameter ............ 30.18 mm (1.188 inch)
Length under test force ... 36.25 mm (1.427 inch) (16) Torque for plug ....... 125 15 Nm (92 11 lb ft)
Test force .......................... 278 14 N (62 3 lb)
Free length after test ............... 44.12 0.50 mm (17) 8B-4624 Shim
(1.737 0.020 inch)
Outside diameter ............ 12.50 mm (0.492 inch) Quantity ............................................................ 4
Thickness ......................... 0.81 mm (0.032 inch)
(13) Torque for the nut ...... 60 10 Nm (44 7 lb ft) Pressure change with one shim ... 30 kPa (4 psi)
22 KENR9932-02
Specifications Section

(18) Rear brake oil cooler relief valve i04038291

Relief valve pressure setting ......... 586 14 kPa Position Sensor (Hoist Control)
(85 2 psi)
Torque for valve body .................... 185 15 Nm SMCS Code: 1408
(136 11 lb ft)
Part No.: 351-6942

g01050428
Illustration 48
Section E-E

(19) 7S-8491 Spring

Length under test force ....... 25.4 mm (1.00 inch)
Test force .................. 19.2 1.6 N (4.31 .35 lb)
Free length after test .......... 41.1 mm (1.62 inch) Illustration 49
g02240761
Outside diameter ............ 30.18 mm (1.188 inch) Position Sensor (Hoist Control)
(1) Mounting screws
(2) Key
(3) Signal
(4) Ground
(5) Battery

Torque for four mounting screws (1) .. 1.7 0.25 Nm

(15 2.2 lb in)

Specifications for the position sensor

Operation voltage ................... 9 VDC to 32 VDC
Operating temperature .................. 40 to 85 C
(40 to 185 F)
Maximum current ...................................... 30 mA
Output type ................................................ PWM
Output frequency ........................... 500 100 Hz

Duty cycle output

30 Degree rotation ............................ 10% 2%
0 Degree rotation ................................ 50% 2%
+30 Degree rotation ............................ 90% 2%
KENR9932-02 23
Specifications Section

i04050669

Hoist Cylinder
SMCS Code: 5102
Part No.: 296-0608

g02265593
Illustration 50

(1) Torque for the six bolts .................. 475 50 Nm Note: Before assembling internal head (5) to internal
(350 37 lb ft) cylinder (3), apply the following two sealants. Apply
green Loctite 609 anaerobic bearing mount retaining
(2) Rod compound to the internal threads on the rod end
of internal cylinder (3). Apply red Loctite 596 high
Outside diameter of the rod (over temperature RTV silicone sealant to the last three
coating) .............................. 139.650 0.038 mm threads on internal head (5).
(5.4980 0.0015 inch)
(6) External head
(3) Internal cylinder
Inside diameter of head ......... 215.98 0.03 mm
Inside diameter of the (8.503 0.001 inch)
cylinder .. 190.55 0.10 mm (7.502 0.004 inch)
Outside diameter of the cylinder (over (7) Lubricate the sealing lip with a small amount of
coating) .............................. 215.850 0.038 mm the lubricant that is being sealed.
(8.4980 0.0015 inch)
Outside diameter of the cylinder end (two (8) Piston
places) .. 240.00 0.13 mm (9.449 0.005 inch)
Outside diameter of piston (two
(4) External cylinder places) .. 190.00 0.03 mm (7.480 0.001 inch)
Inside diameter of the (9) Torque for the 12 bolts ................... 430 60 Nm
cylinder .. 241.30 0.10 mm (9.500 0.004 inch) (317 44 lb ft)
(5) Internal head Note: Before 12 bolts (9) on the external head are
tightened, rod (2) must be fully extended.
Torque for internal head ............... 870 130 Nm
(642 96 lb ft)
Inside diameter of the internal head (three
places) .... 140.20 .05 mm (5.520 0.002 inch)
24 KENR9932-02
Specifications Section

i04064451

Hoist Cylinder and Mounting

SMCS Code: 5102-MT
Part No.: 318-5059

g02278437
Illustration 51

(1) Lubricate the pin assembly with 4C-5592

Anti-Seize Compound prior to assembly.

i04047508

Cab Mounting
SMCS Code: 7266; 7301
Part No.: 343-8791

g01271374
Illustration 52

(1) Before assembly, apply blue Loctite 242 thread

locker to four mounting bolts. Torque for the four
mounting bolts ..... 800 100 Nm (590 70 lb ft)
KENR9932-02 25
Specifications Section

i04047628

Truck Body Mounting

SMCS Code: 7258-MT
Part No.: 308-0618

g02261456
Illustration 53
Typical left-hand side view

g02261033 g02156574
Illustration 54 Illustration 55
View A-A View B

(1) Pad Assembly

(2) Shim
Thickness ............................. 2.0 mm (0.08 inch)

(3) Plate
26 KENR9932-02
Specifications Section

Thickness ............................. 8.0 mm (0.32 inch)

Note: Refer to the Hydraulic System Systems

Operation/Testing and Adjusting, Pad Assembly
(Truck Body) - Install and Adjust for the proper
installation of the pad assemblies.

g02156583
Illustration 56
View C-C

(4) Use the 8W-2897 Thrust Washer (4.0 mm

(0.16 inch)) and use the 9D-3432 Thrust Washer
(6.0 mm (0.24 inch)) to center the body on the
frame.

Note: Refer to Special Instructions, REHS5053,

Assembly Procedure for the 777G Off-Highway
Truck, Use the 308-0618 Body Mounting to Install
the Body.

i03942729

Limit Switch (Truck Body Up)

SMCS Code: 1435
Part No.: 261-8652

g01379583
Illustration 57
KENR9932-02 27
Specifications Section

(A) Maximum travel ....... 75 degrees from horizontal

(B) Travel to trip ............ 15 degrees from horizontal

(C) Reset from trip .......... 5 degrees from horizontal

Maximum operating torque ............ 0.45 Nm (4 lb in)

Operating voltage ................................ 10 to 28 VDC

Operating temperature .......................... 40 to 90 C

(40 to 194 F)
Index
B S

Brake Accumulator (Parking)................................. 8 Service and Parking Brake (Front) (Extended

Brake Accumulator (Service)................................. 9 Life)...................................................................... 11
Brake Valve (Front Service Brake) ........................ 10 Service and Parking Brake (Front) (Standard) ...... 12
Brake Valve (Parking)............................................ 8 Service and Parking Brake (Rear) (Extended
Brake Valve (Rear Service Brake, Retarder Control, Life)...................................................................... 17
Traction Control) .................................................. 14 Service and Parking Brake (Rear) (Standard)....... 16
Slack Adjuster (Front Brakes)................................ 15
Slack Adjuster (Rear Brakes) ................................ 15
C Specifications Section ........................................... 4

Cab Mounting ........................................................ 24

Control Manifold (Brake Accumulator Charge)...... 7 T
Control Manifold (Parking Brake Release) (For
Towing) ................................................................ 5 Table of Contents................................................... 3
Control Valve (Hoist).............................................. 20 Truck Body Mounting............................................. 25

Gear Pump (Brake Cooling) .................................. 6

Gear Pump (Brake, Brake Cooling, Hoist)............. 6

Hoist Cylinder ........................................................ 23

Hoist Cylinder and Mounting ................................. 24
Hydraulic Tank (Brake, Brake Cooling, Hoist) ....... 4

Important Safety Information ................................. 2

Limit Switch (Truck Body Up) ................................ 26

Oil Filter (Brake System) ....................................... 19

Position Sensor (Foot Brake Control).................... 10

Position Sensor (Hoist Control) ............................. 22
Pressure Sensor (Brake Oil Accumulator)............. 7
Pressure Switch (Parking Brake)........................... 9
Pump and Motor (Parking Brake Release, Secondary
Steering) .............................................................. 4

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