- Quarry Truck
- 775B (S/N: 7XJ1-UP)
- Tractor
- 772B (S/N: 64W1-UP)
- Truck
- 773B (S/N: 63W1-UP)
Introduction
This Special Instruction provides the procedure to repower a 772B, 773B Off-Highway Truckand a 775B Quarry Truck. The replacement engine for the machine will be a Tier II level 3412B Engine. The trucks were originally equipped with a 3412 Engine. This Special Instruction will provide the information to install the Tier II level replacement engine.
| Engine Arrangement | |
| Original Engine | Replacement Engine |
| 4N-7826 | |
| 1W-0773 | |
| 103-7416 | |
| (1) | New Repower Engine |
This Special Instruction does not include procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.
When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.
Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.
Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.
This instruction contains some procedures that come from dealer feedback. The emissions replacement engine is not a direct replacement. Additional parts and labor hours may be needed to complete this engine replacement. Variations in machine serial number breaks or options could cause discrepancy in the modifications, required parts, and labor hours to complete this procedure. This documentation is a guideline for Cat Dealer personnel to complete the repower procedure. If errors are found, submit feedback in SIS Web or contact the Emissions Solutions Group. The information that follows will be required:
Register the Retrofit
Reference: Special Instruction, REHS5097, "Instructions to Register the Retrofit"
Documenting changes to a machine configuration is an advantage to Caterpillar and the dealer technicians that are sent to repair a machine. By identifying that the machine has been reconfigured, the technician will have a better opportunity to have the correct parts, tooling, and service information. Identifying that the machine has been reconfigured will also allow Caterpillar to include the retrofitted serial numbers in applicable Service Letters.
Safety
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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death. |
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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. |
| NOTICE |
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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. |
Welding on Electronically Controlled Engines
Proper welding procedures are necessary to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
- Set the engine control to the "STOP" mode.
- Turn OFF the fuel supply to the engine.
- Disconnect the negative terminal from the battery.
- Disconnect the electronic components of the engine from the wiring harnesses: ECM, throttle actuator, actuator of the compressor for the turbocharger bypass, fuel metering valve, and sensors.
- Protect the wiring harnesses from welding debris and/or from welding spatter.
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NOTICE Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
- Connect the ground cable of the welder directly to the engine component that will be welded. Place the clamp as close as possible to the weld to reduce the possibility of welding current damage.
- Use standard welding procedures to weld the materials together.
Required Parts
Refer to Parts Manual, SEBP2670.
Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list.
Note: If part fabrication is necessary, ensure that all fabricated parts are deburred. Use caution when deburring parts. Avoid excessive grinding and notches.
Note: A breakdown of the kit provides a parts list for the repower. The kit part number is not serviceable. Order the engine arrangement plus the list of parts provided in the kit.
| Repower Parts | |||
| Qty | Part Number | Part Name | Description |
| Engine Options | |||
| 1 | Complete Engine Ar | New repower engine | |
| Required Parts | |||
| 1 | Engine Conversion Kit | This kit is non-serviceable and provides a breakdown of the serviceable parts required for the repower, excluding the engine and optional groups. For line drawings and group structure refer to 263-5502 Engine Conversion Ar. | |
Engine and Machine Preparation
- Remove the original engine from the machine.
- Clean any debris and grease from the machine frame.
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Illustration 2 g01205301 - Remove the A/C compressor from the original engine. Install the compressor on the replacement engine.
- Install the 241-7876 Belt Gp.
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Illustration 3 g01205352 - Remove the oil lines from the original engine. Install the lines on the replacement engine. Remove the starter from the original engine. Install the starter on the replacement engine.
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Illustration 4 g01205357 - Install the torque converter housing and the pumps on the engine.
- Remove the turbochargers from the replacement engine to gain clearance for installation of the engine.
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| Illustration 1 | g01205288 |
Installation of the Engine
- Install the engine in the original location. Use the original front crossmember.
- Connect the drive shaft to the engine and the machine.
- Install the new transmission cooler lines on the machine.
- Install the 212-3567 Filler Gp and the 212-3563 Gauge Gp on the machine.
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| Illustration 5 | g01205650 |
Installation of the Air Lines and Exhaust
- Install the turbochargers on the engine. Install the 142-4035 Air Lines Gp on the machine.
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Illustration 7 g01205706 - Fabricate a heat shield to protect wires and lines near the left turbocharger.
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Illustration 8 g01205710 - Install bracket (1) on the engine.
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Illustration 9 g01205717 - Install the 190-3955 Air Lines Gp on the machine.
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| Illustration 6 | g01205693 |
Installation of the Radiator and Aftercooler
- Install the 203-7962 Radiator Gp on the machine.
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Illustration 10 g01205744 - Extend hole (1) on the 128-0496 Plate.
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Illustration 11 g01205763 - Mount the radiator in the original location. Use the 7N-3308 Plate from the original radiator. Do not use the 127-6258 Plate from the 203-7962 Radiator Gp.
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Illustration 12 g01205791 - Install the 125-5070 Suction Fan Gp on the machine.
- Install the cooling lines on the radiator and the engine.
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Illustration 13 g01205782 - Fabricate a bracket that is
57.15 mm (2.25 inch) longer than the original 209-1284 Plate to gain clearance for the aftercooler.Show/hide table
Illustration 14 g01205821 - Install the 190-3953 Aftercooler Gp on the machine.
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Illustration 15 g01205795 - Install the air lines which connect the engine and the aftercooler. Add a
152.4 mm (6 inch) extension in line (2). Fabricate spacers (3) and install the spacers on the machine.Show/hide table
Illustration 16 g01205815 - Fabricate baffles for the bottom of the radiator and the aftercooler.
Installation of the Hood
- Cut the hood to gain clearance for the lines for the aftercooler.
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Illustration 18 g01205883 - Fabricate shield (1) to cover the lines for the aftercooler.
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Illustration 19 g01205885 - Cut the radiator guard to gain clearance for the lines for the aftercooler.
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Illustration 20 g01205887 - Trim hood (2) to gain clearance for the air inlet tube.
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| Illustration 17 | g01205882 |
Installation of The Electrical System
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| Illustration 21 | g01205890 |
- Install the 9W1-9541 Connector in the cab of the machine. Refer to Illustration 21.
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Illustration 23 g01205892 - Install the 112-9775 Accelerator Control Gp in the cab of the machine.
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| Illustration 22 | g01205891 |
