- Truck
- 777C (S/N: 4XJ1-UP)
Introduction
This Special Instruction provides the procedure to repower a 777C Off Highway Truck. The replacement engine will be a Tier I level 3508B engine. See table 1 for the engine arrangement numbers. The 777C Off Highway Truck was originally equipped with a 3508 DITA JWAC engine. The original 3508 DITA JWAC engine is not regulated for emissions. This Special Instruction will provide the information to install the Tier I level replacement engine.
| Engine Arrangement | |
| Original Engine | Replacement Engine |
| 7E-9078 | |
| 121-5777 | |
| (1) | New Repower Engine - Requires Software |
| (2) | Reman Engine - Requires Software |
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.
Note: This instruction contains some procedures that come from dealer feedback. If errors are found, contact the Emissions Retrofit Group.
New Engine Information Label
This repower process will require the engine to be reflashed with new software. Use a new engine information label by using the standard process before performing the repower.
Registering the Repower Machine
Reference: Special Instruction, REHS5097, "Instructions to Register the Retrofit"
Document change 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 engine electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor 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, SEBP4392.
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
( 291-5597 Conversion Ar-Repower) |
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| Qty | Part No | Part Name | Description |
| Engine Options | |||
| 1 | Engine Ar | New Repower Engine - Requires Software 294-4943 Engine Ratings Electronic Software Gp(1) | |
| 1 | Engine Ar | Reman Engine - Requires Software 294-4943 Engine Ratings Electronic Software Gp(1) | |
| 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 291-5597 Engine Conversion Ar | |
| (1) | Get the latest Service Software File from SIS Web |
Procedure to Install the Repower Engine In the Machine
Removal of the Engine
- Remove the original engine. Refer to the Service Manual for your particular machine to remove the original engine.
- Remove dirt and grease from the machine.
Preparation of the Replacement Engine
Remove the following groups from the original engine. Replace any worn parts. Install the groups on the replacement Tier 1 Engine:
- 1W-8703 Refrigerant Compressor Gp
- 1N-3331 Engine Support Gp
- 122-3222 Fan Drive Gp
- 8N-9794 Belt Tightener Gp
- 2W-0175 Engine Oil Filler Gp
- 2W-0167 Oil Level Gauge Gp (Dipstick)
- Install the 8N-9794 Belt Tightener Gp (1) from the original engine. Install the 122-3222 Fan Drive Gp from the original engine.
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Illustration 2 g01275548 The top photo shows the installed bracket for the A/C compressor.
the bottom photo shows the A/C compressor after installation. - Install the bracket for the A/C compressor (2) and A/C compressor (3) from the original engine.
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Illustration 3 g01275622 - Install the fitting for the air compressor (4) from the original engine.
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Illustration 4 g01275581 - Install the original elbow (5) from the oil cooler to the replacement engine.
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Illustration 5 g01285891 - Install the 1N-3331 Engine Support Gp from the original engine.
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Illustration 6 g01275689 - Install the 2W-0175 Engine Oil Filler Gp (6) from the original engine.
- Install the 2W-0167 Oil Level Gauge Gp (Dipstick) (7) from the original engine.
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Illustration 7 g01276347 - Install the 7L-7262 Flared Elbow (8) from the original engine and install the 3P-2298 Flared Elbow (9) from the 2W-0166 Radiator Gp of the original engine.
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Illustration 8 g01276515 - Remove the coolant tube (10) in order to install the bolts (11) for the bracket for the coolant line.
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| Illustration 1 | g01275432 |
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The top photo shows the original engine with tightener gp and fan drive gp. The bottom photo shows the Replacement engine with tightener gp prior to mounting fan drive gp. | |
Installation of the Replacement Engine
- Install the replacement engine in the original mounting location.
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| Illustration 9 | g01276538 |
Installation of the Air Lines Gp
- Modify the 1W-0165 Air Lines Gpin order to connect the turbocharger, the aftercooler, and the intake.
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Illustration 10 g01277686 - Discard the 6I-1352 Hose (2) and discard four 5P-0599 Band Clamps (3). Discard the 6I-1350 Tube As (4) and the 6I-1351 Tube As (1).
- Replace the 6I-1350 Tube As (4) with the 290-6658 Tube As . Replace the 6I-1351 Tube As (1) with the 290-6659 Tube As.
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- Replace the 105-4274 Sensor and Mounting Gp with the 118-2066 Sensor and Mounting Gp (6).
Installation of the Water Lines Gp for the Power Train Cooling System
- Install the following components from the 123-6917 Water Lines Gp.
Note: Replace the 2W-2522 Tube with the 136-8455 Tube As.
Show/hide tableTable 3 Parts for the Water Lines Gp Callout Qty Pt. No. Description 1 1 136-8455 Tube As 2 1 5P-1265 Hose 29 cm 3 5 8T-4985 Clamp 4 1 159-2829 Hose 5 1 121-5730 Tube As 6 1 7C-9597 Flange 7 1 8T-1919 O-Ring Seal 8 1 6J-2680 O-Ring Seal 9 3 8T-4896 Washer 10 2 8T-9377 Bolt 11 1 4W-0530 Retaining Ring 12 2 4W-0531 Retainer 13 1 6V-8724 Elbow 14 2 6V-8397 O-Ring Seal 15 1 3J-1907 O-Ring Seal 16 1 166-2180 Hose As 17 1 6V-9872 Connector 18 1 7X-0288 Bolt 19 1 6D-4246 Clip 20 1 8T-6767 Plug 21 1 3J-7354 O-Ring Seal 22 1 8T-4984 Clamp
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| Illustration 11 | g01277459 |
Installation of the Steering Relief valve
- Place two 8M-7145 Washers (1) at each bolt hole. Place the washers (1) between the mount and valve, which will lower the steering relief valve in order to provide clearance with the oil pan.
- Replace the original bolts with two 8T-8915 Bolts (2).
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| Illustration 12 | g01279149 |
Installation of the Hose for the Torque Converter Cooler
- Replace the 5T-7944 Hose As for the Torque Converter Cooler with the 154-9001 Hose As (1) in order to provide clearance with the oil pan.
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| Illustration 13 | g01279182 |
Installation of the Platform Assembly
- Fabricate two spacers, as shown.
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Illustration 15 g01281385 - Insert the two spacers (1) between the 8X-6517 Platform (2) and the mount. Use one spacer per side, which will raise the platform enough to keep from interfering with the aftercooler and air lines.
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| Illustration 14 | g01279198 |
Installation of the Electrical System
Installation of the Wiring Harness
Modification of the Electrical System for the Cab
- Add the 6T-3643 Circuit Breaker As (1) to the fuse panel.
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Illustration 17 g01282406 - Connect one wire from the 15A breaker to pin 11 on the cab harness connector inside the cab. Connect another wire from the 15A breaker to pin 12 on the cab harness connector inside the cab. Connect a third wire from the 15A breaker to the main breaker.
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Illustration 18 g01282414 - Connect the twisted pair for the ATA data link from the cab harness connector in the cab. Connect one wire from the twisted pair from pin 33 on cab harness connector in the cab to pin H on the engine service connector. Also from other wire from the twisted pair from pin 34 on cab harness connector in cab to pin J on the engine service connector.
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Illustration 19 g01282439 - Connect a wire from Pin 27 on the cab harness connector to Pin 29 on the transmission harness.
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| Illustration 16 | g01282281 |
Modification of the
- Connect wire from pin #4 on Engine MIC to pin #1 on 171-8709 Flow Switch. Connect wire from pin#2 on Engine MIC to pin #2 on 171-8709 Flow Switch.
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Illustration 21 g01285303 - Connect wire from pin #19 on Engine MIC to 7N-7849 Temperature Switch from ADEM1 engine. Connect second wire from 7N-7849 Temperature Switch to pin J1:27 on the Engine ECM .
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Illustration 22 g01285353 Show/hide table
Illustration 23 g01285994 - The original engine uses 7N-7854 Temperature Switch with two wires. The replacement engine uses a temperature switch with three wires. Replace the temperature switch from the replacement engine with the temperature switch from the original engine. The engine harness has a 3-pin connector (2) for the temperature switch. Remove the 3-pin connector (2). Tape the orange wire (F975) back to the harness. Install ring terminals to the pink wire (481) and to the black wire (201). Connect wire from pin #22 on Engine MIC to the temperature switch for power. Connect remaining wire on the temperature switch to circuit 201 BK for ground.
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Illustration 24 g01285377 - Connect wire from pin #24 on Engine MIC to pin J1:21 on the Engine ECM.
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Illustration 25 g01285452 - Install 6N-5926 Temperature Sender As from the original engine. Connect wire from pin #29 on Engine MIC to temperature sender assembly.
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Illustration 26 g01285472 - Connect wire from pin #30 on Engine MICto pin #1 on 144-5661 Pressure Switch. Connect pin #2 on the pressure switch to circuit 201 BK for ground.
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Illustration 27 g01285495 - Connect wire from pin #39 on Engine MIC to pin #1 of 189-5746 Speed Sensor Gp. Connect pin #2 on the speed sensor to circuit 200 BK for ground.
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Illustration 28 g01285522 - Connect 4D-1836 Toggle Switch for the ground level shutdown.
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| Illustration 20 | g01283192 |
Final Modifications to the Machine
- Install the hood and the bottom engine guard.