Procedure to Install the Variable Speed Fan Drive on the 777F Off-Highway Truck{1359} Caterpillar

Off-Highway Truck:

777F (S/N: JRP1-UP)

Introduction

This Special Instruction will provide the necessary information in order to retrofit a truck with a variable speed fan clutch. The clutch is designed for a variable fan to engine pulley speed. The fan is controlled by the following: engine coolant temperature, turbo boosted air temperature, torque converter brake cooling oil temperature and air conditioner temperature. This clutch will keep the engine at a proper operating temperature more efficiently.

Do not perform any procedure that is outlined in this publication, or order any parts until you read all of the contained information. Do not perform any procedure that is outlined in this publication, or order any parts until you understand all of the contained information.

Safety

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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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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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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.

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Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth level surface. Lower the bucket and or attachments to the ground. Stop the engine and engage the parking brake. Block the wheels and install the steering frame lock. Turn the battery disconnect switch to the OFF position and remove the key. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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NOTICE
Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

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NOTICE
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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

Note: Put identification marks on all hose assemblies and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This will help to prevent fluid loss and this helps to prevent contaminants from entering the system.

Note: Work safely. 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 in order to perform these functions properly.

Required Parts

Table 1

Parts that are Needed for the Installation of the 258-0810 Fan Drive Gp
Qty	Part Number	Part Description
1	323-4095	Bracket As
2	8T-4224	Hard Washers
2	8T-6912	Bolts
1	267-6715	Manifold and Valve Group
1	275-9301	Sensor Harness As
1	308-6317	Sensor Harness As
2	7K-1181	Cable Straps
1	3S-2093	Cable Strap
3	130-5300	Clips
3	130-5301	Clip
2	4P-8134	Clips
2	4P-7429	Clips
1	4L-9337	Bolt
1	2M-2742	Retainer Plate
1	8T-4896	Hard Washer
4	0S-0175	Clevis Pin
4	3B-4617	Cotter Pin
2	7N-5959	Springs
1	155-7327	Connector As
1	6V-8636	Connector
5	3J-1907	O-Ring Seals
6	6V-8397	O-Ring Seals
2	148-8367	Elbow As
2	6V-9850	Elbows
1	9X-2304	Connector
1	198-0143	Elbow As
1	157-2348	Elbow
3	7J-9108	O-Ring Seals
1	243-1872	Fan Drive Gp
4	8T-4183	Bolts
8	8T-4223	Hard Washers
1	306-8168	Hose As
1	306-8167	Hose As
1	274-1762	Pulley
6	5S-7382	Bolts
6	8T-4896	Hard Washers
1	274-7515	Fan Adapter
6	0S-1585	Bolts
6	5P-8245	Hard Washers
1	315-1372	Hose As
1	315-1373	Hose As
1	315-1370	Hose As
1	160-0564	Bracket As
5	5K-9660	Clip
15	8T-4136	Bolt
15	8T-4121	Hard Washer
1	8T-3490	Weld Nut
1	310-2652	Bracket
10	1S-0994	Clip
3	9X-8250	Clip
3	8T-4133	Nut
1	148-8365	Elbow As
1	8T-6876	Elbow
1	6V-8398	O-Ring Seal
1	8W-5179	Adapter
4	8T-9389	Bolt
1	212-1336	Tee As
1	6V-8783	Face Seal Tee
1	2M-9780	O-Ring Seal
1	315-9846	Block
1	1P-3706	Rectangular Seal
4	136-4189	Bolt
4	130-2321	Washer
5	223-3490	Clip
1	8D-9671	Clip
1	5P-7471	Clip
1	5P-7470	Clip
1	9R-3854	Plate
1	6B-4312	Clip
1	319-1823	Engine Ratings Electronic Software Gp
3	6V-8724	Elbows
1	6V-9872	Connector
1	4J-0525	O-Ring Seal
5	3J-1907	O-Ring Seals

Removal Procedure

1. Start by removing the hood of the truck.

   ReferenceRefer to the Disassembly and Assembly manual in order to remove the hood.

2. Completely drain any cooling fluids in the system previous to removing the fan drive unit.

   ReferenceRefer to the Disassembly and Assembly manual in order to drain any necessary fluids.

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Illustration 1	g01453257
View of the aftercooler tubes

3. Remove two aftercooler tubes (D). Loosen two clamps (A). Remove four bolts (B). After the removal of the tubes, reinstall clamp (A) so that the clamp is not lost. Remove clamps (C) from aftercooler tubes (D) .

   Note: Retain the hardware that was removed.

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Illustration 2	g01537753

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Illustration 3	g01331071

4. Loosen clamps (E) at the other end of aftercooler tubes (D). After the removal of tubes (D), reinstall clamps (E) in order to ensure that clamps (E) are not misplaced. This will allow both aftercooler tubes (D) to be removed.

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Illustration 4	g01333199

5. Loosen two clamps (F) in order to remove tube (G). This procedure will allow you to have access to the end of tube (G) .

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Illustration 5	g01333317

6. Loosen two clamps (K) in order to remove tube (G). This procedure will allow you to have access to the end of tube (G) .

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Illustration 6	g01333330

7. Disconnect fitting (H) from tube (G) .

8. Remove tube (G) .

   Note: Retain the hardware that was removed.

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Illustration 7	g01335519
Front view of the fan guard, the belt guard and the bolts that need to be removed

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Illustration 8	g01452532
View of the guards that need to be removed

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Illustration 9	g01536974
View of the location of bolts (CC)

9. Remove bolts (CC) that attach the belt guard to the fan guard. Three belt guards and ten bolts (CC) attach the belt guards together. These bolts (CC) also connect the belt guard to the fan guard.

   Note: Retain the hardware that was removed. The hardware will be reused.

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Illustration 10	g01333635
View of the belt guard with one section that is removed

10. Remove the rest of bolts (CC) for the other two belt guards. The removal process will involve eight additional bolts (CC) that will need to be removed. A total of three belt guards need to be removed.

    Note: Retain the hardware that was removed.

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Illustration 11	g01537173
View of the location of bolts (CC)

11. A total of three fan guards need to be removed. A total of fourteen bolts (CC) will be removed.

    Note: Retain the hardware that was removed. The hardware will be reused.

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Illustration 12	g01333383

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Illustration 13	g01303740

12. Remove fan guard (N) .

    Note: Retain the hardware that was removed. The hardware will be reused.

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Illustration 14	g01537216

13. Connect an appropriate lifting strap to fan (T). The fan weighs 55 kg (121 lb).

14. Disconnect fan (T) from the drive unit by removing eight bolts (DD) that attach fan (T) to adapter (U) .

    Note: Retain the hardware that was removed. The hardware will be reused.

15. Lift fan (T) through the top of the machine.

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Illustration 15	g01537255

16. Remove six bolts (EE) and six washers (FF) in order to disconnect adapter (U) from the fan drive system.

    Note: Discard the hardware that was removed. The hardware will be reused.

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Illustration 16	g01537316
View of one end of hose (V)

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Illustration 17	g01537319
View of one end of hose (V)

17. Disconnect 286-2215 Hose As (V). Hose (V) will not be used in the installation of the Rockford fan.

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Illustration 18	g01537357

18. Release the tension on tensioner (W) in order to remove belts (X) .

    Note: Retain belts (X) that were removed.

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Illustration 19	g01452642

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Illustration 20	g01537374
View A-A of fan drive

19. Remove cotter (Y) and pin (Z) in order to remove springs (AA) .

    Note: Retain the hardware that was removed.

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Illustration 21	g01537454

20. Remove six bolts (GG) in order to remove large fan pulley (HH). Remove one bolt (JJ) in order to remove tensioner (Z).

    Note: Retain the hardware that was removed. The hardware will be reused.

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Illustration 22	g01537514

21. Remove the four bolts (KK) in order to remove bracket assembly (BB) .

    Note: Retain the hardware that was removed. The hardware will be reused.

Installation Procedure for the 323-4095 Bracket As

Table 2

Parts that are needed in order to Install 323-4095 Bracket As
Item	Qty	Part Number	Part Description
1	1	274-1760	Bracket As
2	3	4P-8134	Clips
3	4	8T-9389	Bolts
4	4	8T-4223	Hard Washers
5	1	3S-2093	Cable Strap
6	2	7K-1181	Cable Straps
7	3	130-5300	Clips
8	1	275-9301	Sensor Harness As
9	1	308-6317	Sensor Harness As
10	1	267-6715	Manifold and Valve Group
11	2	8T-6912	Bolts
12	2	8T-4224	Hard Washers
13	3	6V-8724	Elbows
14	4	6V-8397	O-Ring Seals
15	4	3J-1907	O-Ring Seals
16	1	6V-8636	Connector
17	1	7X-0288	Bolt
18	1	8T-4896	Hard Washer
19	1	2M-2742	Retainer Plate
20	2	7N-5959	Springs
21	4	0S-0175	Clevis Pins
22	4	3B-4617	Cotter Pins

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Illustration 23	g01303385
View of the location of bracket assembly (1)

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Illustration 24	g01457306

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Illustration 25	g01457492
View of the side of the bracket assembly (1) with clips (2) and clip (7)

1. Position bracket assembly (1) to the engine. Refer to Illustration 23 in order to view the location of bracket assembly (1). Use four bolts (3) and four washers (4) in order to secure bracket (1).

2. Install two clips (2) with two bolts (3) and two washers (4) that were used to install bracket assembly (1). Use bolt (3) to attach clip (2) and clip (7).

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Illustration 26	g01456965
Side view

3. Install wire harness (9) to clip (2) with strap (5) and strap (6). Use strap (6) to attach wire harness (8) to clip (2) .

4. Connect wire harness (8) to wire harness (9) .

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Illustration 27	g01457117
Bottom front view

5. Install the manifold and valve group (10) with two bolts (11) and two washers (12) .

6. Plug wiring harness (8) into the manifold and valve group (10) .

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Illustration 28	g01459917
View of elbows (13), connector (16), seals (14) and seals (15)

7. Install O-ring seal (14) and O-ring seal (15) to each of three elbows (13). There are a total of three elbows (13) .

8. Install O-ring seal (14) and O-ring seal (15) to connector (16) .

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Illustration 29	g01457158

9. Install three elbows (13) in three locations on the manifold and valve group (10). Refer to Illustration 29 in order to orient elbows (13) correctly.

10. Install connector (16) to manifold and valve (10) .

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Illustration 30	g01454387
Installation of belt tightener (Z)

11. Reinstall 266-2365 Belt Tightener Gp (Z) that was removed in Step 20 of the ""Removal Procedure" ". Install one bolt (17), one hard washer (18 ) and one retainer plate (19) in order to hold the belt tightener group (Z) onto mounting bracket (1) .

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Illustration 31	g01454397
Installation of spring (20) with clevis pin (21) and cotter pin (22)

12. Install one spring (20) by connecting spring (20) to bracket assembly (1) and belt tightener group (Z) with two clevis pins (21) and two cotter pins (22).

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Illustration 32	g01457272
View of springs (16)

13. Repeat Step 12 in order to install the second spring (20) .

Installation Procedure for the 243-1872 Fan Drive Gp

Table 3

Parts that are needed in order to Install 243-1872 Fan Drive Gp
Item	Qty	Part Number	Description
1	1	243-1872	Fan Drive Gp
2	1	6V-9872	Connector
3	2	6V-8397	O-Ring Seals
4	1	3J-7354	O-Ring Seal
5	1	3J-1907	O-Ring Seal
6	1	6V-8636	Connector
7	1	6V-9850	Elbow
8	1	3K-0360	O-Ring Seal
9	1	9X-2304	Connector
10	1	6V-8398	O-Ring Seal
11	1	7J-9108	O-Ring Seal
12	1	157-2348	Elbow
13	4	8T-4183	Bolts
14	10	8T-4223	Hard Washers
15	2	130-5300	Clips
16	1	274-1762	Pulley
17	6	5S-7382	Bolts
18	6	8T-4896	Hard Washers
19	1	274-7515	Fan Adapter
20	6	5P-2566	Bolts
21	4	4N-8197	V-Belts

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Illustration 33	g01455567
View of the fan drive group (1) and hydraulic ports (CC), (DD), and (EE)

1. Remove caps in all three ports on fan drive group (1) .

2. Install seal (3) and seal (4) in connector (2) .

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Illustration 34	g01455207
View of the fan drive group (1) with connector (2) and connector (6)

3. Install connector (2) into port (CC) on fan drive group (1). Make sure that connector (2) is tightly fastened to fan drive group (1).

4. Install seal (5) and seal (3) in connector (6) .

5. Install connector (6) into port (DD) on fan drive group (1). Make sure that connector (6) is tightly fastened to fan group (1).

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Illustration 35	g01458409
View of the installation of elbow (7) onto connector (6)

6. Install seal (3) onto elbow (7) .

7. Install elbow (7) onto the connector assembly (6) that was installed in the previous step. Make sure that elbow (7) is tightly fastened to connector (6). Elbow (7) needs to be installed parallel with fan drive group (1) .

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Illustration 36	g01458493
View of the fan drive group with connector (9) and elbow (7) and connector (2)

8. Install seal (8) and seal (10) onto connector (9) before installing connector (9) onto fan drive group (1) .

9. Install connector (9) into the port (EE) on fan drive group (1).

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Illustration 37	g01458521
View of fan drive group (1) with connectors and elbows

10. Install seal (11) onto elbow (12) .

11. Install elbow assembly (12) onto connector (9) that was installed in Step 9.

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Illustration 38	g01458528
Typical view of fan drive group

12. Use a suitable lifting device in order to install fan drive group (1) .

    Note: Fan drive group (1) has a weight of 37 kg (81.5 lb). A 141-0289 Fabric Sling (FF) is recommended in order to lift fan drive group (1) .

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Illustration 39	g01454490

13. Install two clips (15) to the upper right corner of the fan drive group (1) with bolt (13) and washer (14). Refer to Illustration 39 in order to view the location of clip (15). Use four bolts (13) and four washers (14) to attach the fan drive group (1) to the bracket.

14. Attach the wiring harness to clip (15).

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Illustration 40	g01458658

15. Install pulley (16) on fan drive group (1) with six bolts (17) and six washers (18) .

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Illustration 41	g01454823
View of the installation of the fan adapter

16. Install fan adapter (19) with six bolts (20) and six washers (14).

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Illustration 42	g01458660
Technique that is used in order to tighten six bolts (20)

17. Install two bolts (KK) in order to tighten six bolts (20) .

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Illustration 43	g01336768

18. Attach a wrench to the lip of belt tightener (Z). Refer to the Illustration above in order to view the operation. The belt tightener needs to be pulled just over the center position so that the tightener will stay in the position. This will allow the belt to be easily installed.

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Illustration 44	g01458662
View of belts (21)

19. Install four belts (21) onto pulley (16) and belt tightener (Z) .

Installation Procedure for the Hydraulic Lines

Table 4

Parts that are Needed in order to Install Hydraulic Lines
Item	Qty	Part Number	Description
1	1	306-8168	Hose As
2	1	306-8167	Hose As
3	1	315-1372	Hose As
4	1	315-1373	Hose As
5	1	315-1370	Hose As
6	5	5K-9660	Clips
7	1	160-0564	Bracket As
8	15	8T-4136	Bolts
9	15	8T-4121	Hard Washers
10	1	310-2652	Bracket
11	10	1S-0994	Clips
12	2	9X-8250	Clips
13	3	8T-4133	Nuts
14	1	8T-6876	Elbow
15	1	3J-1907	O-Ring Seal
16	1	6V-8398	O-Ring Seal
17	1	4J-0524	O-Ring Seal
18	1	8W-5179	Adapter
19	4	8T-9389	Bolts
20	4	8T-4223	Hard Washers
21	1	6V-8783	Face Seal Tee
22	2	7J-9108	O-Ring Seals
23	1	2M-9780	O-Ring Seal
24	1	315-9846	Block
25	1	1P-3706	O-Ring Seal
26	4	136-4189	Bolts
27	4	130-2321	Washers
28	5	223-3490	Clips
29	1	8D-9671	Clip
30	1	9R-3854	Plate
31	1	5P-7471	Clip
32	1	5P-7470	Clip
33	1	6B-4312	Clip

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Illustration 45	g01454547
Rear view

1. Install hose assembly (1) on the right hand side of the fan drive group.

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Illustration 46	g01454595
Left side view

2. Install hose assembly (2) to the left side of the fan drive group.

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Illustration 47	g01449405
View of hose assembly (3) and hose assembly (4)

3. Install hose assembly (3) and hose assembly (4) to the fittings in Step 9 and Step 10 in section ""Installation Procedure for the 323-4095 Bracket As " ".

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Illustration 48	g01449348
Left side rear view

4. Install hose assembly (5) .

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Illustration 49	g01449595
View of the installation of bracket (7) to hose (5)

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Illustration 50	g01480072
View of bracket (7) that is installed

5. Install bracket assembly (7) to hose assembly (5) by using clip (6), bolt (8) and hard washer (9) .

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Illustration 51	g01449624
View of bracket (10) that is installed on hose (3) and hose (4)

6. Install bracket (10) onto hose (3) and hose (4) with clip (11) and clip (12). Use bolt (8), washer (9) and nut (13) in order to attach the clips on the hoses.

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Illustration 52	g01478281

7. Attach bracket (10) to cover (A) with the existing hardware for the cover.

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Illustration 53	g01449924
View of the installation of elbow (14) to hose (5)

8. Install seal (15) and seal (16) onto elbow (14) .

9. Install hose (5) onto elbow assembly (14) .

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Illustration 54	g01459231

10. Install seal (17) onto adapter (18) .

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Illustration 55	g01435765
View of the installation of elbow (14) to adapter (18) with bolts (19) and washers (20)

11. Install elbow assembly (14) to adapter (18) .

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Illustration 56	g01435767
View of the installation of adapter (18) on the filter group

12. Install adapter (18) to the power train filter group with four bolts (19) and four hard washers (20). View Illustration 56 in order to see adapter (18) .

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Illustration 57	g01435770
View of the installation of the lines (3) and (4) to tee assembly (21)

13. Install two seals (22) and one seal (23) onto tee (21) .

14. Connect both return lines (3) and (4) onto tee assembly (21) .

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Illustration 58	g01459381
View of seal (25) that is installed on block (24)

15. Install seal (25) onto block (24) .

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Illustration 59	g01435771
View of the installation of tee assembly (21) on block (24)

16. Install tee assembly (21) onto block (24).

17. Install block (24) onto the hydraulic tank with four bolts (26) and four hard washers (27) .

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Illustration 60	g01450701
View of hydraulic lines on the inside of the frame

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Illustration 61	g01450733
Close view of the inside left hand of the frame

18. Install five clips (11) and five clips (28) with bolts (8) and washers (9). Clips (11) are installed on hose (3) and clips (28) are installed on hose (4). Clips (11) and clips (28) are attached together. The clips are secured to the frame with five bolts (8) and five washers (9) .

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Illustration 62	g01450783

19. Install hose assembly (3) onto the frame by using clip (29). Install hose assembly (4) onto the frame by using clip (12). Use bolt (8) and hard washer (9) to attach clips (12) and (29) to the frame.

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Illustration 63	g01450845

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Illustration 64	g01450891

20. Install clip (11) on hose (3). Attach plate (30) on clip (11) with bolt (8), washer (9) and nut (13). Attach clip (31) and clip (32) to the hydraulic line that is shown in Illustration 64. Use bolt (8), washer (9) and nut (13) to attach clips (31) and (32) to plate (30) .

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Illustration 65	g01450893

21. Install clip (11) to hose (3). Attach clip (33) to clip (11) with bolt (8), washer (9) and nut (13) .

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Illustration 66	g01451112
View of clip (11)

22. Install clip (11) on a boss on the tank. Attach clip (11) to hose (4) with bolt (8) and washer (9) .

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Illustration 67	g01451792
LH view of hose (5) that is installed

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Illustration 68	g01451821
RH side of frame

23. Attach four clips (6) on hose (5). Use four bolts (8) and four washers (9) to attach four clips (6) to the frame.

Reinstall Procedure

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Illustration 69	g01537693

1. Use a suitable lifting device in order to position fan (S) to the adapter (U) .

   Note: The approximate weight of fan (S) is 55 kg (121 lb).

2. Attach fan (S) and adapter (U) to the fan drive with eight bolts (DD) that were removed earlier.

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Illustration 70	g01336925

3. Use the hardware that was retained in Step 11 of the ""Removal Procedure" " in order to secure the fan guards.

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Illustration 71	g01337033

4. Install belt guards that were previously removed in Step 9 of the ""Removal Procedure" ".

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Illustration 72	g01333317

5. Place pipe (G) in the correct position and then tighten clamps (K) that were removed in Step 6 of the ""Removal Procedure" ".

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Illustration 73	g01333199

6. Install pipe (G).

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Illustration 74	g01333330

7. Reconnect the fitting (H) to the elbow that was disconnected in Step 7 of the ""Removal Procedure" ".

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Illustration 75	g01537698

8. Install aftercooler tubes that were removed in Step 3 of the ""Removal Procedure" ".

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Illustration 76	g01455203
View of assembled aftercooler tubes with clamps (C)

9. Install two clamps (C) that were removed in Step 3 of the ""Removal Procedure" ".

10. Reinstall the hood. Refer to the Disassembly and Assembly manual in order to install the hood.

Procedure to Activate Fan Control Program

Table 5

Parts that are Needed to Activate Fan Control Program
Item	Qty	Part Number	Description
1	1	319-1823	Engine Ratings Electronic Software Gp

1. Retrieve engine software (1) .

   Note: Verify that the software that is being used is the most recent version.

2. Go into the engine Caterpillar Electronic Technician (ET).

3. Under "Configure Control Screen", select the "Engine Fan Control".

4. Turn the "Engine Fan Control" to ON.