Procedure to Update the 225-8210 Accumulator Lines Gp on Certain 773F and 775F Off-Highway Trucks{4257, 4263, 5068} Caterpillar

Off-Highway Truck/Tractor:

773F (S/N: EED1-UP)

Quarry Truck:

775F (S/N: DLS1-UP)

Introduction

This special instruction will provide the detailed instruction for replacing the 225-8210 Accumulator Lines Gp with the latest engineering change. The instruction applies to the machines listed above.

Important Safety Information

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 must also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

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Personal injury or death can result from machine movement. Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

Reference Manuals

ReferenceOperation and Maintenance Manual, SEBU7794, "773F and 775F Off-Highway Trucks", "Hoist and Brake Oil - Change".

ReferenceOperation and Maintenance Manual, SEBU7794, "773F and 775F Off-Highway Trucks", "Capacities (Refill)".

ReferenceOperation and Maintenance Manual, SEBU7794, "773F and 775F Off-Highway Trucks", "Body Retaining Pin".

ReferenceSpecial Instructions, REHS1841, "General Welding Procedures".

Required Parts

Welding Details

ReferenceRefer to Special Instructions, REHS1841, "General Welding Procedures" for additional welding instructions.

Shielded Metal Arc Welding

The Shielded Metal Arc Welding (SMAW) process may be used with the E7018 (ANSI/AWS A5.1) welding electrode. The weld that will be deposited by these electrodes will have the following mechanical properties.

These low hydrogen electrodes must be stored in an electrode oven at 120 °C (248 °F) when the electrodes are not being used. Scrap the electrodes if the electrodes get damp.

Note: Welding parameters will vary due to the position of the weld and the parameters will vary due to the manufacturer of the welding electrode.

The following chart relates to the electrode diameter and approximate current settings for welding.

The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass. Weld all joints from the bottom upward. The number of weld passes will depend on the width of the weld joint. Remove all slag after welding. Inspect the weld for low areas. Grind high spots in the weld with a coarse pad. Be sure not to grind out any base material. Finish blending the weld with a fine pad. No sharp edges are acceptable.

Flux Cored Arc Welding

The Flux Cored Arc Welding (FCAW) process may be used with the E71T-1 (AWS A5.20) welding electrode. The FCAW process may also be used with shielding gas. The weld that will be deposited by these electrodes will have the following mechanical properties.

Note: Welding parameters will vary due to the position of the weld and the parameters will vary due to the manufacturer of the welding electrode.

For a 1.1 mm (0.045 inch) electrode, the typical welding parameters should be the following.

For a 1.3 mm (0.052 inch) electrode, the typical welding parameters should be the following.

The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass. Weld all joints from the bottom upward. The number of weld passes will depend on the width of the weld joint. Remove all slag after welding. Inspect the weld for low areas. Grind high spots in the weld with a coarse pad. Be sure not to grind out any base material. Finish blending the weld with a fine pad. No sharp edges are acceptable.

Note: All vertical welds will be welded with a vertical up technique.

Machine Preparation

1. Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.

2. Move the machine to a smooth horizontal location. Move the machine away from any machines that are working and any personnel.

3. Move the transmission control to the "PARK" position.

4. Raise the body so that you can install the retaining pins for the dump body. For the proper procedure, refer to Operation and Maintenance Manual, SEBU7794, "773F and 775F Off-Highway Trucks", "Body Retaining Pin"

5. Activate the parking brakes. Stop the Engine.

6. Place blocks in front of the wheels and behind the wheels.

7. Make sure that all oil pressure is released before any fittings, hoses, or components are worked.

8. Drain the tank for the hoist system and the brake system. Refer to Operation and Maintenance Manual, SEBU7794, "773F and 775F Off-Highway Trucks", "Hoist and Brake Oil - Change".

Removal of Existing Single Oil Filter System

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Illustration 1	g02442077

1. Remove the 287-4577 Hose As (32) by loosening four 5S-7382 Bolts (33) and removing one 1P-4577 Half Flange (34) from the 237-3960 Gear Pump Gp (35). Retain the 5S-7382 Bolts (33) and 1P-4577 Half Flange (34). Refer to Illustration 1.

   Note: If the machine is equipped with, remove one 8T-4195 Bolt (37), two 7X-7729 Washers (38), one 8T-4133 Nut (39), one 5P-8112 Grommet (40), one 5P-7466 Clip (41), one 5P-7467 Clip (42), and remove the 287-4577 Hose As (32) .

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Illustration 2	g02442121

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Illustration 3	g02442157

2. Remove the 176-1379 Hose As (43) from the 7X-0873 Tee (48) by removing one 8T-4186 Bolt (44), two 8T-4121 Hard Washers (45), one 8T-4133 Nut (39), one 5P-8112 Grommet (40), one 8E-1042 Clip (46), and one 8E-1043 Clip (47). Retain the 8T-4186 Bolt (44), two 8T-4121 Hard Washers (45), and 8T-4133 Nut (39). Refer to Illustration 2 and 3.

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Illustration 4	g02442176

3. Remove all the fittings from the 155-6061 Oil Filter Gp (5). Remove four 8T-4137 Bolts (49), four 8T-4121 Hard Washers (45), disconnect the existing switch assembly (50), and remove the 155-6061 Oil Filter Gp (5). Refer to Illustration 4.

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Illustration 5	g02442236

4. Remove the 9U-3863 Hose As (52) or 312-4964 Hose As (52) at the 6V-9007 Elbow (29) and at the 6V-8640 Connector (30) on the 281-4029 Tube As . Retain the 6V-9007 Elbow (29) and the 6V-8640 Connector (30). Refer to Illustration 5.

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Illustration 6	g02442257

5. Remove the mounting plate for the 155-6061 Oil Filter Gp (5) from the frame and prepare the frame area for locating and welding a 280-7090 Plate (1) .

   Note: Take the necessary precautions to ensure that the surrounding components are protected from damage during the removal and installation procedures.

Installation of Dual Oil Filter System

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Illustration 7	g02442258
(A) 120 mm (4.72 inch) from the top of the frame rail to the top of the plate (B) 637 mm (25.08 inch) from the weld joint on the center tube to the edge of the plate. (W1) a 6 mm (0.24 inch) fillet weld around the plate

1. Locate 280-7090 Plate (1) using dimensions (A) and (B) in Illustration 7. Attach 280-7090 Plate (1) to frame with a 6 mm (0.24 inch) fillet weld all around. Refer to Illustration 7.

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Illustration 8	g02450142

2. Remove the 136-7032 Hydraulic Oil Filter Housing from the 136-7033 Hydraulic Oil Filter Base and replace the 134-0964 Oil Filter Element As (2). Install the 136-7032 Hydraulic Oil Filter Housing to 136-7033 Hydraulic Oil Filter Base and tighten to 101.7 ± 10 N·m (75.010 ± 7.4 lb ft).

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Illustration 9	g02442524

3. Install a 128-7625 Tee (4) and 238-5082 O-Ring Seal (3) to the existing filter assembly.

4. Position 128-7625 Tee (4) as shown in Illustration 9 and torque the fitting to 190 +19/ - 0 N·m (140.1 +14/-0 lb ft).

5. Install a 7I-8310 Coupling As (7) and a 3D-2824 O-Ring Seal (6) to the new right hand 155-6061 Oil Filter Gp (5). Torque the 7I-8310 Coupling As (7) to 190 +19/ - 0 N·m (140.1 +14/-0 lb ft).

6. Assemble the two 155-6061 Oil Filter Gp (5) by connecting the 128-7625 Tee (4) to the 7I-8310 Coupling As (7) with a 228-7092 O-Ring Seal (8). Torque the fitting to 144 +15/-0 N·m (106.2 +11.1/-0 lb ft). Refer to Illustration 9.

7. Install a 6V-9854 Elbow (9) to the 128-7625 Tee (4) on the 155-6061 Oil Filter Gp (5) with a 228-7093 O-Ring Seal (10). Torque the fitting to 216 +22/-0 N·m (159.3 +16.2/-0 lb ft). Refer to Illustration 9.

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Illustration 10	g02442677

8. Secure the 366-9502 Bracket As (11) to the 280-7090 Plate (1) using four 8T-4139 Bolts (36) and four 8T-4223 Hard Washers (17). Tighten the four 8T-4139 Bolts (36) to 100 ± 20 N·m (74 ± 15 lb ft). Refer to Illustration 10.

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Illustration 11	g02442760

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Illustration 12	g02450482

9. Assemble the oil filter subassembly to 366-9502 Bracket As (11) using eight 8T-4136 Bolts and 7X-7729 Washers (38) and three 130-5300 Clips (12) positioned as shown in Illustration 11 and 12. Tighten the eight 8T-4136 Bolts (51) to 55 ± 10 N·m (40.6 ± 7.4 lb ft).

10. Connect the 328-8309 Sensor Harness As (13) to two switch assemblies (50) and chassis harness breakout from Step 3 in ""Removal of Existing Single Oil Filter System" ". Refer to Illustration 11 and 12.

11. Connect 328-8309 Sensor Harness As (13) connections to three 130-5300 Clips (12). Refer to Illustration 11 and 12.

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Illustration 13	g02442797

12. Install a 6V-8714 Connector (15) and a 3D-2824 O-Ring Seal (6) to the left hand 155-6061 Oil Filter Gp (5). Torque the fitting to 190 +19/-0 N·m (140 +14/-0 lb ft).

13. Install a 6V-9840 Swivel Tee (14) to the 6V-8714 Connector (15) with a 5K-9090 O-Ring Seal (16). Position the 6V-9840 Swivel Tee (14) as shown in Illustration 13. Torque the fitting to 216 +22/-0 N·m (159.3 +16.2/-0 lb ft).

14. Install an 8T-6684 Elbow (18) and a 3D-2824 O-Ring Seal (6) to the right hand 155-6061 Oil Filter Gp (5). Position the 8T-6684 Elbow (18) as shown in Illustration 13. Torque the fitting to 190 +19/-0 N·m (140 +14/-0 lb ft). Refer to Illustration 13.

15. Assemble the 366-9503 Hose As (19) loosely to 8T-6684 Elbow (18) using one 5K-9090 O-Ring Seal (16). Refer to Illustration 13.

16. Assemble the 366-9503 Hose As (19) loosely to 6V-9840 Swivel Tee (14) using one 5K-9090 O-Ring Seal (16). Ensure that the hose assembly is in its natural position. Tighten both ends of 366-9503 Hose As (19) to 216 +22/-0 N·m (159.3 +16.2/-0 lb ft). Refer to Illustration 13.

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Illustration 14	g02442936

17. Assemble 369-3819 Hose As (20) loosely to 6V-9854 Elbow (9) using one 228-7093 O-Ring Seal (10). Assemble 369-3819 Hose As (20) to 237-3960 Gear Pump Gp (35) using one 4J-0520 O-Ring Seal (21) and existing 5S-7382 Bolts (33) and 1P-4577 Half Flange (34) from Step 1 in ""Removal of Existing Single Oil Filter System" ". Refer to Illustration 14.

18. Tighten the four 5S-7382 Bolts (33) to 47 ± 9 N·m (34.7 ± 6.6 lb ft). Refer to Illustration 14.

19. Torque the fitting at the 6V-9854 Elbow (9) to 216 +22/-0 N·m (159.3 +16.2/-0 lb ft).

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Illustration 15	g02443720

20. Remove 7X-0873 Tee (48) part of 148-8430 Tee As and 6V-9007 Elbow (29) part of 148-8347 Elbow As both part of 274-7854 Brake Accumulator and Mounting Gp . Refer to Illustration 15.

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Illustration 16	g02443778

21. Loosely assembly 8T-6684 Elbow (18) to 228-6815 Accumulator Charging Valve (55) using one 3D-2824 O-Ring Seal (6). Refer to Illustration 16.

22. Loosely assembly one 8T-4834 Swivel Orifice Tee (22) to 8T-6684 Elbow (18) using one 5K-9090 O-Ring Seal (16). Leave all fittings loose. Refer to Illustration 16.

23. Loosely assemble 328-8782 Hose As (23) to 6V-9840 Swivel Tee (14) using one 5K-9090 O-Ring Seal (16). Refer to Illustration 13.

24. Loosely assemble 328-8782 Hose As (23) to 8T-4834 Swivel Orifice Tee (22) using one 5K-9090 O-Ring Seal (16). Refer to Illustration 16.

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Illustration 17	g02443916

25. Clip 328-8782 Hose As (23) to 282-9499 Hose As (56) using one 5P-7468 Clip (24), one 5P-7469 Clip (25), one 5P-8444 Grommet (26), and one 8T-4186 Bolt (44), two 8T-4121 Hard Washers (45), and one 8T-4133 Nut (39) from Step 2 in ""Removal of Existing Single Oil Filter System" ". Refer to Illustration 17

26. Tighten 8T-4186 Bolt (44) to 55 ± 10 N·m (40.6 ± 7.4 lb ft).

27. Tighten 8T-6684 Elbow (18) to 190 +19/-0 N·m (140 +14/-0 lb ft).

28. Tighten 8T-4834 Swivel Orifice Tee (22) to 216 +22/-0 N·m (159.3 +16.2/-0 lb ft).

29. Tighten both ends of 328-8782 Hose As (23) to 216 +22/-0 N·m (159.3 +16.2/-0 lb ft). Refer to Illustrations 16 and 17.

30. Remove 6V-3965 Fitting (57) and 6V-0852 Dust Cap (58) from 7X-0873 Tee (48) and assemble into the 8T-4834 Swivel Orifice Tee (22) using one 3J-1907 O-Ring Seal (27). Tighten 6V-3965 Fitting (57) to 27 ± 2 N·m (20 ± 1.5 lb ft). Refer to Illustration 16.

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Illustration 18	g02444338

31. Assemble 144-5194 Hose As (28) to 6V-9007 Elbow (29) part of 148-8347 Elbow As part of 236-7266 Torque Converter Lines Gp and 6V-8640 Connector (30) on 281-4029 Tube As part of 229-2094 Power Train Oil Lines Gp using two 6V-9746 O-Ring Seals (31). Tighten both ends of 144-5194 Hose As (28) to 144 +15/-0 N·m (106.2 +11.1/-0 lb ft). Refer to Illustration 18.

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Illustration 19	g02444385

32. Remove the existing grommet from the 292-9759 Hose As (54) and install a 6V-7359 Grommet (53) to the 292-9759 Hose As (54). Refer to Illustration 19.

33. Inspect service brake oil filtration system for any leaks. Observe all hydraulic tank sight gauges in order to ensure that the system is refilled to the proper level. Add fluid as required in accordance with the Operation and Maintenance Manual, SEBU7794, "773F and 775F Off-Highway Trucks", "Capacities (Refill)". Remove all tools from the machine.