- Off-Highway Truck/Tractor:
- 777G (S/N: T5A1-UP; RDR1-UP)
- Quarry Truck:
- 773G (S/N: JWS1-UP; T5T1-UP)
- 775G (S/N: T5F1-UP; MJS1-UP)
Introduction
This special instruction contains the information and procedures that are required in order to install the cold-weather cover group onto certain Tier IV 773G, 775G, and 777G Off-Highway Trucks.
Note: The 446-0464 Wiring Harness is only required for Tier 4 engines not equipped with right-hand side Intake Manifold Absolute Pressure Sensor (IMAP). In some instances machine may have already been reworked with the 446-0464 Wiring Harness . Refer to list below:
- 773G JWS1-249
- 773G T5T1-103
- 775G MJS1-398
- 775G T5F1-102
- 777G RDR1-297
- 777G T5A1-118
Note: If the engine software is updated, per the instructions in this document and the IMAP sensor is not installed the machine will log the following Diagnostic Code: 1785-3 Intake Manifold Pressure Sensor; Voltage Above Normal.
Read the entire special instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.
 |
Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility. |
 |
|
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. |
|
|
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 |
|---|
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. |
| 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, "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. |
Machine Preparation
- Move the machine to a hard level surface.
- Avoid sudden steering inputs when you are parking the machine.
- Apply the service brakes in order to stop the machine.
- Move the transmission control lever to the PARK position.
- If the body is fully lowered, place the hoist control lever in the FLOAT position for at least 10 seconds.
- If the body is in the raised position, ensure that all of the body pins have been installed correctly, or that the retaining cable has been installed correctly. Refer to Operation and Maintenance Manual, "Body Retaining Pins - Installation", or Operation and Maintenance Manual, "Cable (Truck Body Retaining) - Installation" for instructions on securing the truck body. Place the hoist control lever in the FLOAT position for at least 10 seconds.
- Turn the engine start switch to the OFF position in order to stop the engine.
- Turn the battery disconnect switch to the OFF position.
- Disconnect the battery. Refer to Special Instruction, SEHS7633, "Battery Maintenance Procedure" for additional information on the battery.
- Chock the front wheels and the rear wheels. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".
Required Parts
| Required Parts to Install the 449-8545 Cover Gp onto the 773G and 775G Off-Highway Truck | ||
| Qty | Part Number | Description |
| 1 | 449-8539 | Bracket As |
| 1 | 449-8541 | Bracket As |
| 2 | 449-8543 | Bracket As |
| 1 | 449-8544 | Cover As |
| 4 | 5P-4116 | Hard Washer |
| 4 | 8T-4189 | Bolt |
| 5 | 7K-1181 | Cable Strap |
| 1 | 228-7101 | O-Ring Seal |
| 1 | 320-3061 | Pressure Sensor |
| 1 | 446-0464 | Wiring Harness |
| 1 | 458-2978 Engine Software (1) | Engine Ratings Electronic Software Gp |
| 1 | 458-3398 Engine Software (2) | Engine Ratings Electronic Software Gp |
| ( 1 ) | Replaces 450-9934 Engine Ratings Electronic Software Gp or earlier software version for 773G |
| ( 2 ) | Replaces 451-0603 Engine Ratings Electronic Software Gp or earlier software version for 775G |
| Required Parts to Install the 449-0978 Cover Gp onto the 777G Off-Highway Truck | ||
| Qty | Part Number | Description |
| 1 | 449-0972 | Bracket As |
| 1 | 449-0974 | Bracket As |
| 2 | 449-0976 | Bracket As |
| 1 | 449-0977 | Cover As |
| 4 | 5P-4116 | Hard Washer |
| 4 | 8T-4189 | Bolt |
| 5 | 7K-1181 | Cable Strap |
| 1 | 228-7101 | O-Ring Seal |
| 1 | 320-3061 | Pressure Sensor |
| 1 | 446-0464 | Wiring Harness |
| 1 | 458-3399 Engine Software (1) | Engine Ratings Electronic Software Gp |
| ( 1 ) | Replaces 451-0606 Engine Ratings Electronic Software Gp or earlier software version for 777G |
Install the 449-8545 Cover Gp onto the 773G and 775G Off-Highway Truck
| Required Parts to Install the 449-8545 Cover Gp onto the 773G and 775G Off-Highway Truck | |||
| Item | Qty | Part Number | Description |
| 1 | 1 | 449-8539 | Bracket As |
| 2 | 1 | 449-8541 | Bracket As |
| 3 | 2 | 449-8543 | Bracket As |
| 4 | 1 | 449-8544 | Cover As |
| 5 | 4 | 5P-4116 | Hard Washer |
| 6 | 4 | 8T-4189 | Bolt |
| 7 | 5 | 7K-1181 | Cable Strap |
| 8 | 1 | 228-7101 | O-Ring Seal |
| 9 | 1 | 320-3061 | Pressure Sensor |
| 10 | 1 | 446-0464 | Wiring Harness |
| 11 | 1 | 458-2978 Engine Software (1) | Engine Ratings Electronic Software Gp |
| 12 | 1 | 458-3398 Engine Software (2) | Engine Ratings Electronic Software Gp |
| ( 1 ) | Replaces 450-9934 Engine Ratings Electronic Software Gp or earlier software version for 773G |
| ( 2 ) | Replaces 451-0603 Engine Ratings Electronic Software Gp or earlier software version for 775G |
- Remove and retain ten bolts (A) and ten hard washers (B) .
 | |
| Illustration 1 | g03599717 |
Front view of the cowling group (A) Bolt (B) Hard washer | |
- Install bracket assembly (2) and secure into position using ten bolts (A) and ten hard washers (B) retained in Step 1.
 | |
| Illustration 2 | g03599777 |
Left side view of the cowing group (A) Bolt (B) Hard washer (2) Bracket assembly | |
- Install both bracket assemblies (3) onto bracket assembly (2) and secure using two hard washers (5) and two bolts (6) .
 | |
| Illustration 3 | g03632039 |
Front view of the cowling group (2) Bracket assembly (3) Bracket assembly (5) Hard washer (6) Bolt | |
- Remove and retain ten bolts (C) and ten hard washers (D) .
 | |
| Illustration 4 | g03599877 |
Right side view of the cowling group (C) Bolt (D) Hard washer | |
- Install bracket assembly (1) and secure into position using ten bolts (C) and ten hard washers (D) retained in Step 4.
 | |
| Illustration 5 | g03599946 |
Right side view of the cowing group (C) Bolt (D) Hard washer (1) Bracket assembly (3) Bracket assembly (5) Hard washer (6) Bolt | |
- Secure bracket assemblies (3) to bracket assembly (1) using two hard washers (5) and two bolts (6) .
- Install cover assembly (4) by sliding cover assembly (4) eyelets over each turnbuckle (E) and rotating each turnbuckle (E) 90 degrees.
Note: Ensure that the flaps on cover assembly (4) are on the outside when installed.
 | |
| Illustration 6 | g03603896 |
Front view of the cowling group (E) Turnbuckle (4) Cover assembly | |
- Locate the ECM (F). ECM (F) is located on the left-hand side of the engine.
 | |
| Illustration 7 | g03604736 |
View of the left-hand side of the engine (F) Electronic Control Module (ECM) (G) Pin cover | |
- Remove pin cover (G) (if equipped).
- Remove and retain air intake tube and elbow (H) .
 | |
| Illustration 8 | g03604959 |
View of the right-hand side of the engine (H) Air intake tube and elbow (J) Clip (K) Bolt (L) Oil filter assembly | |
- Remove clip (J) and four bolts (K) used to secure oil filter assembly (L) .
- Rotate oil filter assembly (L) in order to achieve access to the intake manifold. Secure oil filter assembly.
- Remove plug assembly (M) on the right-hand side of the engine. Refer to Illustration 9 for location of plug assembly (M) .
 | |
| Illustration 9 | g03620220 |
Typical view of the right-hand side of the engine | |
 | |
| Illustration 10 | g03606577 |
View of the right-hand side of the engine (M) Plug assembly | |
- Install O-Ring seal (8) and pressure sensor (9) .
 | |
| Illustration 11 | g03606878 |
Top view of the engine (N) Engine harness (8) O-Ring seal (9) Pressure sensor (10) Wiring harness | |
- Connect wiring harness (10) to pressure sensor (9) .
- Route wiring harness (10) along the side of existing engine harness (N) to ECM.
- Make the following connections to the pin connector:
- Yellow "C822" to pin 41 Wire harness label "ECM-41"
- Brown "G826" to pin 80 Wire harness label "ECM-80"
- Blue "G827" to pin 93 Wire harness label "ECM-93"
- Yellow "C822" to pin 41 Wire harness label "ECM-41"
 | |
| Illustration 12 | g03607096 |
Close up view of pin connector (10) Wiring harness | |
- Route wiring harness (10) and secure using five cable straps (7) .
 | |
| Illustration 13 | g03607136 |
(G) Pin cover (7) Cable straps (10) Wiring harness | |
- Install pin cover (G) (if equipped).
- Install air intake tube and elbow (H), clip (J), and oil filter assembly (L) .
 | |
| Illustration 14 | g03607197 |
View of the right-hand side of the engine (H) Air intake tube and elbow (J) Clip (L) Oil filter assembly | |
- Update machine with appropriate software. Refer to Table 3 for the appropriate software part number.
Note: If the engine software is updated, per the instructions in this document and the IMAP sensor is not installed the machine will log the following Diagnostic Code: 1785-3 Intake Manifold Pressure Sensor; Voltage Above Normal.
Install the 449-0978 Cover Gp onto the 777G Off-Highway Truck
| Required Parts to Install the 449-0978 Cover Gp onto the 777G Off-Highway Truck | |||
| Item | Qty | Part Number | Description |
| 1 | 1 | 449-0972 | Bracket As |
| 2 | 1 | 449-0974 | Bracket As |
| 3 | 2 | 449-0976 | Bracket As |
| 4 | 1 | 449-0977 | Cover As |
| 5 | 4 | 5P-4116 | Hard Washer |
| 6 | 4 | 8T-4189 | Bolt |
| 7 | 5 | 7K-1181 | Cable Strap |
| 8 | 1 | 228-7101 | O-Ring Seal |
| 9 | 1 | 320-3061 | Pressure Sensor |
| 10 | 1 | 446-0464 | Wiring Harness |
| 11 | 1 | 458-3399 Engine Software (1) | Engine Ratings Electronic Software Gp |
| ( 1 ) | Replaces 451-0606 Engine Ratings Electronic Software Gp or earlier software version for 777G |
- Remove and retain eight bolts (A) and eight hard washers (B) .
 | |
| Illustration 15 | g03595158 |
Front view of the cowling group (A) Bolt (B) Hard washer | |
- Install bracket assembly (1) and secure into position using eight bolts (A) and eight hard washers (B) retained in Step 1.
 | |
| Illustration 16 | g03595356 |
Left side view of the cowing group (A) Bolt (B) Hard washer (1) Bracket assembly | |
- Install both bracket assemblies (3) onto bracket assembly (1) and secure using two hard washers (5) and two bolts (6) .
 | |
| Illustration 17 | g03632638 |
Front view of the cowling group (1) Bracket assembly (3) Bracket assembly (5) Hard washer (6) Bolt | |
- Remove and retain eight bolts (C) and eight hard washers (D) .
 | |
| Illustration 18 | g03595445 |
Front view of the cowling group (C) Bolt (D) Hard washer | |
- Install bracket assembly (2) and secure into position using eight bolts (C) and eight hard washers (D) retained in Step 4.
 | |
| Illustration 19 | g03596316 |
Right side view of the cowing group (C) Bolt (D) Hard washer (2) Bracket assembly (3) Bracket assembly (5) Hard washer (6) Bolt | |
- Secure bracket assemblies (3) to bracket assembly (2) using two hard washers (5) and two bolts (6) .
- Install cover assembly (4) by sliding cover assembly (4) eyelets over each turnbuckle (E) and rotating each turnbuckle (E) 90 degrees.
Note: Ensure that the flaps on cover assembly (4) are on the outside when installed.
 | |
| Illustration 20 | g03597054 |
Front view of the cowling group (E) Turnbuckle (4) Cover assembly | |
- Locate the ECM (F). ECM (F) is located on the left-hand side of the engine.
 | |
| Illustration 21 | g03607296 |
View of the left-hand side of the engine (F) Electronic Control Module (ECM) (G) Pin cover | |
- Remove pin cover (G) (if equipped).
- Remove plug assembly (H) on the right-hand side of the engine. Refer to Illustration 22 for location of plug assembly (H) .
 | |
| Illustration 22 | g03620496 |
Typical view of the right-hand side of the engine | |
 | |
| Illustration 23 | g03607756 |
View of the right-hand side of the engine (H) Plug assembly | |
- Install O-Ring seal (8) and pressure sensor (9) .
 | |
| Illustration 24 | g03607829 |
Top view of the engine (J) Engine harness (8) O-Ring seal (9) Pressure sensor (10) Wiring harness | |
- Connect wiring harness (10) to pressure sensor (9) .
- Route wiring harness (10) along the side of existing engine harness (N) to ECM.
- Make the following connections to the pin connector:
- Yellow "C822" to pin 41 Wire harness label "ECM-41"
- Brown "G826" to pin 80 Wire harness label "ECM-80"
- Blue "G827" to pin 93 Wire harness label "ECM-93"
- Yellow "C822" to pin 41 Wire harness label "ECM-41"
 | |
| Illustration 25 | g03607845 |
Close up view of pin connector (10) Wiring harness | |
- Route wiring harness (10) and secure using five cable straps (7) .
 | |
| Illustration 26 | g03607848 |
(G) Pin cover (7) Cable straps (10) Wiring harness | |
- Install pin cover (G) (if equipped).
- Update machine with appropriate software. Refer to Table 4 for the appropriate software part number.
Note: If the engine software is updated, per the instructions in this document and the IMAP sensor is not installed the machine will log the following Diagnostic Code: 1785-3 Intake Manifold Pressure Sensor; Voltage Above Normal.
Operating Conditions
| Operating Conditions for the use of the 449-0978 Cover Gp and the 449-8545 Cover Gp | ||
| Ambient Temperature | Operating Machine | Machine Extended Idle |
| −40° C (−40° F) and Below | Cover closed | Cover closed |
−40° C (−40° F) to 0° C (32° F) |
Cover half open | Cover closed |
0° C (32° F) to 15° C (59° F) |
Cover fully open | Cover closed |
15° C (59° F) and Above |
Remove cover | Remove cover |
- When the machine is at extended idling over 5 minutes or machine is operating in a temperature of −40° C (−40° F) and below, close the cover group.
 | |
| Illustration 27 | g03604000 |
View of the cover group closed 777G | |
 | |
| Illustration 28 | g03620577 |
View of the cover group closed 773G/775G | |
- When operating the machine in temperatures between −40° C (−40° F) to 0° C (32° F) open half, top or bottom, of the cover group,
 | |
| Illustration 29 | g03604096 |
View of the cover group half-way open 777G | |
 | |
| Illustration 30 | g03620604 |
View of the cover group half-way open 773G/775G | |
- When operating the machine in temperatures between 0° C (32° F) to 15° C (59° F) fully open (top and bottom) of the cover group.
 | |
| Illustration 31 | g03604176 |
View of the cover group fully opened 777G | |
 | |
| Illustration 32 | g03620618 |
View of the cover group fully opened 773G/775G | |
- When operating the machine in temperature 15° C (59° F) and above, remove the cover group.
 | |
| Illustration 33 | g03604198 |
View of the cover group removed 777G | |
 | |
| Illustration 34 | g03620641 |
View of the cover group removed 773G/775G | |