Procedure to Retrofit a Single Window Wiper to Dual Window Wipers on 770G and 772G Off-Highway Trucks{7305} Caterpillar

Off-Highway Truck:

770G (S/N: ECM1-264)

772G (S/N: LTS1-357)

Introduction

The following instructions provide the needed information to retrofit a 770G or 772G cab with a single-window wiper to dual window wipers.

Safety

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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.

Prepare the Machine

Note: 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.

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

2. Move the transmission control to the P position.

3. Stop the engine.

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

5. Refer to Operation and Maintenance Manual, SEBU8491, "Prepare the Machine for Maintenance".

Procedure

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Illustration 1	g03700107
View of the front of the cab (A) 318-0049 Window Wiper Arm Gp (B) 5C-7261 Nut (C) 3F-9556 Lockwasher (D) 8T-5400 Connector As

1. Remove nut (B) and lockwasher (C) that secures window wiper arm group (A). Disconnect window wiper arm group (A) hose from connector assembly (D). Discard window wiper arm group (A), nut (B), and lockwasher (C) .

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Illustration 2	g03700145
View of the front of the cab (E) Cowling assembly

2. Remove cowling assembly (E). Retain cowling assembly (E) and all mounting hardware.

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Illustration 3	g03700177
View of the front of the cab (D) 8T-5400 Connector As

3. Loosen the nut that secures connector assembly (D). Rotate connector assembly (D) 90 degrees clockwise. Retighten the nut to secure connector assembly (D) to a torque of 0.35 ± 0.05 N·m (3 ± 0.44 lb in).

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Illustration 4	g03700211
View of the front of the cab (F) Rubber shaft (G) Nut (H) Plastic washer (J) Rubber washer (K) Bolt (L) Washer

4. Remove the hardware from the motor group. Remove rubber shaft (F), nut (G), plastic washer (H), and rubber washer (J). Retain all the hardware.

5. Remove bolt (K) and washer (L) .

   Note: Leave the motor group in place.

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Illustration 5	g03700246
(1) 437-2320 Template

6. Position template (1) onto the front of the cab.

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Illustration 6	g03700248
View of the front of the cab (1) 437-2320 Template (F) Rubber shaft (G) Nut (H) Plastic washer (J) Rubber washer (K) Bolt (L) Washer

7. Secure template (1) to the front of the cab by using rubber shaft (F), nut (G), plastic washer (H), rubber washer (J), bolt (K), and washer (L) .

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Illustration 7	g03700309
View of the front of the cab (1) 437-2320 Template (2) 8Y-3795 Boss (AA) 6 mm (0.236 inch) hole (three places)

8. Align four bosses (2) to the notches in template (1). Mark the locations of bosses (2) and three holes (AA) .

9. Remove bosses (2), template (1), and the hardware that secures template (1). Discard template (1), the mounting hardware, and the motor group.

10. Drill three 6 mm (0.236 inch) holes in areas (AA) .

11. Prepare the areas marked for bosses (2) for welding. Remove all paint, dirt, debris, or grease.

    Note: Refer to Special Instruction, REHS1841, "General Welding Procedures"

12. Tack weld four bosses (2) to the plate.

    Repaint the area, as needed.

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Illustration 8	g03700353
View of the front of the cab (3) 437-2321 Template As

13. Secure template (3) to the front of the cab by using the three bolts shipped with the new 328-2264 Window Wiper Motor Gp .

14. Mark the location of the 22 mm (0.866 inch) diameter hole in the center of template (3). Remove template (3) and the mounting hardware. Drill a 22 mm (0.866 inch) diameter hole at the location marked.

15. Repeat Step 13.

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Illustration 9	g03700356
View of the front of the cab (2) 8Y-3795 Boss (3) 437-2321 Template As (4) 436-0529 Cover As (5) 237-2228 Bolt (6) 8T-4121 Hard Washer

16. Check the alignment of the drilled holes and bosses (2). Secure cover assembly (4) to bosses (2) by using four bolts (5) and four hard washers (6). If the bolts, holes, and bosses do not align properly, make adjustments, as needed.

17. Remove and retain cover assembly (4), bolts (5), and hard washers (6) .

    Remove and discard template assembly (3). Retain the bolts from template assembly (3) .

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Illustration 10	g03700402
(7) 5C-9553 Bolt (8) 9X-2038 Washer (9) 9X-8256 Washer (10) 344-5673 Nut (11) 328-2264 Window Wiper Motor Gp

18. Seal the available hole by using bolt (7), washer (8), washer (9), and nut (10) .

    Note: Bolt (7) and washer (8) should be on the outside of the plate. Washer (9) and nut (10) should be on the inside of the plate.

19. Secure window wiper motor group (11) to the cab by using the three bolts provided with window wiper motor group (11).

    Note: Tighten the bolts to a torque of 12 ± 3 N·m (106 ± 26 lb in).

    Note: Two people are required.

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Illustration 11	g03700425
(4) 436-0529 Cover As (12) 426-0439 Window Wiper Arm Gp (BB) Nut

20. Remove the cap ends and remove nuts (BB) from window wiper arm group (12) .

21. Insert window wiper arm group (12) into cover assembly (4). In two places, hold the inner nut steady and secure window wiper arm group to cover assembly (4). Tighten nut (BB) to a torque of 38 ± 2 N·m (28 ± 1.5 lb ft).

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Illustration 12	g03700477
(12) 426-0439 Window Wiper Arm Gp (CC) Plastic cap

22. Secure two plastic caps (CC) onto window wiper arm group (12). Finger tighten plastic caps (CC) .

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Illustration 13	g03700739
(4) 436-0529 Cover As (13) 436-2615 Gasket

23. Clean the area around the hole in the back of cover assembly (4) for the location of gasket (13) with alcohol and let dry. Adhere gasket (13) to the back of cover assembly (4) .

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Illustration 14	g03700743
View of the front of the cab (2) 8Y-3795 Boss (4) 436-0529 Cover As (5) 237-2228 Bolt (6) 8T-4121 Hard Washer (12) 426-0439 Window Wiper Arm Gp

24. Secure cover assembly (4) to four bosses (2) by using four bolts (5) and four hard washers (6). Tighten bolts (5) to a torque of 55 ± 10 N·m (40 ± 7.4 lb ft).

    Note: The link ends should be removed from the ball studs at the motor crank of window wiper arm group (12) .

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Illustration 15	g03700763
View of the front of the cab (4) 436-0529 Cover As (11) 328-2264 Window Wiper Motor Gp (12) 426-0439 Window Wiper Arm Gp (DD) Nut and washer from window wiper motor group

25. Secure window wiper arm group (12) to window wiper motor group by using nut and washer (DD) from window wiper motor group (11) .

    Note: Hold the motor crank steady, and tighten the nut to a torque of 20 ± 2 N·m (177 ± 17 lb in).

    Reassemble the link ends and ball studs for window wiper arm group (12) .

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Illustration 16	g03700838
View of the front of the cab (4) 436-0529 Cover As (14) 6V-9335 Seal

26. Clean the area around the top hole on cover assembly (4) with alcohol and let the alcohol dry.

27. Adhere seal (14) around the top hole.

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Illustration 17	g03700798
View of the front of the cab (4) 436-0529 Cover As (7) 5C-9553 Bolt (9) 9X-8256 Washer (15) 436-0530 Plate (16) 437-1893 Plate (17) 436-0531 Plate

28. Secure two plates (15), plate (16), and plate (17) to cover assembly (4) by using 12 bolts (7) and 12 washers (9) .

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Illustration 18	g03700854
View of the front of the cab (D) 8T-5400 Connector As (4) 436-0529 Cover As (18) 144-0195 Hose (19) 2U-4504 Tee (20) 3S-2093 Cable Strap (21) 3V-3263 Connector

29. Connect 138 ± 5 mm (5.43 ± 0.19 inch) of hose (18) to connector assembly (D) .

    Insert tee (19) to hose (18). Connect a 400 ± 5 mm (15.75 ± 0.19 inch) and a 281 ± 5 mm (11.06 ± 0.19 inch) hose (18) to tee (19).

    Insert one connector (21) into the end of each hose (18) .

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NOTICE
Do not overtighten cable straps (20). Cable straps (20) should secure, but not constrict the hoses.

30. Secure hose (18) to cover assembly (4) by using three cable straps (20) .

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Illustration 19	g03700876
View of the front of the cab (21) 3V-3263 Connector (22) 436-6567 Window Wiper Arm Gp (23) 146-6433 Wiper Blade (24) 320-1390 Wiper Blade

31. Secure two window wiper arm groups (22) to the window wiper arm group by using the nut and washer from the window wiper arm group.

    Note: Do not final tighten.

32. Connect the hoses from window wiper arm groups (22) to connectors (21) .

33. Connect wiper blade (23) and wiper blade (24) to window wiper arm groups (22) .

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Illustration 20	g03700898
View of the front of the cab (A) 81 ± 3 mm (3.18 ± 0.118 inch) (B) 90 ± 3 mm (3.54 ± 0.118 inch)

34. Ensure that the wipers are located at the correct distance from the bottom of the front window and tighten the nuts to secure the wipers. Tighten nuts to a torque of 24 ± 1 N·m (212 ± 9 lb in).

    Wait a minimum of 30 minutes, then retighten the nuts to 24 ± 1 N·m (212 ± 9 lb in).

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Illustration 21	g03700935
(A) 60 mm (2.36 inch) (B) 150 mm (5.90 inch) (C) 450 mm (17.71 inch) (D) 400 mm (15.75 inch) (E) 50 mm (1.97 inch)

35. Adjust the jets of the washer nozzles by using 0.05 mm (0.00197 inch) wire so that the jets spray to the locations shown in Illustration 21.

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Illustration 22	g03701032

36. Verify the wipers and washers work correctly.

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Illustration 23	g03701058
Before modification (E) Cowling assembly

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Illustration 24	g03701060
(A) 65 ± 3 mm (2.55 ± 0.118 inch) (B) 870 ± 3 mm (34.25 ± 0.118 inch) (C) 5 mm (0.197 inch) radius (four places) (E) Cowling assembly

37. Enlarge the notch in cowling assembly (E) that was removed in Step 2. Refer to Illustration 24 for the dimensions.

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Illustration 25	g03701519
View of the front of the cab

38. Reinstall cowling assembly (E) that was removed in Step 2 and modified in Step 37.