- Quarry Truck
- 773G (S/N: MWH1-422; JWS1-386; T5S1-126; T5T1-106)
- 775G (S/N: T5F1-103; RFM1-890; MJS1-561; T5W1-112)
Introduction
This Special Instruction outlines the parts and procedures needed to install improved engine mounts on certain 773G and 775G Off-Highway Trucks. Improved front engine mounts are now available for the machines listed above. The new mounts are composed of a stiffer material compound and are more resistant to deformation. The fan shroud clearance tolerances can be better maintained by utilizing the improved mounts.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. Refer to the Disassembly and Assembly Manual for your machine for any additional information.
Safety Section
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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 work tool to the ground and engage the parking brake. Stop the engine and remove the key. Block the wheels and install the steering frame lock. |
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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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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage. |
Required Parts
| Parts List | ||||
| Item | Qty | New Part Number | Description | Former Part Number |
| 1 | 4 | Mount As | ||
| 2 | 4 | Tapered Sleeve | ||
| 3 | 2 | Bolt | ||
| 4 | 2 | Bolt | ||
| 5 | 4 | Nut | ||
| 6 | 6 | Hard Washer | ||
| 7 | 8 | Washer | ||
| 8 | 2 | Hard Washer | ||
| 9 | 2 | Washer (shim) | ||
| 10 | 2 | Washer | ||
| 11 | 20 | Hard Washer | ||
| 12 | 1 | Pin (Alignment tool) | ||
| (1) | The |
| (2) | Two extra washer may be needed as extra shim stock for fan shroud clearance. |
| (3) | This hard washer only used if replacing the fan shroud assembly |
Installation Procedure
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| Illustration 1 | g06142514 |
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View of location of the front mounts | |
Removal of the Engine Mounts
- Raise Machine Body and install safety pins.
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Illustration 2 g06142074 View of underside of the machine. - Remove engine compartment lower skid plates. Retain all hardware for reuse.
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Illustration 3 g06142234 View of guards - Remove all fan belt and fan guards from fan shroud. Retain all hardware for later use.
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Illustration 4 g06142247 View of lower hoses and ATAAC tube Show/hide table
Illustration 5 g06142281 View of upper hoses and ATAAC tubes - Remove upper and lower radiator tubes, upper and lower ATAAC tube, upper ATAAC flexible hose connections and remove right-hand upper exhaust tube from DOC canister.
Note: The right-hand upper exhaust tube from the DOC canister is equipped to HRC machines only.
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Illustration 6 g06142352 - Loosen all hoses from engine cross member.
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Illustration 7 g06142319 View from right-hand side of machine - Remove engine cooling fan.
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Illustration 8 g06142496 View from top of machine - Sling engine from above utilizing the front lifting eye. Use an appropriate lifting device.
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Illustration 9 g06142549 Front of Engine assembly - Remove bolts from center two engine mounts and raise front of engine approximately
114.3 mm (4.5 inch) for clearance.Show/hide table
Illustration 10 g06142563 - Press or drive out engine mounts from pedestal casting assembly. Discard the old mounts.
Installation of Front Engine Mounts
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| Illustration 11 | g06145076 |
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Overview of right-side engine mount assembly (1A) (1B) (2) (3) (5) (6) (7) (8) (9) | |
- Install one 6Y-6884 Tapered Sleeve (2) into each 9W-9958 Mount (1B).
Note: The new 6Y-9980 Mount As (1) have 6Y-6884 Tapered Sleeves (2). The sleeves (2) will only install one direction as shown.The 6Y-9980 Mount As (1) is made up of two halves, 9W-9958 Mount (1B) and 9W-8095 Rebound Pad (1A).
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Illustration 13 g06146296 Front view
(1B)9W-9958 Mounts - Install both 9W-9958 Mounts (1B) into front engine mounting bracket.
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Illustration 14 g06146329 Front view
(1B)9W-9958 Mounts
(9)493-4495 Washers (shims) - Place two 493-4495 Washers (shims) (9) between the top of the front cross member and the bottom of both 9W-9958 Mounts (1B).
- Lower engine assembly back down onto the cross member.
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Illustration 15 g06146362 Front view
(1A)9W-8095 Rebound Pad
(3)9X-8477 Bolt
(5)8T-4001 Nut
(6)8T-4167 Hard Washer
(7)8Y-7119 Washer
(8)267-3507 Hard Washer - Place two 9W-8095 Rebound Pads (1A), two 8Y-7119 Washers (7), and two 8T-4167 Hard Washers (6) in place on top of the engine mounting bracket.
- Insert one 9X-8477 Bolt (3) along with one 267-3507 Hard Washer (8) up through the mounting hole in the bottom of the front cross member for each mount.
- Continue to thread 9X-8477 Bolt (3) up through the front cross member, Rebound pads (1A), Washers (7), and hard washer (6). Secure Bolt (3) using 8T-4001 Nut (5).
Note: Do not fully tighten Bolt (3)now to help facilitate in setting the cooling fan to fan shroud clearance.
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| Illustration 12 | g06142830 |
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View of new mount and sleeve. (1B) (2) | |
Removal of Front Cross Member to Frame Mounts
- Remove hardware from outer engine mounts.
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Illustration 17 g06146414 - Using the appropriate size jack, raise the cross member above the frame mount high enough to allow removal of the old rubber mounts.
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Illustration 18 g06142830 - Insert 6Y-6884 Tapered Sleeve (2) into the 6Y-9980 Mount As (1B) as done previously.
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Illustration 19 g06146746 Right-hand side cross member support
(1B)6Y-9980 Mount As - Install one 6Y-9980 Mount As (1B) into the frame support bracket.
- Install one 8Y-7119 Washer (7) between the mount (1B) and the bottom of the cross member assembly carefully lining up the center hole.
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Illustration 20 g06146775 View of right-hand mount - Lower the cross member back onto the frame support.
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Illustration 21 g06146844 View of right-side mount position
(4)7X-2579 Bolt
(8)267-3507 Hard Washer
(10)8W-6731 Washer - Insert one 7X-2579 Bolt (4) with one 267-3507 Hard Washer (8), and one 8W-6731 Washer (10) through the top mounting hole in the cross member support.
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Illustration 22 g06146855 View of right-hand mount
(1A)9W-8095 Rebound Pad
(4)7X-2579 Bolt
(5)8T-4001 Nut
(7)8Y-7119 Washer
(8)267-3507 Hard Washer - Continue inserting Bolt (4) down through the cross member, Washer (7), and Mount (1B).
- Install one 9W-8095 Rebound Pad (1A), one 8Y-7119 Washer (7), one 267-3507 Hard Washer (8) onto Bolt (4) and secure using one 8T-4001 Nut (5).
Note: Do not torque down Bolt (4) until the cooling fan shroud is being installed.
- Repeat Steps 1 through 9 for removal and installation of the left-side cross member to frame mount.
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| Illustration 16 | g06143141 |
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View of outer cross member mounts | |
Checking Shroud for Fan Clearance
- Loosen all bolts that retain fan shroud assembly to the cooling package.
Note: If the shroud is damaged, it will be necessary to replace the entire 333-7314 Shroud assembly along with 20 7X-0632 Hard Washers.
- Reinstall the engine cooling fan assembly.
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Illustration 24 g06142953 View of clearance between shroud and fan blade
(12)199-0808 Pin - Utilize the
7 mm (0.28 inch) 199-0808 Pin (12) as a guide to maintain equal clearance between the fan blade tips and the inner circumference of the shroud assembly. Torque engine and frame mounting bolts to800 ± 100 N·m (590 ± 74 lb ft) . Adjust the shroud up or down on the shrouds mounting slots to set clearance then tighten the shroud to the cooling package.Note: It may be necessary to add or subtract shims (washers) from the engine mounts to attain the desired clearance for the fan blades if the distance cannot be corrected by adjusting the shrouds position.
- Reinstall the fan guards onto the shroud and continue to verify blade tip clearance as the guards are tightened to the shroud.
- If, the blade tip clearance is correct reinstall all other components and the machine can go back to work.
- Monitor the inner surface of the shroud for the next 1000 hours to identify any indication of shroud to fan contact.
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| Illustration 23 | g06143037 |
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Bolts continue around the entire shroud | |
