- Off-Highway Truck/Tractor
- 777E (S/N: KDP1-687,689-690,699-754)
Description Of Change: The hose routing in the fuel lines group has been improved on certain 777E Off-Highway Trucks. The improved hose routing will help to reduce hose rubbing near the fuel tank in the fuel lines group.
Adaptable To:
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| Illustration 1 | g06316499 |
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View of the updated area (A) Previous design (B) New design | |
Updating the routing of the fuel lines group includes changes to the power train lines group, frame assembly, and fuel line group.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.
Refer to the procedure below for instructions to update the fuel lines group.
Procedure to Update the Fuel Lines Group
References
Operation and Maintenance Manual, SEBU9388, 777E Off-Highway Truck
Special Instruction, REHS1841, "General Welding Procedures"
Safety
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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility. |
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Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. |
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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death. |
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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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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 by reading and understanding 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 instructions of the manufacturer and the safety practices of your employer. Do not touch live electrical parts. See “American National Standard Z49.1, Safety in Welding and Cutting” which is published by the American Welding Society. American Welding Society8669 NW 36 Street #130 Miami, Florida 33166-6672 1-800-443-9353 See “OSHA Safety and Health Standards, 29 CFR 1910” which is available from the U.S. Department of Labor. U.S. Department of LaborWashington, D.C. 20210 See applicable requirements for your local area. |
| NOTICE |
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Do not reuse O-ring seals. Replace with Cat® approved replacement O-ring seals. Apply clean lubricant to the new O-ring seals. Ensure that the O-ring seals are seated correctly. Use caution not to damage the O-ring seals during the tightening procedure. |
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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. |
Required Parts
| Required Parts | |||
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| Item | Qty | Part Number | Part Name |
| 1 | 1 | Boss | |
| 2 | 1 | Elbow | |
| 3 | 1 | O-Ring Seal | |
| 4 | 1 | Bolt | |
| 5 | 2 | Hard Washer | |
| 6 | 1 | Nut | |
| 7 | 1 | Plate As | |
| 8 | 1 | Bolt | |
| 9 | 1 | Washer | |
Machine Preparation
- Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, SEBU9388, "Prepare the Machine for Maintenance" for instructions.
- Release the pressure in the fuel system. Refer to Operation and Maintenance Manual, SEBU9388, "System Pressure Release" for instructions.
Procedure
- Remove and retain bolts (A) and washers (B) that secure clipping to plate assembly (C).
- Remove and discard bolt (D) and washer (E) that secure plate assembly (C) to the frame. Remove and discard plate assembly (C).
Show/hide table
Illustration 3 g06316133 View of the fuel lines group
(F) Hose assembly
(G) Hose assembly
(H) Clip
(J) Boss - Move aside hose assembly (F), hose assembly (G), and clip (H) to gain access to boss (J).
Note: The hose assemblies do not need to be completely removed.
- Remove and discard boss (J) from the frame.
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Illustration 4 g06316105 View of the frame
(1)9D-6166 Boss
(D1)47 ± 5 mm (1.85 ± 0.197 inch)
(D2)719 ± 5 mm (28.31 ± 0.197 inch)
(W1) Square groove weld on both sidesNote: Refer to Special Instruction, REHS1841, "General Welding Procedures" prior to performing any welding on the machine.
- Locate boss (1) onto the frame using the dimensions given in Illustration 4.
Prepare the area for welding. Make sure that the area is free from dirt, oil, debris, paint, and other substances.
Weld boss (1) to the frame.
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Illustration 5 g06316137 View of the fuel lines group
(K) Hose assembly
(L) Hose assembly - Disconnect hose assembly (K) and hose assembly (L) from the fuel tank.
Note: The hose assemblies only need to be disconnected from the fuel tank connections.
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Illustration 6 g06316145 View of the fuel lines group
(2)8T-8899 Elbow
(3)228-7092 O-Ring Seal
(K) Hose assembly
(L) Hose assembly - Connect elbow (2) to the fuel tank.
- Connect hose assembly (K) with O-ring seal (3) to elbow (2).
Note: Ensure that hose assembly (K) is routed on top of the power train lines group.
- Reconnect hose assembly (L) to the fuel tank.
Note: Ensure that hose assembly (L) is routed on top of the power train lines group.
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Illustration 7 g06316178 View of the fuel lines group
(4)8T-4136 Bolt
(5)8T-4121 Hard Washer
(6)344-5675 Nut
(7)536-5402 Plate As
(K) Hose assembly
(L) Hose assembly - Secure the existing clip for hose assembly (K) and hose assembly (L) to plate assembly (7) by using one bolt (4), two hard washers (5), and one nut (6).
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Illustration 8 g06316193 View of the fuel lines group
(1)9D-6166 Boss
(7)536-5402 Plate As
(8)4L-6454 Bolt
(9)7X-7729 Washer
(A) Bolt
(B) Washer - Secure the existing clipping from the power train lines group to plate assembly (7) by using retained bolts (A) and retained washers (B).
- Secure plate assembly (7) to boss (1) by using bolt (8) and washer (9).
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| Illustration 2 | g06316131 |
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View of the fuel lines group (A) Bolt (B) Washer (C) Plate Assembly (D) Bolt (E) Washer | |
