Installation of OR3951 and OR3961 3508 (MUI) Remanufactured Engines in 776B Tractors and 777B Trucks{1000} Caterpillar

Installation of OR3951 and OR3961 3508 (MUI) Remanufactured Engines in 776B Tractors and 777B Trucks{1000}

Usage:

776B (6JC1-Up);
777B (47C1-Up)

Introduction

This instruction contains adaptability and installation information for the Remanufactured Engines listed in the chart that follows.

NOTE: If the engine is to be used for core credit, refer to:

* SELD0164 Core Acceptance Criteria

Reference Literature

NOTE: Refer to the Parts Manual for parts information for a specific Engine Arrangement.

Each Remanufactured Engine arrangement has a Literature Group attached, which includes:

* Parts Manual

* Operation & Maintenance Manual

* Lubrication Instructions

* Torque Specifications (for fasteners) .. and

Specific Special Instructions that will provide, as close as possible, the most current engine/machine configuration.

Refer to Special Instructions in this instruction.

An attached envelope will contain:

* Core Credit Request/Packing List .. and

* Engine Delivery Service Record.

Special Instructions

NOTE: For maximum life and optimum performance, it is factory RECOMMENDED that the following specific Special Instructions be performed at installation.

Each Special Instruction will be referenced by:

* Form Number

* Title

* Model Designation and

* Effective Product Identification Number (PIN) .. and/or

* Effective engine serial number or engine serial number range

A brief review of the instruction is also included.

SEHS9329 .. Installation of Automatic Ether Injection System (AEIS)

776B 6JC1 - 83

777B 4YC1 - 1383

The automatic ether injection system controls the amount of ether to be injected into the engine intake manifold during cold weather starting.

Correct operation of this electrically controlled system is required to prevent possible damage to the engine during cold-start conditions.

SEHS9241 .. Operator Instruction Card for Automatic Ether Injection (AEIS) Card

All Machine Models

This provides a new card to be installed in the machine cab.

SEHS9340 .. Jacket Water Heater Installation Procedures

All Machine Models

The jacket water heater keeps the engine water temperature warm when ALL the ambient air temperature is below 13°C (55.4°F).

The warm jacket aids in preventing rough combustion after cold start-ups.

SEHS9397 .. Installation of Multipoint Pressure Sensing System (MPPS) Version of Automatic Ether Injection System (AEIS)

776B 6JC1 - 98

777B 4YC1 - 1639

The Multipoint Pressure Sensing System Version of the Automatic Ether Injection System (AEIS) provides a low oil pressure warning whose switch point varies with engine speed.

The current low oil pressure warning on EMIS has only a single switch point which may not signal a loss of pressure at higher engine rpm until the oil level is very low.

The MPPS measures engine rpm and oil pressure and compares it to a switch point curve of oil pressure vs rpm.

It uses this to determine when a low oil pressure condition exists for any given rpm and signals it through the EMS Panel.

This feature provides better protection of the engine in the event of a loss of oil pressure when running at or near rated speed.

SEHS9227 .. Installation of Switches/Sensors with Sure-Seal Connectors

All Machine Models

This instruction provides the necessary procedure for field installation of upgraded electrical components where the original parts used screws, studs, blade, bullet or MS connectors instead of Sure-Seal connectors.

Sure-Seal connectors offer improved reliability over the mentioned terminals.

Installation of an upgraded component in place of the former component requires installation of a mating Sure-Seal connector on the machine harness.

SEHS9256 .. Thermal Heat Shield Removal

This instruction provides the necessary information for the removal of the heat shields on these machines.

When the heat shields are removed (revised), a work platform, an oil filler tube shield and several other shields will be installed on the machine.

The removal will require ether start line re-routng.

Exchange of Parts

Each Remanufactured Engine is built to a reference engine arrangement, as shown in the Reference Literature Chart in this instruction.

All 3500 series MUI Remanufactured Engines are remanufactured to the most critical engineering changes for the arrangement ordered:

* Alternator belt guard

* Connecting rods

* Crankshaft

* Exhaust manifold

* Exhaust thermocouples

* Fuel lines and clamps

* Gear train

* Governor

* Improved camshaft

* Lubrication tubes and clamps

* New exhaust valves

* Oil pan

* Oil cooler cores

* Turbocharger

* Valve lifters

NOTE: All non-metallic parts (gaskets, seals) and fasteners (bolts) are replaced and the improved parts are Remanufactured where applicable.

This minimizes or eliminates the need for the user to make modifications and reduces downtime provided the CORRECT arrangement was ordered.

However, some of the engine related engineering changes incorporated in the Remanufactured engine received may require machine changes at installation time to achieve optimum performance available from this updated Remanufactured Engine.

The Special Instructions, as shown in the Reference Literature Chart, provides the effective Product Information Number of all the changes which may apply to the machine.

If the machine's Product Information Number appears in the Reference Literature Chart it is RECOMMENDED that the update/changes be made to maximize the performance of this new Remanufactured Engine.

Each Remanufactured Engine is built to the advertised Rated Power @ RPM, that agrees with the original engine's power rating and rpm.

This is recorded on each Remanufactured Engine Information Plate.

NOTE: Do NOT change/adjust any fuel setting(s) before referring to the specific Fuel Setting and Related Information Library.

Inspect (Replace as REQUIRED), (OPTIONAL Parts Replacement), (RECOMMENDED Parts Replacement)

For maximum life of the Caterpillar Remanufactured Engine, the following machine components MUST be inspected for reusability before engine installation and REPLACED as REQUIRED.

1N3331 Support Group

Inspect 7W0392 Mount Assembly (front) and 7W0443 Mount Assembly (rear) rubber for:

* Loss of bond, oil damage (sticky, soft or spongy) .. and

* Heat or ozone damage (cracked, crumbles or hard spots).

Replace if damage is evident.

If inspection indicates no apparent damage, rotate position from:

* Left to right .. or

* Right to left and REUSE

1N3331 Support Group (Optional Parts Replacement)

1N3262 Oil Drain Group (Replace as REQUIRED)

2W0167 Gauge Group .. Oil Level (REQUIRED Parts Replacement)

NOTE: This update is REQUIRED to accommodate SEHS9256 .. Thermal Heat Shield Removal.

776B 6JC1 - 88

777B 4YC1 - 1638

2W0175 Filler Group .. Oil (REQUIRED Parts Replacement)

NOTE: This update is REQUIRED to accommodate SEHS9256 .. Thermal Heat Shield Removal.

776B 6JC1 - 88

777B 4YC1 - 1638

1W6363 Starting Motor Group .. Electric (OPTIONAL Parts Replacement)

6G7873 Lines Group .. Fuel (Replace as REQUIRED)

776B 6JC1 - 83

777B 4YC1 - 1365

776B 6JC84 - Up

777B 4YC1366 - Up

6G7865 Control Group (Governor) .. Chassis

NOTE: This update is REQUIRED for:

776B 6JC1 - 64

777B 4YC1 - 433

NOTE: Replace as REQUIRED for:

776B 6JC65 - Up

777B 4YC434 - Up

2W0164 Air Cleaner Group (REQUIRED Parts Replacement)

776B 6JC1 - 69

777B 4YC1 - 695

776B 6JC70 - 83

777B 4YC696 - 1286

776B 6JC84 - Up

777B 4YC1287 - Up

2W0165 Air Lines Group (REQUIRED Parts Replacement)

776B 6JC1 - 66

777B 4YC1 - 1576

NOTE: The following parts are RECOMMENDED for machines operating in dust conditions.

The parts update include a bypass tube between the left and right air filters to improve air filter element service life and reduce engine exhaust temperature.

2W0169 Water Lines Group (Brake Oil Cooler) (REQUIRED Parts Replacement)

RECOMMENDED Parts Replacement

5T3554 Lines Group .. Oil Cooler (REQUIRED Parts Replacement)

5T8103 Cowling Group

Inspect the rubber baffles and replace as required.

NOTE: The baffles are required for optimum radiator air flow for cooling.

2W0163 Fan Group .. Suction (Replace Parts as REQUIRED)

Inspect the 2W1526 Spider Assembly (Fan) for:

* Loose or missing rivets .. and/or

* Damaged blades.

Replace if REQUIRED

Inspect the 2W3124 Guard Assembly (Fan) for:

* Broken and/or separated weldments .. and

* Broken wires

Replace if REQUIRED

6Y3276 Torque Convertor Group (REQUIRED Parts Replacement)

NOTE: The following parts are REQUIRED to install the torque convertor to the engine.

Show/hide table

NOTICE

The 7T4083 Ring is a critical part. Failure to install the 7T4083 Ring will cause power train impact loading to the engine's crankshaft.

2W0166 Radiator Group

Inspect the 7W4074 Radiator for:

* Coolant leaks

* Plugged Cores .. and

* Cracked side channels

Replace as REQUIRED

7W4074 Radiator Group

The 7W4074 Radiator Group has been redesigned with improved side channels to improve structural life.

This design is in effect with:

776B 6JC99 - Up

777B 4YC1772 - Up

The update is RECOMMENDED for:

776B 6JC1 - 98

777B 4YC1 - 1771

NOTE: Do NOT use the two 7C5414 Support(s) .. Link to bumper.

7W4047 Radiator Group

776B 6JC1 - Up

777B 4YC1 - Up

The following parts are REQUIRED for the installation of the 7W4047 Radiator Group.

1N3599 Cover Group .. Protection (Filler Cap) (REQUIRED Parts Replacement)

NOTE: The 0R3951 and 0R3961 Remanufactured engines are built with revised Laminated Thermal Shielding (LTS) and should NOT be installed in 776B or 777B machines which have NOT been modified per Special Instruction SEHS9256 .. Thermal Heat Shield Removal.

The following parts are REQUIRED installation for:

776B 6JC1 - 88

777B 4YC1 - 1638

Refer to Special Instruction SEHS9256 .. Thermal Heat Shield Removal for parts location and installation instructions.

NOTE: The parts required to reposition the oil filler tube, for the following machines, are listed in 2W0175 Filler Group .. Oil and 2W0167 Gauge Group .. Oil Level in this instruction.

776B 6JC1 - 69

777B 4YC1 - 757

NOTES:

* The 2W0165 Air Line Group part of this update is in this instruction.

* Relocate the Starting Aid Group (Ether Aid) lines and retaining clip as required.

* The remaining parts in Special Instruction SEHS9256 .. Thermal Heat Shield Removal pertaining to the engine shielding are included with the engine.

Refer to Special Instruction SEHS9256 .. Thermal Heat Shield Removal for parts location for the following parts.