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Diesel engine exhaust contains products of combustion which may cause personal injury. Always start and operate the engine in a well ventilated area, and, if in an enclosed area, vent the exhaust to the outside. |
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Personal injury can result from rotating and moving parts. Stay clear of all rotating and moving parts. Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified. The machine must be parked on a level surface and the engine stopped. Attach a "Do Not Operate" or similar warning tag to the start switch and controls before servicing, repairing, or making adjustments to the machine. |
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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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| NOTICE |
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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 machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
Note: The illustrations in the following procedure show the Water Delivery System installed on a 777G WTR OEM Off-Highway Truck and a 785D WTR OEM Off-Highway Truck.
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Description | Qty |
| A | 8T-0855 | Pressure Gauge 0 to 4000 kPa (0 to 580 psi) |
2 |
| 6V-4144 | Quick Connect Coupler | 2 | |
| B | 177-7860 | Hose As | 2 |
| 6V-4142 | Fitting | 2 | |
| 6V-4143 | Quick Connect Coupler | 2 | |
| C | 6V-9510 | Plug | 1 |
| 6V-9746 | O-Ring Seal | 1 | |
| D | 6V-9832 | Cap As | 2 |
| E | 6V-3831 | O-Ring Seal | 2 |
| 6V-8397 | O-Ring Seal | 1 | |
| F | 6V-9829 | Cap As | 2 |
| Optional Tools (1) | |||
|---|---|---|---|
| Tool | Part Number | Description | Qty |
| G (2) | 198-4234 | Digital Indicator | 1 |
| H (2) | 198-4236 | Adapter Cable As | 2 |
| J | 198-4237 | Pressure Sensor Gp 0 to 3500 kPa (0 to 500 psi) |
2 |
| ( 1 ) | The optional tools can be used to replace the analog pressure gauges in the required tool list. |
| ( 2 ) | Tool (G) , Tool (H) , Tool (J) are part of the 198-4240 Digital Pressure Indicator Gp . |
- Drive the machine to a smooth, horizontal surface.
- Place the transmission gear selector in the PARK position.
- Operate the engine at low idle for a few minutes. Shut down the engine.
- Place blocks in front of the rear wheels and behind the rear wheels.
- Locate charge filter (1) . Disconnect hose (2) from tee (4) at the outlet of the charge filter.
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| Illustration 1 | g02773916 |
Charge Filter for the 777G WTR OEM Off-Highway Truck | |
- Cap outlet of tee (4) with Tool (D) . Plug hose (2) with Tool (C) .
- Disconnect hose (3) from tee (4) at the outlet of the charge filter.
- Cap outlet of tee (4) with Tool (F) . Plug hose (3) with Tool (E) .
- Assemble Tool (A) and Tool (B) . Connect Tool (A) to Tool (B) .
- Install Tool (B) on charge pressure tap (5) .
- Start the engine. Run the engine at low idle.
- Record the pressure at charge pressure tap (5) on the charge filter inlet. The pressure should be 3200 kPa (464 psi).
- Shut down engine.
- If the pressure is within the specified range, go to Step 17. If the pressure is not within the specified range, go to Step 15.
- Locate cold start relief valve (6) . Replace the cold start relief valve.
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| Illustration 2 | g03412073 |
Location of cold start relief valve (6) on a 777G WTR OEM Off-Highway Truck | |
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| Illustration 3 | g03399505 |
Location of cold start relief valve (6) on a 785D WTR OEM Off-Highway Truck | |
- Go to Step 11 and retest.
- Remove the tooling. Reconnect hose (2) and hose (3) to tee (4) at outlet of charge filter (1) .