2004/11/29 Caterpillar

Excavator:

5230B (S/N: 4HZ1-UP)

Off-Highway Truck/Tractor:

777C (S/N: 4XJ1-UP)

777D (S/N: AGC1-UP; 2YW1-UP)

777D HAA (S/N: AGY1-UP)

785C (S/N: APX1-UP; 5AZ1-UP)

789B (S/N: 7EK1-UP)

789C (S/N: 2BW1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)

793D (S/N: FDB1-UP)

Track-Type Tractor:

D11N (S/N: 74Z1-UP)

D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)

Wheel Loader:

992G (S/N: 7HR1-UP; ADZ1-UP)

994D (S/N: 3TZ1-UP)

Description of Change: Longer bolts are now used to retain the starting motor for the machines that are listed above. Spacers are also now used. This will provide improved sealing of the gasket and improved retention of the bolts that mount the starting motor to the engine.

Adaptable To: The addition of the longer bolts and spacers are adaptable to first production. The bolts and spacers that are used depends on the type of starting motor. Table 1 lists the bolts and spacers that are used.

The new 263-7751 Air Starting Motor Gp (Turbine) is a direct replacement for the 205-4824 Air Starting Motor Gp (Turbine). The new 263-7751 Air Starting Motor Gp (Turbine) will have the correct orientation of the starter pinion nose housing.

Refer to the following steps in order to adapt the former 205-4824 Air Starting Motor Gp (Turbine).

1. Shut off the air supply and purge the air supply from the starting system.

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Illustration 1	g01118001
(1) Starting motor (2) Bolts (3) 4H-7869 Gasket (4) Starter pinion nose housing

2. Remove the air lines from the starting motor.

3. Attach a suitable lifting device in order to support the starting motor.

4. Remove bolts (2) from the mounting flange to the engine. Discard the bolts. Remove the starting motor.

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Illustration 2	g01118008
(5) Bolts

5. Remove twelve bolts (5) that retain the starter pinion nose housing (4) .

6. Rotate the starter pinion nose housing by one hole in the counterclockwise direction. Install the twelve bolts that retain the housing. Tighten the twelve bolts evenly.

   Torque ... 13.5 N·m (120 lb in)

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Illustration 3	g01118125
(6) 9X-8881 Bolts (7) 6I-6123 Spacers

7. Install starting motor (1). Use a new gasket (3) when you install the starting motor. Install one (7) for each of the longer (6). Tighten the bolts.

   Torque ... 215 ± 40 N·m (159 ± 30 lb ft)

8. Install the air lines to the starting motor.

9. Turn on the air supply for the starting motor.