0281913 JOHNSON MOTOR COVER ASSY.,235

Introduction
Table 1
Revision History
Revision Summary of Changes
06 Part numbers in Table 4 have been updated. This Special Instruction provides the procedure to repower a 777B and 777C Off-Highway Truck. The replacement engine will be a Tier 2 level C32 engine. See Table 2 below for the engine arrangement numbers. The 777B and 777C Off-Highway Truck was originally equipped with a 3508B engine. The original 3508B engine is not regulated for emissions. These instructions will provide the information to install the Tier 2 level replacement engine.
Table 2
Engine Arrangement
Original Engine Replacement Engine
2W-0174
121-5777 347-5835(1)
20R-1351(2)
(1) New Repower Engine
(2) RemanThis Special Instruction does not include procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.This instruction contains some procedures that come from dealer feedback. The emissions replacement engine is not a direct replacement. Additional parts and labor hours may be needed to complete this engine replacement. Variations in machine serial number breaks or options could cause a discrepancy in the modifications. Discrepancies can also occur in required parts, and in the labor hours to complete this procedure. This documentation is a guideline for Cat dealer personnel to complete the repower procedure. If errors are found, contact the Caterpillar Emissions Solutions Group. This list is the information that will be required:
Machine serial #
Original engine arrangement #
Emissions engine arrangement #
Original engine serial #
Details of the error
Photos of error and photos after the proposed solutionReference
Reference: Specification, SENR3130, "Torque Specification"Reference: Special Instruction, REHS1841, "General Welding Procedures"Safety
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar.Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
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.