PLATE A 6T6821 - Caterpillar

If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".
Refer to the Service Manual if/as necessary.
Refer to the Operation and Maintenance manual, for your machine, in order to release system pressure.
Notes:
- This rework is for the 777G hoist and brake pumps.
- Only one tube and one hose will be replaced. The others will be reused.
- Some hardware and fittings to be reused so do not discard until fit-up is complete.
1. Remove pumps, suction tubes, and discharge hoses; indicated suction tube and discharge hose will be replaced while the remaining clips, hardware, other hoses, and tube will be reused. Refer to Image1.2.1.
Image1.2.1
2. Assemble the O-ring seal provided in the rear housing of the 485-9674 Gear Pump Group onto the new 497-3512 Gear Pump Group. Refer to Image1.3.1.
Image1.3.1
3. Connect the 497-3512 Gear Pump Group to the new 485-9674 Gear Pump Group using four new 6C-3241 Bolts and four new 8T-4223 Hard Washers. Refer to Image1.4.1.
Image1.4.1
4. Assemble the new 8F-8733 O-Ring Seal to the 485-9674 Gear Pump Group. Refer to Image1.5.1.
Image1.5.1
5. Assemble the pump stack to the ITG reusing four 8T-7338 Bolts and four 9X-8257 Hard Washers. Refer to Image1.6.1.
Image1.6.1
6. Reconnect the suction tubes using a new sleeve composed of a 13cm piece of 5P-1295 Hose and two 209-4577 Clamps on the new 490-8129 Tube Assembly. Refer to Image1.7.1.
Image1.7.1
7. Reconnect the hoist pump discharge hose. Refer to Image1.8.1.
Image1.8.1
8. Reconnect the brake cooling pump discharge hose, replacing the existing bolts with four new 8T-4183 Bolts. Refer to Image1.9.1 and 1.9.2.
Note: The other end may need to be adjusted to achieve necessary slack for the pump end. Refer to Image1.9.1.
Note: To achieve necessary slack in the hose, the coupling may need to be loosened and angled.
Image1.9.1
Image1.9.2
9. Reconnect the brake charge pump discharge hose. Refer to Image1.10.1.
Image1.10.1
10. Ensure all connections are tight.
11. Replace the 293-3645 Element Assembly.
12. Replace the brake charge pump valve screen which is found in the 369 -4109 Repair Kit. Refer to Image1.11.1.
Image1.11.1
13. Fill the hydraulic tank to the required level.
14. Prime new pump following the procedure in KENR9933.