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Instrucción Especial
Tier II Level Emissions Engine Repower for a 623B Wheel Tractor-Scraper{1000}
Número de medio -REHS3061-00 Fecha de publicación -10/05/2006 Fecha de actualización -10/05/2006

i02490803

Tier II Level Emissions Engine Repower for a 623B Wheel Tractor-


Scraper{1000}
SMCS - 1000

Wheel Tractor-Scraper:
623B (S/N: 46P1-UP)

Introduction
This Special Instruction provides the procedure in order to repower a 623B Wheel Tractor-Scraper. The
replacement engine will be a Tier II level 3406E engine. See table 1 for the engine arrangement numbers. The
623B Wheel Tractor-Scraper was originally equipped with a 3406 engine. The original 3406 engine is not
regulated for emissions. This Special Instruction will provide the information in order to install the Tier II level
replacement engine.

Table 1
Engine Arrangement

Original Engine Replacement Engine


4N-2252
256-7542
8N-5405

This 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.

ReferenceService Manual, Parts Manual, Operation and Maintenance Manual.

Note: This instruction contains some procedures that come from dealer feedback. If errors are found please submit
feedback inSIS Web or contact the Emissions Retrofit Group.

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Safety

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.

Do not attempt to assemble this machine until you read and you
understand the assembly instructions.

Improper assembly procedures could result in injury or death.

Personal injury or death can result from improper lifting or blocking.

When a hoist or jack is used to lift any part or component, stand clear
of the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.

Approximate weights of the components are shown. Clean all surfaces


where parts are to be installed.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. 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 Dealer Service


Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Welding on Electronically Controlled Engines

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Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the
engine according to the following procedure.

1. Set the engine control to the "STOP" mode.

2. Turn OFF the fuel supply to the engine.

3. Disconnect the negative terminal from the battery.

4. Disconnect the engine's electronic components from the wiring harnesses: ECM, throttle actuator, actuator
for the turbocharger compressor's bypass, fuel metering valve and sensors.

5. Protect the wiring harnesses from welding debris and/or from welding spatter.

NOTICE
Do NOT use electrical components (ECM or ECM sensors) or
electronic component grounding points for grounding the welder.

6. Connect the welder's ground cable directly to the engine component that will be welded. Place the clamp as
close as possible to the weld in order to reduce the 5 mm (0.20 inch)possibility of welding current damage to
the engine bearings, to the electrical components, and to other engine components.

7. Use standard welding procedures to weld the materials together.

Parts Needed
Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list. Refer to
the 623G (S/N: CES) Wheel Tractor-Scraper for the parts that are used to install the replacement engine.

Table 2
Parts for the Exhaust

Qty Pt. No. Description

1 224-4335 shield
1 197-7023 Elbow Gp

1 135-9962 Exhaust Connection


1 6L-2927 Exhaust Elbow
1 6N-5354 Extension

Table 3
Parts for the Cooling System

Qty Pt. No. Description


1 170-9236 Bracket

1 170-9237 Bracket

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1 188-7463 Suction Fan Gp

1 219-3110 Fan Guard Gp

1 219-3100 Radiator Gp

1 215-5653 Radiator Gp
1 224-2400 Water Lines Gp

Table 4
Parts for the Engine Enclosure
Qty Pt. No. Description

1 215-2128 Hood Gp

1 215-2127 Hood Gp (1)


(1) Do not use the 215-2126 Rear Hood or the 217-2605 Door As .

Table 5
Parts for the Power train Cooling System (1)

Qty Pt. No. Description

1 166-0552 Tube

1 183-6585 Plate

1 1P-5762 Flange
1 4T-6149 Spacer

1 7X-0326 Grommet

1 8T-4835 Bolt

1 8T-8917 Bolt

1 9K-2522 Clamp
1 166-0551 Tube
(1) The parts in the list are from the 157-2430 Oil Lines .

Table 6
Parts for the Electrical System

Qty Pt. No. Description


1 166-0552 Tube

1 183-6585 Plate

1 1P-5762 Flange

1 4T-6149 Spacer

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1 5P-8444 Grommet

1 7X-0326 Bolt

1 8T-4835 Bolt

1 8T-8917 Bolt

1 9K-2522 Clamp
1 166-0551 Tube

5 1S-0994 Clip

1 3B-6552 Elbow

1 3B-7721 Bushing

2 3B-7722 Bushing
1 3E-5169 Guard

1 3E-9759 Film

1 3J-7354 Seal

2 3K-8782 Fuse
54 3S-2093 Tie

1 4D-7794 Clip

1 4M-5317 Bushing

1 4P-7582 Clip

4 4P-8134 Clip
15 5M-3062 Bolt

1 5N-2126 Adapter

2 5P-1838 Adapter

1 5P-3413 Sealant

1 5P-3501 Adapter
2 5P-8522 Grommet

1 5P-9297 Clip

1 5S-7379 Bolt

1 6H-4005 Grommet
1 6N-5926 Sender

2 6T-3643 Circuit

1 6V-3265 Clip

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3 6V-8801 Nut
3 7K-1181 Tie

1 7N-3718 Clip

5 7T-1099 Link

1 8B-2664 Bushing

1 8C-6354 Cap
2 8D-8719 Fuse

4 8M-2770 Clip

9 8M-2773 Clip

20 8T-4986 Washer

140 8T-8737 Plug


1 8W-7413 Harness

1 8W-7473 Harness

1 9R-2926 Plate

2 9V-9311 Bracket
1 9W-1494 Meter

1 9W-1951 Receptacle

2 9X-0141 Plug
1 9X-1343 Receptacle

8 102-8802 Receptacle
5 102-8803 Receptacle

2 107-0612 Switch
1 107-0616 Switch
1 111-9563 Switch

1 124-2466 Tachometer
7 130-5300 Clip

1 139-2116 Switch
3 155-2260 Plug
9 155-2270 Plug

1 161-9926 Sensor
1 163-1201 Horn

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1 165-5970 Switch
1 170-4870 Bolt

1 172-6833 Clip
4 174-5907 Clip

1 174-7875 Horn
50 186-3735 Connector
50 186-3736 Socket

1 189-5746 Sensor
1 203-3222 Switch
1 213-8722 Harness

1 214-1720 Film

Table 7
Parts for the Air Conditioning System
Qty Pt. No. Description

1 1P-6356 Plate
1 1S-4698 Rod

1 3E-1906 Compressor
1 4L-6454 Bolt
8 4L-9337 Bolt

1 5C-6565 Bolt
12 5M-3062 Bolt

5 5P-1075 Washer
1 5P-2424 Bolt
1 5S-7379 Bolt

4 5S-7383 Bolt
2 6D-1641 Clip

1 6K-8178 Clip
4 6N-8744 Grommet
1 6V-8188 Nut

10 6V-8801 Nut
1 7C-7595 Bracket

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2 7K-1181 Tie
1 7X-0288 Bolt
2 7X-0448 Nut

1 8C-4436 Bolt
1 8L-8413 Tie

1 8N-3525 Spacer
1 8S-5383 Block
2 8T-4122 Washer

4 8T-4223 Washer
25 8T-4896 Washer
1 8T-6466 Bolt

1 8T-7934 Clamp
1 8X-6263 Hose

2 9B-1722 Screw
4 9B-7237 Bolt
1 9M-7958 Clamp

1 9R-2926 Plate
2 9X-2488 Clamp

2 9X-7385 Seal
1 008-6904 Elbow
1 107-8704 Guard

1 114-0061 Plate
1 130-5300 Clip

1 159-3206 Support
1 159-3207 Bracket
1 159-8320 Plate

1 172-4264 Bracket
1 172-4265 Bracket

1 172-4880 Seal
1 174-9030 V-Belt
4 175-7141 Half Nut

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1 180-7180 Valve

1 180-7181 Valve
1 215-8341 Hose

Table 8
Parts for the Engine Control

Qty Pt. No. Description


1 113-4799 Pedal
1 123-9431 Cover

1 140-2961 Kit
2 140-2963 Screw

2 160-6365 Screw
2 160-6366 Clip

Table 9
Parts for the Alternator
Qty Pt. No. Description

1 2W-8662 Wire
3 5P-1075 Washer

1 5P-2566 Bolt
1 5S-7382 Bolt
2 5S-7383 Bolt

1 6V-8801 Nut
1 7X-0296 Bolt

1 7X-0345 Bolt
2 7X-0448 Nut
1 8T-4122 Washer

2 8T-4223 Washer
1 9N-1320 V-Belt

1 156-9558 Bracket
1 162-5465 Strap

Table 10
Parts for the Engine Oil Lines
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Qty Pt. No. Description


2 4H-6147 Union
1 6V-8995 Union

1 6V-9008 Elbow
2 7M-8485 Seal

34 in 9X-2371 Hose
89 in 9X-2371 Hose
156 in 9X-2372 Hose

4 9X-3808 Coupler
2 9X-3823 Coupler

1 104-7995 Base
84 in 122-6870 Hose
25 in 122-6870 Hose

2 124-1963 Coupler
1 124-2117 Coupler
1 124-2162 Coupler

1 214-5861 Hose

Table 11
Parts for the Hydraulic Tank
Qty Pt. No. Description

1 1A-3709 Gasket
12 1F-0750 Nut

1 1J-8595 Gasket
2 1R-0732 Filter
2 2H-6578 Gasket

1 2M-9189 Gasket
1 2S-4078 Seal

1 3S-1223 Seal
1 4F-7507 Ring
1 4J-0524 Seal

1 5M-3038 Seal
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2 5P-0598 Clamp

2 5P-3092 Seal
1 6G-1249 Gasket
2 6J-1080 Grommet

17 cm 7X-7893 Hose

Procedure to Install the Repower Engine In the Machine


Removal of the Engine

Illustration 1 g01244936

1. Remove the original engine. Refer to the Service Manual for your particular machine in order to remove the
original engine.

2. Remove dirt and grease from the machine.

Preparations for the Engine

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Illustration 2 g01245420

1. Install fan drive (1) from the original engine on the replacement engine.

2. Install the 194-6715 Belt Tightener Gp (2) on the engine.

3. Install alternator (3) on the engine.

4. Install 4N-2276 Engine Support Gp (4) on the engine.

5. Install the A/C compressor on the engine.

6. Install the engine wiring harness on the machine.

Illustration 3 g01245432

7. Install 222-4335 Shield (5) on the engine.

8. Install 6L-2997 Elbow (6) on the engine.

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Illustration 4 g01245703

9. Install cover (7) on the engine.

10. Install pump (8) on the engine.

Installation of the Replacement Engine

Illustration 5 g01245790

1. Install the replacement engine in the original location.

2. Connect the drive shaft to the torque converter.

Installation of the Radiator and Fan

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Illustration 6 g01245804

1. Remove the supports from the 215-5681 Bracket and the 215-5682 Bracket . Mount the supports on the
brackets 76.2 mm (3.0 inch) toward the rear of the radiator. Moving the supports will gain extra clearance
for the fan.

Note: The radiator might need to be removed in order to mount the oil cooler.

Illustration 7 g01248766

2. Install the radiator fan on the engine.


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3. Install the aftercooler on the machine.

4. Connect the radiator to the engine.

5. Install the fan guard on the machine.

Illustration 8 g01248827

6. Modify the screen in order to allow clearance for the bumper.

Illustration 9 g01248783

7. Install the radiator guard on the machine.

8. Install the screen on the machine.


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Illustration 10 g01248784

9. The side guards will require some modification in order to allow the guard to fit.

Installation of the Cooling System for the Power Train

Illustration 11 g01245807

1. Mount the original oil cooler on the radiator brackets.

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Illustration 12 g01247622
Right Side Lines

Illustration 13 g01245817
Left Side Lines

2. Install the lines for the hydraulic oil cooler. Use the original lines on the frame.

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Illustration 14 g01248585

3. Use the original lines to connect the torque converter and the cooler.

Illustration 15 g01248582

4. Connect the cooler to the lines that are located on the frame.

Installation of the Air Lines

1. Remove the hydraulic tank.

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Illustration 16 g01247817

2. Modify the tank in order to allow the air cleaner to fit.

3. Install the hydraulic tank on the machine.

Illustration 17 g01248153

4. Install the 164-2555 Air Cleaner Gp on the machine.

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Illustration 18 g01249556

5. Install the air lines on the precleaner to the inlet filter.

Illustration 19 g01272922
Additional bottom view of air line to precleaner assembly

Installation of the Lines for the Engine Oil

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Illustration 20 g01248168

1. Fabricate plate (1) .

2. Install plate (1) on the engine.

Illustration 21 g01248246

3. Weld a plate to the hydraulic tank. Attach the engine oil filter to the block.

4. Attach the oil filter housing to the plate (1) .

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Installation of the Fuel System

Illustration 22 g01248256

1. Weld blocks to the hydraulic tank in order to mount the fuel filters.

Illustration 23 g01248264

2. Fabricate a bracket in order to mount bulkhead fittings for the fuel lines.

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Illustration 24 g01248493

3. Fabricate a bracket in order to mount fuel fittings on the left side of the engine.

Installation of the Hood

Illustration 25 g01249720

1. Use the original rear hood. Cut new holes for the muffler and the precleaner.

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Illustration 26 g01249761

2. Install the muffler support on the hood.

3. Install a new hinge on the rear hood in order to install the front hood.

Illustration 27 g01250516

4. Fabricate bracket (1) in order to support the front hood while the hood is open.

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Illustration 28 g01250560

5. Fabricate panel (2) for the left side of the hood.

Illustration 29 g01250521

6. Fabricate panel (3) for the right side of the hood.

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Illustration 30 g01250562

7. Cut the front hood in order to gain clearance for hydraulic filler cap (4). Align the hood with panel (2).

Installation of the Throttle Foot Pedal

Illustration 31 g01273154

1. Remove the existing governor control.

2. Install TPS control (1) .

Final Modifications to the Machine

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Illustration 32 g01249543

1. Remove material from the bottom guard in order to gain clearance for the cooling lines.

Illustration 33 g01249538

2. Fabricate a panel that goes between the hood and the cab.

Repowered Machine/Assembled Views

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Illustration 34 g01273422

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Illustration 35 g01273656

Illustration 36 g01273663

Copyright 1993 - 2018 Caterpillar Inc. Mon May 07 2018 09:10:04 GMT-0300 (Hora estándar de Argentina)
Todos los derechos reservados.
r120pxco
Red privada para licenciados del SIS.

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