Tier II Level Engine Repower for a 657B Wheel Tractor-Scraper (Scraper) {1000} Caterpillar

Wheel Tractor-Scraper:

657B (S/N: 47M1-UP; 53K1-UP)

Introduction

This Special Instruction provides the procedure in order to repower a 657B Wheel Tractor-Scraper. The scraper engine will be a Tier II level 3406E Engine. The scraper was originally equipped with a D343 Engine. This Special Instruction will provide the information in order to install the Tier II level replacement engines.

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.

Reference: Service 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.

Safety

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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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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.

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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.

Welding on Electronically Controlled Engines

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.

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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 component that will be welded. Place the clamp as close as possible to the weld in order to reduce the 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.

657B Scraper Engine Repower Arrangement

Procedure for Installing the Rear Engine

Removal of the Original Engine

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Illustration 1	g01168627

1. Remove the drive shaft from the engine and install jig assembly (1). Tack weld plates (2) to the scraper. The jig assembly will be used for alignment.

2. Unbolt the jig assembly from the engine. Remove the original engine and the radiator from the rear frame.

3. Remove the original retarder valve from the pump drive.

4. Remove all of the original mounts from the frame.

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Illustration 2	g01168684

5. Relocate the bracket for the transmission wiring harness.

6. Remove the rear fenders from the machine.

Fabrication of the Engine Subframe

The rear engine is mounted in a subframe that allows the engine and the radiator to be removed as a pack.

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Illustration 3	g01169455
(A) 561.98 mm (22.125 inch) (B) 2063.75 mm (81.250 inches) (C) 1482.73 mm (58.375 inch) (D) 1781.18 mm (70.125 inch)

1. Fabricate rails (7) and (8). Rails (7) and (8) are made from 3" X 4" X 3/8" steel tubing. Weld front engine mount (3) to the top of the frame. Install both of the 7E-0502 Supports to the engine. Attach rear engine mounts (6) to the support. Attach the front engine mount to mount (3). Tack weld mount (6) to the frame. Remove the engine and weld the rear mount to the frame. Weld radiator mount (1) on top of the frame 15.875 mm (0.625 inches) from the front end of the frame. Weld supports (2) for mounting the assembly to the inside of the frame rail. Weld plates (4) under the rear mount for bolting the subframe to the scraper.

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Illustration 4	g01170351

2. Attach the subframe to the engine.

Preparation of the Engine

1. Install the starter and the alternator.

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Illustration 5	g01170784

2. Install the 8X-1040 Gear Gp . Install the lines on the gear gp.

3. Install the original retarder valve on the gear gp. Make sure that the retarder valve has no open port in the location that mates to the transfer gear. A different valve must be used if the original valve has a open port on the mating surface.

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Illustration 6	g01170950

4. Install the fan drive and the belt tensioner. Relocate grease line (2) for the fan drive.

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Illustration 7	g01170644

5. Assemble the radiator and the aftercooler. Cut the light brackets from the radiator. Fill the holes of 171-3751 Bracket As . Weld plate (8) to the left side of the radiator. Fit the radiator in place and tack weld the brackets in place. Mark the bolt holes in the brackets. Remove the radiator and weld brackets (9) in place. Drill the holes for mounting the radiator. Bolt the radiator to the subframe.

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Illustration 8	g01171004

6. Install the radiator hoses and the air lines.

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Illustration 9	g01171124

7. Install the lower radiator hoses. Hose (2) must be cut and coupled with a hose in order to have clearance around the front engine mount.

8. Install the lines for bleeding the cooling system.

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Illustration 10	g01171429

9. Install the 9N-2699 Support and the 175-2931 Muffler As . Connect the muffler to the turbocharger.

Fabrication of the Radiator Guard

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Illustration 11	g01171456

1. Modify the 171-3752 Bracket As and the 171-3751 Bracket As . Cut mount (1) from the brackets. Mount (1) will be reused for mounting the radiator guard. Cut 127 mm (5 inches) from the top of support (2). Cut 76.2 mm (3 inches) from the bottom of each bracket.

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Illustration 12	g01171500

2. Widen the 2A-7021 Top .

   203.2 mm (8 inches)

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Illustration 13	g01171517

3. Assemble the radiator guard and tack weld a strap in order to keep the sides square.

Installing the Engine Pack

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Illustration 14	g01171572

1. Lift the pack in place. Make sure that the transmission breather, the oil filler tube, and the dipstick have clearance between the engine and the subframe. Lower the engine in place. Get the engine close to the mounting location. Get the engine square with the frame and level. Use the level from the original engine for reference. Mount the jig assembly to the transfer gear flange. Rotate the engine flywheel in order to align the jig assembly. Bolt the jig assembly to the frame. The jig assembly will pull the engine pack in place.

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Illustration 15	g01171578

2. Tack weld the mounts to the frame. Remove the jig assembly and the engine pack. Weld the mounts to the frame and add gussets.

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Illustration 16	g01171568

3. Install the transmission oil cooler lines. The cooler lines need to be made. The first line is made from the following items.
   • One 124-2104 Elbow

   • One 124-2103 Flange

   • 2400.3 mm (94.5 inches) of 122-6873 Hose

   The second line is made from the following items.

   • One 124-2055 Flange

   • One 124-2103 Flange

   • 2319 mm (91.3 inches) of 122-6873 Hose

4. Install the engine pack and fasten the mounting bolts.

Installation of the Radiator Guard

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Illustration 17	g01171608

1. Weld mounting blocks (2) to the mount for the stinger. Bolt angle (1) to the block. Align the top support in order to be level with the engine. The radiator guard should be approximately 19 mm (0.75 inches) above the mounting block. Tack weld angle (1) to the side guard.

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Illustration 18	g01172901

2. Weld the original mounting holes of support (3). Hold the support against the mount and the radiator support. Mark the holes. Bolt support (3) to the original mount for the rear fender. Weld the support to the radiator guard.

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Illustration 19	g01172930

3. Bolt plates (4) to each side of the radiator guard. The plates are 152 mm (6 inches) wide and 1174.8 mm (46.25 inch) tall. The plates are 3.2 mm (0.125 inches) thick. Weld grill (5) to plates (4) .

4. Weld tabs to the radiator guard in order to support the radiator.

Installation of the Hood and Air Lines

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Illustration 20	g01172944

1. Install the 133-9448 Cleaner Gp . A mount must be fabricated in order to install the new air cleaner in the same location.

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Illustration 21	g01173008
(A) 1047.8 mm (41.25 inches) (B) 3048 mm (120 inches) (C) 1499 mm (59.0 inches) (D) The radius is 38 mm (1.5 inches).

2. Fabricate the hood. Holes will need to be made for the exhaust, the precleaner, and the radiator filler cap. Ribs must be welded to the inside of the hood in order to add strength to the hood.

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Illustration 22	g01173032

3. Weld extensions to the front of the hood in order to mount the front hood support. Weld tabs to the extension in order to allow the hood to be bolted to the front hood support.

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Illustration 23	g01173040

4. Fabricate extensions (1) in order to raise the hood support approximately229 mm (9 inches). Install the hood in order to gain a measurement for the actual height of the extensions.

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Illustration 24	g01173042

5. Install the air inlet lines which connect the turbocharger and the air cleaner. Attach the hanger for the air inlet to the hood support.

Final Installation Procedures

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Illustration 25	g01173040

1. Install the fuel lines and filters. Connect the fuel system in the same manner as the original engine. Mount the filters to extension (1) .

2. Install the drive shaft.

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Illustration 26	g01173049

3. Connect the remaining hydraulic lines. Line (2) connects the scavenge pump to the flange bearing.

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Illustration 27	g01173063

4. Connect lines (3) and (4) to the oil cooler.

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Illustration 28	g01173068

5. Connect port (5) to retarder valve (6) .

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Illustration 29	g01173076

6. Connect the vent line to ports (7) and (8). Plug the bottom port of the vent and connect the line to the side.

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Illustration 30	g01173078

7. Connect the gauges to the engine. Make a plate and mount the gauges in the radiator guard. Modify the radiator guard in order to allow the gauge panel to be mounted to the inside of the radiator guard. The gauge panel can now be disconnected and removed with the engine pack.

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Illustration 31	g01173082

8. Trim the rear fenders. Mounts (9) must be welded to the rear frame.