F654396 Force DECAL, ENGINE COVER STARBOARD

Introduction
Table 1
Revision History
Revision Summary of Changes
6 Added table 5 Bulk Material Note: These instructions are for repowering a standard 980G Wheel Loader. This solution is not compatible with a high ambient machine. The high ambient cores are required for this machine repower and the radiator cores limit the package to a 45° C (113° F) ambient day.Note: This solution is not compatible with a Waste Handler machine because the software does not support a reversing fan and the radiator cores limit the package to a 45° C (113° F) ambient day.Note: The 980G repower software will not communicate with the implement and transmission controllers on the 980G Series II and the 820G Series II machines.This Special Instruction provides the procedure to repower a 980G Wheel Loader. The replacement engine will be a Tier III level C15 ACERT engine. See Table 2 for the engine arrangement numbers. The 980G Wheel Loader was originally equipped with a 3406C engine. The original 3406C engine is not regulated for emissions. This Special Instruction will provide the information to install the Tier III level replacement engine.
Table 2
Engine Arrangement
Original Engine Replacement Engine
108-0348
134-4138
144-3431
152-7468
192-7101
202-3123 340-8888(1)
10R-8922(2)
N/A(3)
(1) New Repower Engine
(2) Reman - Requires Software and Front Support Change From original engine (142-4951)
(3) New Replacement Engine Exchange-NREEThis 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.Note: This instruction contains some procedures that come from dealer feedback. The Emission replacement engine is not a direct replacement. Additional parts and labor hours may be needed to complete replacement of the engine. Variations in breaks of the machine serial numbers or various options could cause discrepancies. The discrepancies may include the modifications, required parts that are needed, or the labor hours that are reported to complete this procedure. This documentation is a guideline for Caterpillar Dealer personnel to complete the repower procedure. If errors are found, submit feedback in SIS Web or contact the Emissions Solutions Group. Note the following information with your feedback:
Machine Serial Number:
Original Engine Arrangement Number:
Original Engine Serial Number:
Emissions Engine Arrangement Number:
Details of the Error:
Photos of the Error and the Photos after the Proposed Solution:New Engine Information Label
This repower process will require the engine to be reflashed with new software, if a reman engine is used. Use a new engine information label by using the standard process before performing the repower.Register the Retrofit
When performing a retrofit installation, record the vital information in Table 3.Note: If the procedure is performed by the customer, ask the customer to record the proper information.
Table 3
Repair Date
Product Serial Number
Service Hours or Service Meter Units
Removed Component Part Number(1)
Removed Component Serial Number(1)
Installed Component Part Number(2)
Installed Component Serial Number(3)
(1) Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
(2) Record the highest level retrofit kit, arrangement, or group part number.
(3) Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.
Update the product configuration by entering the information from Table 3 into SIMSi and AIMS.Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ11