0328640 JOHNSON COVER PLATE

Introduction
This Special Instruction provides the procedure in order to repower a 637E Wheel Scraper. The replacement engine will be a Tier I level 3306B engine. Refer to Table 1 for the engine arrangement numbers. The 637E Wheel Scraper was originally equipped with a 3306 engine. The original 3306 engine is not regulated for emissions. This Special Instruction will provide the information in order to install the Tier I level replacement engine.
Table 1
Engine Arrangements    
Original Engine     Replacement Engine    
1W-3231 Engine Ar     125-1181 Engine Ar (1)    
( 1 ) New Repower EngineThis 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.When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.ReferenceService Manual, Parts Manual, Operation and Maintenance Manual.Note: This instruction contains some procedures that come from dealer feedback. The emissions replacement engine is not a direct replacement. Additional parts and additional labor hours may be needed in order to complete this engine replacement. Variations in machine serial number breaks or options could cause a discrepancy in the modifications, parts needed, and labor hours to complete this repower. This documentation is a guideline for Caterpillar dealer personnel in order to complete the repower procedure. If errors are found, submit feedback in SIS Web or contact the Emissions Retrofit Group.
Machine serial number
Original engine arrangement number
Original engine serial number
Emissions engine arrangement number
Details of the error
Photos of the error and photos after the proposed solutionRegistering the Retrofit
ReferenceSpecial Instruction, REHS5097, "Instructions to Register the Retrofit"Documenting changes to a machine configuration is an advantage to Caterpillar and the dealer technicians that are sent to repair a machine. By identifying that the machine has been reconfigured, the technician will have a better opportunity to have the correct parts, tooling, and service information. Identifying that the machine has been reconfigured will also allow Caterpillar to include the retrofitted serial numbers in applicable Service Letters.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.
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 Machines and Engines with Electronic Controls
Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. When possible, remove the component that must be welded from the machine or the engine and then weld the component. When welding near an electronic control on the machine or the engine, temporarily remove the electronic control in order to prevent heat-related damage. The following steps should be followed in order to weld on a machine or an engine with electronic controls.
Set the engine control to the STOP mode.
Turn off the fuel supply to the engine.
If equipped, turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.
Protect the wiring harness from welding debris and from any welding spatter.
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.
Connect the welder 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 possibility of current damage to the engine components.
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.Note: If you are required to fabricate a part, ensure that all fabricated parts are deburred. Use caution when deburring parts. Avoid excessive grinding and notches.
Table 2
366-1952 Engine Conversion Ar    
Q