01550-06957 Suzuki BOLT

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.
Table 1
Engine Arrangement    
Original Engine     Replacement Engine    
8S-9994     249-9188     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
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 Tools and Shop Products Guide" 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
Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.
Set the engine control to the "STOP" mode.
Turn OFF the fuel supply to the engine.
Disconnect the negative terminal from the battery.
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.
Protect the wiring harnesses from welding debris and/or from welding spatter.
Do NOT use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder.
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.
Use standard welding procedures to weld the materials together.657B Scraper Engine Repower Arrangement
Table 2
263-5507 Conversion Kit    
Qty     Part Number     Description    
1     249-9188     Engine Ar    
10     0L-1178     Bolt    
1     1A-8063     Bolt    
4     1D-4625     Bolt    
1     1F-0748     Nut    
3     1F-0750     Nut    
1     1P-3703     Seal    
2     1P-4577     Flange    
4     1P-4579     Flange    
4     1P-4582     Flange    
1     1P-6886     Adapter    
1     1S-0994     Clip    
1     1S-7251     Terminal    
1     1S-7252     Terminal    
1 &n