48641-96J01 Suzuki MANIFOLD, PTT

Introduction
This Special Instruction provides the procedure in order to repower a D7G Track-Type Tractor. The engine will be a Tier I level 3306B Engine. The tractor was originally equipped with a 3306 Engine. This Special Instruction will provide the information in order to install the Tier I level replacement engine.
Table 1
Engine Arrangement    
Original Engine     Replacement Engine    
4N-4559     122-4210    
1W-0542    
7N-1551    
4N-5606    
7N-1552    
1W-0543    
1N-4987     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 in SIS 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 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
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.Required Parts
Note: Fabricated parts are required. Refer to the procedure for details of the parts that need to be fabricated.Note: The front gear group of the replacement engine are spur gears. The front gear group of the original engine are helical gears. Replace any accessory that is driven by the front gear group. The front gear group can also be switched with the original front gear group.Note: The parts in this instruction are for reference. The parts in the tables are from the dealer work order. The contents of the parts lists can vary. The condition of the machine will determine if more parts are required.
Table 2
Parts for Air Inlet    
Quantity     Pt. No.     Description    
1     1W-5417     Elbow    
1     4S-7455     Precleaner As    
2     5P-0597     Clamp    
1     5P-0599     Clamp    
128 in     9X-2362     Hose    
1     163-1850     Air Cleaner    
1     1W-0613     Indicator