982293 Volvo.Penta Plug

Introduction
This Special Instruction provides the procedure to repower a D8R Track-Type Tractor. The replacement engine will be a Tier III C15 engine. The D8R Track-Type Tractor was originally equipped with a 3406 engine. The original 3406 engine is not regulated for emissions. This Special Instruction will provide the information to install the Tier III level replacement engine.
Table 1
Engine Arrangements
Original Engine Replacement Engine
105-9697 350-6770 (1)
N/A (2)
N/A (3)
111-0592 (4)
111-0593 (5)
111-0594 (6)
222-5432
222-5433 (4)
222-5434 (5)
222-5435 (6)
(1) New Repower Engine-No Sound Suppression
(2) Reman
(3) New Replacement Engine Exchange-NREE
(4) Sound Suppression - Submit DSN ticket for support
(5) Turbo Heat Shield
(6) Sound Suppression & Turbo Heat Shield-Submit DSN ticket for supportThis 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.This instruction contains some procedures that come from dealer feedback. The emissions replacement engine is not a direct replacement. More parts and labor hours may be needed to complete this engine replacement. Variations in machine serial number breaks or options could cause a discrepancy in the modifications. Discrepancies may include required parts or the labor hours to complete this procedure. This documentation is a guideline for Cat dealer personnel to complete the repower procedure. If errors are found, contact the Caterpillar Emissions Solutions Group. This list is the information that will be required:
Machine serial #
Original engine arrangement #
Emissions engine arrangement #
Original engine serial #
Details of the error
Photos of error and photos after the proposed solutionRegister the Retrofit
Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.The following information includes instructions on registering the updates and retrofits.
When performing a retrofit installation, record the vital information in Table 2.Note: If the procedure is performed by the customer, ask the customer to record the proper information.
Table 2
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 2 into SIMSi and AIMS.Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".
For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".Safety Information