827664 Volvo.Penta Reduction gear

Introduction
This Special Instruction provides the procedure to repower a R1600G Underground Load Haul Dump machine. The replacement engine will be a Tier II level C11 engine. See table below for the engine arrangement numbers. The R1600G LHD machine was originally equipped with a 3176C engine. The original LHD engine is Tier-I or Tier-II regulated for emissions. These instructions will provide the information to install the Tier II level replacement engine.
Table 1
Engine Arrangement
Original Engine Replacement Engine
223-5805
329-6713
324-0049
363-7874 418-7784
446-0287(1)
(1) For use with flow through filter and low sulphur fuel and low ash engine oil.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 these instructions until the information has been read and understood.Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.Note: This Special 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, in the required parts, and in the labor hours to complete this procedure. This documentation is a guideline for Caterpillar Dealer personnel to complete the repower procedure. If errors are found, contact the Caterpillar Emissions Solutions Group. Information that will be required:
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 Repower Machines
Reference: Special 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, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Welding on Electronically Controlled Engines
Proper welding procedures are necessary 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.
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 harnesses from welding debris and/or from 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 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: 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
Qty Part Number