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Introduction
This Special Instruction provides the procedure in order to repower a D8N Track-Type Tractor. The replacement engine will be a Tier I level 3406C engine. See table 1 for the engine arrangement numbers. The D8N 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 in order to install the Tier 1 level replacement engine.
Table 1
Engine Arrangement
Original Engine Repower Engine
4W-9497
9Y-5555 10R-2065(1)
222-5432(2)
10R-9821(3)
(1) Reman repower engine - This Reman engine does not require swapping of Flywheel housing and Rear group rear.
(2) New repower engine - For 9TC or 1XJ prefix machines the new repower engine will require swapping of Flywheel housing and Rear gear group from original engine
(3) Reman repower engine - This Reman engine will require swapping of Flywheel housing and Rear group rear from original 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.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, submit feedback in SIS Web or contact the Emissions Retrofit Group.Register the Retrofit
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, NENG2500, "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 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 electronic components of the engine from the wiring harnesses: ECM, throttle actuator, actuator of the compressor for the turbocharger 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 sensors) or electronic component grounding points for grounding the welder.
Connect the ground cable of the welder 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 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
Refer to Parts Manual, SEBP5300 (S/N: 97C; 1XJ), or SEBP5313(S/N:5TJ), , SEBP5314(S/N:7TK).Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list.Note: If part fabrication is necessary, ensure that all fabricated parts are deburred. Use caution when deburring parts. Avoid excessive grinding and notches.Note: A breakdown of the kit provides a parts list for the repower. The kit part number is not serviceable. Order the engine arrangement plus the list of parts provided in the kit.
Table 2
Qty Part No Part Name Description
1 10R-2065 Complete Engine Ar Reman repower engine - This Reman engine does not require swapping of Flywh