- Load Haul Dump
- R1600G (S/N: 9PP1-UP; 9YZ1-UP)
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.
| Engine Arrangement | |
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| Original Engine | Replacement Engine |
| (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 solution
Registering 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
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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. |
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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. |
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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. |
| NOTICE |
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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.
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NOTICE 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.
| Qty | Part Number | Part Description | Description |
|---|---|---|---|
| Required Parts | |||
| 1 | Engine Conversion Kit | This kit contains the required parts to upgrade the machine with New C11 engine. For line drawings and group structure refer to 479-3351 Machine Conversion Ar. | |
| 1 | Software - Engine | Download the latest software from SIS web. This action will also require new factory passwords. Call DSN for factory passwords and also request new engine info label. | |
| Engine and Exhaust options (Select one set) | |||
| Engine with standard Muffler | |||
| 1 | Complete Engine Ar | Engine for use with a standard Muffler. | |
| 1 | Purifier Exhaust Gp | Includes standard Muffler.
Order the serviceable parts within the group number. |
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| Engine with the DPF option | |||
| Note: This option requires usage of Ultra Low Sulphur Diesel (ULSD) and CJ-4 Low ash engine oil. | |||
| 1 | Complete Engine Ar | Engine for use with the DPF (Diesel Particulate Filter) | |
| 1 | Purifier Exhaust Gp | Includes the DPF.
Order the serviceable parts within the group part number. Refer to Special Instruction, REHS5919 for installation of DPF on the machine. |
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Original Machine Cycle Times
Record the cycle times for the original machine. Refer to the Service Manual for your particular machine to record cycle times.
Original Machine Stall Speed (If Applicable)
Refer to Service Information System (SIS) for the Special Instruction, SEHS7050, "Techniques for Loading Engines".
| NOTICE |
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Do not leave the converter in a stall condition for a prolonged period. Only stall the converter to record engine speed and boost pressure. Observe the temperatures of the torque converter oil and cooling system. Do not allow the converter oil or cooling system to overheat. |
Preparation of the Machine
- Wash the machine.
- Remove Engine and Torque converter from machine. Refer to Disassembly and Assembly, KENR9076, "Engine, Torque Converter and Updrive Gears - Remove".
- Remove Torque converter from engine. Refer to Disassembly and Assembly, KENR6828, "Updrive Gears - Remove".
- Drain the coolant into a suitable container and disconnect water lines.
- Drain engine oil into a suitable container.
- Remove oil filters & fuel filters.
- Remove air cleaner.
- Disconnect the remaining lines and electrical wires that are connected to the engine.
Reflash the Engine with New Software
This solution uses a specific engine software developed for use in this application. Download the latest software file from SIS web and flash the engine with the software.
You will also need to order a new engine info label to go with the engine.
Engine Preparation
Note: Many of the following steps use parts from the original engine/machine. Inspect all components that are used from the original engine/machine. Repair or replace any damaged components.
- Install the torque converter on new engine. Install the seals (3) and (4) before installing the torques converter on the engine. After attaching the converter to the engine, install the bolts (1) and Washers (2). Refer to Disassembly and Assembly, KENR6828, "Updrive Gears - Install"
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Illustration 2 g03868305 Right-Hand Rear Support Mount
(5)0S-1589 Bolts
(6)5P-8247 Hard Washers
(7)228-6120 Engine Mount - Install the right side rear support mount (7) on the engine using bolts (5) and washers (6).
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Illustration 3 g03868309 Left-Hand Rear Support Mount
(8)228-6119 Engine Mount
(9)0S-1589 Bolt
(10)5P-8247 Hard Washers - Install the left side rear support mount (8) on the engine using bolts (9) and washers (10).
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Illustration 4 g03868395 - Install 370-2605 Engine Oil Filter Gp. Refer to drawing for installation of the group.
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Illustration 5 g03868399 Bracket 110-8213
(11) Cut off the portion towards arrows
(12)110-8213 Bracket As
(13) A modified bracket after cutoff - Modify the bracket as 110-8213 Bracket As from the original machine as shown in the picture above.
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Illustration 6 g03868410 (14) Modify 110-8213 Bracket As
(15) Engine Oil Filter BracketShow/hide table
Illustration 7 g03868607 Show/hide table
Illustration 8 g03877651 - Weld the modified bracket (14) to the (15) engine oil mounting support.
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Illustration 9 g03870578 Show/hide table
Illustration 10 g03870592 (15) 475-9742 Harness - Install engine harness assembly (15). Refer to 379-9914 Engine Wiring Gp for installation. Except replace 384-0017 Engine Harness As with 475-9742 Harness.
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Illustration 11 g03870691 (16) 183-4403 Clip
(17)8D-9671 Clip - Install P-clips (16) and (17) as shown in Illustration 11.
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Illustration 12 g03870697 (18) 1S-0994 Clip - Install P-clips (18) as shown in Illustration 12.
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Illustration 13 g03870699 (19) 124-0174 Clip
(20)6K-8178 Clip
(21)9M-8406 Clip - Install P-clips (19), (20), and (21) as shown in Illustration 13.
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Illustration 14 g06036810 Original Speed Sensor - Remove the original speed sensor mounted on the flywheel housing on the original engine.
- Install the speed sensor on the new engine flywheel housing and reconnect the machine harness.
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Illustration 15 g03870726 (22) 385-9753 Alternator Guard Gp. - Install alternator guard (22).
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Illustration 16 g03870750 (23) 173-1198 Engine Oil Drain Lines Gp. - Install engine oil drain lines (23).
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Illustration 17 g03870744 (24) 1K-4649 Spacer
(25)1P-4578 Half Flange
(26)1P-4579 Half Flange
(27)4J-0522 O-Ring Seal
(28)4J-0524 O-Ring Seal
(29)5P-2566 Bolts
(30)5P-7468 Clip
(31)5P-7469 Clip
(32)5P-8444 Grommet
(33)7X-0328 Bolts
(34)8T-4223 Hard Washers
(35)8T-5360 Washers
(36)8T-8916 Bolts
(37)201-0494 Transmission Oil Lines Gp
(38)225-0418 Hose As - Install hose As (38) on the power train oil cooler using split flanges (26), o-ring Seal (28), bolts (29), washers (34) . Run the hose under the engine and attach (30) clamp and (31) clamp, (32) grommet, (24) spacer, with (33) bolt, and (34) washer. Install the other end with (27) o-ring seal, (25) split flanges, (36) bolts, (35) washers. Refer to 201-0494 transmission oil lines for installation drawing.
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| Illustration 1 | g03867978 |
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Torque converter (1) (2) (3) (4) | |
Installation of Cooling System
Note: Many of the following steps use parts from the original engine. Inspect all components that are used from the original engine. Repair or replace any damaged components.
- Fabricate a threaded boss as shown in the Illustration 18 for the new turbo water inlet line. Use ASTM A513/A519 or A656 Grade 50 steel material.
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Illustration 19 g03870823 - Using the dimensions shown in the Illustration 19 and cut a hole in the coolant tank of 30 mm diameter.
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Illustration 20 g03870824 - Weld the boss made in previous step on the coolant tank. Ensure that 10 mm of the boss length sticks out of the coolant tank.
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| Illustration 18 | g03870769 |
Installation of Engine
Note: Many of the following steps use parts from the original engine. Inspect all components that are used from the original engine. Repair or replace any damaged components.
- Install the new engine in the frame using bolt (39), washer (40), washer (41), upper rubber mount (42) , lower rubber mount (43), lock nut (44). Refer to 421-1846 Engine Mounting Gp for installation drawing.
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Illustration 22 g03870842 - Install the 370-2681 Air Cleaner Gp on machine as shown in Illustration 22.
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Illustration 23 g06124124 - Modify the frame as shown in the images to install the new muffler.
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Illustration 24 g03870843 Note: Follow the step below only if you use standard engine. - Install the 370-2610 Purifier Exhaust Gp as shown in Illustration 24.
Note: Follow the below step only if a Vent Reduction engine with flow through filter.
- Install the 437-2549 Purifier Exhaust Gp.
Refer to Special Instruction, REHS5919 for installation of DPF on the machine.
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Illustration 25 g03870844 (45) 6N-2687 Fan Spider As - Install original machine fan spider (45) on the new engine. Refer to 161-5662 Blower Fan and Guard Gp for installation drawing.
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Illustration 26 g03870845 (46) 9X-2201 Hose Clamp
(47)186-8973 Hose
(48)473-1427 Tube
(49)262-3106 Tube As
(50)127-0929 Clamp
(51)473-1426 Tube - Install one end of the hose (47) to the radiator and other end to the tube (48) and attach with two hose clamp (46) on each end of the hose. The other ends of the tube attach hose (47) and two clamps (46) before assembling to a tube assembly (49). Attach tube to the turbo with V band clamp (50).
- Left side installs one end of the hose (47) to the radiator and other end to the tube (51) and attach with two hose clamp (46) on each end of the hose. Install hose (47) on tube (51) to the air line.
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Illustration 27 g03870846 - Install water tubes as shown in Illustration 27.
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Illustration 28 g03870847 - Fabricate the plate shown in the image above. Use structural steel.
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Illustration 29 g03870850 (52) 6V-1867 Clip
(53)6V-1868 Clip
(54)6V-1869 Grommet
(55)8T-8917 Bolt
(56)8T-4223 Hard Washer - Install (52) Clip, (53) Clip, (54) Grommet, (55) Bolt, (56) Washer along with fabricated bracket on the tube. Mark approximate location of bracket on the water tank and weld the fabricated plate to the bottom of the tank.
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Illustration 30 g06036824 (57) 392-3322 Hose As
(58)8C-6872 Connector
(59)6V-8398 O-Ring Seal - Fabricate the hose (57). Install the Hose assembly on the machine as shown using the (58) and (59).
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| Illustration 21 | g03870840 |
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(39) (40) (41) (42) (43) (44) | |
Installation of Hydraulic System
Note: Many of the following steps use parts from the original engine. Inspect all components that are used from the original engine. Repair or replace any damaged components.
Repower Machine Cycle Times
Record the cycle times for the repower machine. Refer to the Service Manual for your particular machine to record cycle times.
Repower Machine Stall Speed (If Applicable)
| NOTICE |
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Do not leave the converter in a stall condition for a prolonged period. Only stall the converter to record engine speed and boost pressure. Observe the torque converter oil and the cooling system temperatures. Do not allow the converter oil or the cooling system to overheat. |
Record the stall speed for the repower machine. Refer to Special Instruction, SEHS7050, "Techniques for loading engines". Refer to the Service Manual for your particular machine to record stall speed.
Registering Repower Machines
Refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit" for the procedure.
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.