Tier III Level Emissions Engine Repower for a 637E Wheel Scraper {1000} Caterpillar

Wheel Tractor-Scraper

637E (S/N: 1HB1-UP; 1LB1-UP)

Introduction

This Special Instruction provides the procedure in order to repower a 637E Wheel Scraper. The replacement engine will be a Tier III level C9 engine. See Table 1 for the engine arrangement numbers. The 637E Wheel Scraper was originally equipped with a 3306 engine. The original Wheel Scraper engine is not regulated for emissions. This Special Instruction will provide the information in order to install the Tier III level replacement engine.

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, 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

Show/hide table

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.

Show/hide table

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.

Show/hide table

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.

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.

1. Set the engine control to the "STOP" mode.

2. Turn OFF the fuel supply to the engine.

3. Disconnect the negative terminal from the battery.

4. Disconnect the engine electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor bypass, fuel metering valve, and sensors.

5. Protect the wiring harnesses from welding debris and/or from welding spatter.
   Show/hide table

   NOTICE
   Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

6. 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.

7. Use standard welding procedures to weld the materials together.

Initial Tests

Original Machine Stall Speed

Record the stall speed for the original machine. Refer to “Techniques for Engine Loading” in Special Instruction, SEHS7050, "Using The 5P2160 Engine Horsepower Meter Arrangement" for techniques for engine loading. Refer to the Service Manual for your machine in order to record the stall speed.

Parts Needed

Reference: Refer to Parts Manual, SEBP5252, "C9 Engine Emissions Retrofit Repower Tier III For 637E Scraper".

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.

Procedure to Install the Repower Engine In the Machine

Removal of the Engine

1. Remove the power pack. Refer to the Service Manual for your particular machine in order to remove the original power pack.

2. Remove the engine from the power pack.

3. Remove dirt and grease from the machine.

Modifications to the Engine Mounting Components

Show/hide table

Illustration 1	g01388588

1. Remove the mounting plates (1) from 190-3528 Engine Support As (2). The Engine Support Assembly is from the 190-3527 Engine Support Gp.
   Show/hide table

   Illustration 2	g01388492

   Show/hide table

   Illustration 3	g01388493

2. Fabricate the right mounting plate (3). Fabricate the left mounting plate (4).
   Show/hide table

   Illustration 4	g01388501

3. Fabricate two gussets (5).
   Show/hide table

   Illustration 5	g01388503

   Show/hide table

   Illustration 6	g01388505

4. Locate the left mounting plate. Weld the left mounting plate (4) to the engine support. Locate the right mounting plate. Weld the right mounting plate (3) to the engine support. Weld the gussets (5).
   Show/hide table

   Illustration 7	g01430161

5. Install the new 302-4563 Engine Ar to the torque converter.

Preparation of the Replacement Engine

Note: Refer to Parts Manual, SEBP4241 for steps 1 through 3.

Show/hide table

Illustration 8	g03672252

1. Install the 230-4584 Fan Drive Gp on the new engine.
   Show/hide table

   Table 3

   230-4584 Fan Drive Gp
   Callout	Qty	Pt. No.	Description
   1	1	123-0858	Alternator Pulley
   2	1	279-2589	Idler Pulley As
   3	1	190-0643	Belt Tensioner Gp
   4	1	198-3635	Fan Adapter
   5	1	303-8286	Serpentine Belt
   6	1	303-8287	Serpentine Belt
   7	1	311-0330	Belt Tensioner
   8	1	230-1422	Idler Pulley As
   9	6	7X-0818	Bolt
   10	3	8T-4121	Washer
   11	1	8T-4172	Bolt
   12	1	8T-4196	Bolt
   13	1	8T-4178	Bolt

   Show/hide table

   Illustration 9	g03672274

2. Install the 194-7249 Air Cleaner Gp on the new engine.
   Show/hide table

   Table 4

   194-7249 Air Cleaner Gp
   Callout	Qty	Pt. No.	Description
   14	1	2W-9312	Tube
   15	1	4S-8473	Body As
   16	2	5P-0597	Hose Clamp
   17	2	5P-2230	Hose Clamp
   18	1	7S-6340	Prescreen As
   19	1	7S-7680	Clamp
   20	1	9S-1102	Hose
   21	1	9S-2378	Inlet Pipe As
   22	1	145-4211	Filter Adapter
   23	1	189-0573	Air Cleaner Gp
   24	1	194-7252	Hose
   25	2	216-0069	Fitting
   26	1	224-0807	Clamp
   27	1	224-0808	Clamp
   28	2	0A-2926	Fitting
   29	1	145-4212	Air Filter Change Indicator As
   30	1	3B-8822	Elbow
   31	1	7D-1553	Clip
   32	4	7X-7729	Washer
   33	4	8T-4133	Nut
   34	1	8T-4185	Bolt
   35	4	8T-4195	Bolt
   36		6V-1362	Hose (30cm)
   37		5P-2817	Hose (55cm)

   Show/hide table

   Illustration 10	g01430434

3. Install the 194-7245 Muffler Gp on the new engine.
   Show/hide table

   Table 5

   194-7245 Muffler Group
   Callout	Qty	Part no	Description
   38	1	4W-8118	Clamp
   39	1	141-1480	Clamp As
   40	1	235-1860	Pipe As
   41	1	194-7246	Muffler As
   42	1	199-5012	Bracket As
   43	1	199-8034	Bracket As
   44	1	213-5011	Tube As
   45	4	198-4777	Washer
   46	4	7X-7729	Washer
   47	1	8H-2758	Clamp
   48	3	8T-4121	Washer
   49	1	8T-4133	Nut
   50	3	8T-4136	Bolt
   51	4	8T-4195	Bolt
   52	4	8T-4196	Bolt
   53	1	8T-6466	Bolt

   Show/hide table

   Illustration 11	g01389222

   Show/hide table

   Illustration 12	g01389232

4. Reposition the support (54) for the transmission oil tank so that the drain (55) for the transmission oil tank does not interfere with the engine oil cooler (56). Move the bracket away from the cooler approximately 38.1 mm (1.5 inch). The bracket may need to be located toward the outside of the machine by approximately 25.4 mm (1 inch).

   Note: Be sure not to move the support for the transmission oil tank toward the rear too much. The relocated magnetic filter (57) will contact the frame (58) when the power pack is installed.

   Show/hide table

   Illustration 13	g01389282

5. Relocate the magnetic filter (57) to the opposite side of the transmission oil tank in order to avoid the turbocharger inlet tube. Repair the hole left in the transmission oil tank. Weld the magnetic filter to the opposite side of the transmission oil tank (59).
   Show/hide table

   Illustration 14	g01389256

6. Connect the magnetic filter to the power train pump with 198-8543 Tube As (60), 5P-1292 Hose ( 90 cm (35.4 inch)) (61), and custom tube (62). Fabricate the custom tube with a 38.1 mm (1.5 inch) tube with a 2.29 mm (0.090 inch) wall thickness and 1S-4472 Flange (63). Heat the braze on the flange of the return line (64) and rotate the tube in order to line up with the tube from the pump without interfering with the custom tube (62). Connect the tubes with hose (65).
   Show/hide table

   Illustration 15	g01389423

7. It may be necessary to cut the hardnose strut mounting blocks from the frame of the power pack (67). If necessary, relocate the hard nose strut mounting blocks (66) in order to accommodate the new hard nose

Installation of the Radiator and Radiator Guards

Show/hide table

Illustration 16	g01430353

1. Install the 233-8449 Radiator Gp (1) in the 234-7894 Radiator Guard Gp (2). Refer to Parts Manual, SEBP4242.
   Show/hide table

   Illustration 17	g01389430

2. Bolt the struts (6) to the 234-7894 Radiator Guard Gp (7) and bolt the Radiator Guard to the power pack. Refer to Parts Manual, SEBP4242. Determine the location of mounting blocks (4) and weld the mounting blocks to the frame of the power pack (5).

3. Remove material (8) from sides of hard nose in order to avoid interference from the machine.
   Show/hide table

   Illustration 18	g01389439

4. Mount the new 195-2392 Lifting Gp (9) in order to accommodate the taller hard nose. Refer to Parts Manual, SEBP4242.

Installation of the Water Lines Gp

Show/hide table

Illustration 19	g01430391

1. Install the 231-1224 Water Lines Gp. Refer to Parts Manual, SEBP4242.
   Show/hide table

   Table 6

   231-1224 Water Lines Gp
   Callout	Qty	Part No.	Description
   1	2	1P-4278	Hose Clamp
   2	1	1P-9328	Fitting
   3	1	3E-4041	Elbow
   4	1	5P-1838	Adapter
   5	1	5P-3415	Adapter
   6	2	7X-7958	Hose Clamp
   7	1	8F-8151	Shutoff Valve As
   8	1	8L-6005	Pipe Tee
   9	1	8S-9379	Radiator Hose
   10	2	5P-1262	Hose (152.4cm each)
   11	2	9X-6772	Cable Strap
   12	1	111-7092	Hose
   13	1	157-0670	Dust Cap
   14	1	194-4598	Hose As
   15	1	231-1225	Tube
   16	1	231-1226	Tube As
   17	1	112-5282	O-Ring Seal
   18	1	148-8365	Elbow As
   19	1	154-9024	Valve Gp
   20	1	171-6731	Connector As
   21	1	1S-1015	Clip
   22	5	209-4573	V Band Clamp
   23	3	212-6933	Clamp
   24	1	3D-2824	O-Ring Seal
   25	1	4B-0418	Clip
   26	1	5D-1026	Hose Clamp
   27	1	7D-7233	Clip
   28	1	8T-7525	O-Ring Seal
   29		5P-0767	Hose (37cm)
   30		5P-6442	Hose (86cm)
   31		5P-1251	Hose (106cm)

Installation of the Air Lines Gp

Show/hide table

Illustration 20	g01430399

1. Install the 231-1221 Air Lines Gp. Refer to Parts Manual, SEBP4242.
   Show/hide table

   Table 7

   231-1221 Air Lines Gp
   Callout	Qty	Pt. No.	Description
   1	1	9R-5008	Spacer
   2	3	106-9858	Hose
   3	1	177-0581	Hose
   4	1	202-0058	Bracket As
   5	8	209-4578	Clamp
   6	1	231-1219	Tube As
   7	1	231-1220	Tube
   8	1	2A-3034	Air Cleaner Clamp
   9	2	7X-2537	Bolt
   10	3	8T-4121	Washer
   11	1	8T-4136	Bolt
   12	1	8T-4186	Bolt
   13	2	8T-4224	Washer

Modifications to the Engine Compartment

Show/hide table

Illustration 21	g01389565

Show/hide table

Illustration 22	g01389578
Hydraulic tank shown installed after metal removal

1. Cut metal (1) in order to allow space for the hydraulic tank.

2. Add lug (2) for fuel line.
   Show/hide table

   Illustration 23	g01389584

3. Relocate lug (3) for the brake valve.

Installation of the Replacement Engine

1. Install the power pack.
   Show/hide table

   Illustration 24	g01430777

   Show/hide table

   Illustration 25	g01430779

2. Install the 269-2866 Hood Gp. Refer to Parts Manual, SEBP4242.
   Show/hide table

   Table 8

   269-2866 Hood Gp
   Callout	Qty	Pt. No.	Description
   1	8	1P-7115	Grommet As
   2	8	6G-9943	Bolt
   3	1	201-9109	Door Gp
   3A	1	203-6066	Latch As
   3B	1	202-7670	Lock Gp
   3C	1	219-6036	Door As
   4	1	263-4095	Hood As
   5	2	269-8597	Hood As
   6	8	5P-1075	Washer
   7	8	6V-8189	Nut
   8	8	7X-0772	Washer
   9	2	8C-9987	Washer
   10		8T-9371	Bolt

Installation of the Electrical System

Illustration 26	g01435406

Illustration 27	g01435408

Illustration 28	g01435409

Illustration 29	g01435593

Show/hide table

Illustration 30	g01435521

Show/hide table

Illustration 31	g01435538
(A) 6T-3642 10 Amp Circuit Breaker (B) 140-4118 40 Amp Circuit Breaker (C) 9W-1951 Data Link Connector (D) ACTION IND. LIGHT: 3T-0304 Base As, 6T-7058 Lens (Red), 7N-1996 Lamp (E) INST. PANEL LIGHT: 9G-3057 Base, 9G-3058 Cap, 7N-5876 Lamp (F) 3T-0204 Diagnostic Connector (G) AIR INLET HEATER LIGHT: 2G-0151 Socket As, 156-0520 Lens (Green) (H) 197-8832 Service Meter (I) 165-5970 Remote Engine Start Switch (J) 139-2116 EMS Test Switch (K) 139-2116 Instrument Panel Lamp Switch (L) 139-2116 Remote Throttle ON/OFF Switch (M) 146-0240 Remote Throttle ACCEL/DECEL Switch (N) ENGINE SHUT-OFF SWITCH: 165-5970 Switch, 3E-5169 Guard

1. Fabricate a new Control/Monitor panel. The new panel can be made from 213-6176 Panel As. Reuse the original EMS panel. New features include the following: a remote C9 toggle start switch (I), a ground level shutdown switch located on the lower right side of the radiator guard, a throttle ON/OFF switch (L), a throttle ACCEL/DECEL switch (M), an engine shutdown switch (N), an additional diagnostic connector to support added CDL (C) and a turbocharger air inlet heater lamp (G).

2. Prior functionality of the EMS I remains intact with regards to the scraper engine remote panel. Disconnect the coolant flow alarm. The C9 engine does not support the coolant flow alarm. Ground the input to the monitor.

3. Install sensors that are used to provide signals to the EMS I. This will maintain the functionality of the E series. Upgrade the sensors with the service replacement if an updated service replacement is available.

   Note: Three sensors are not transferred to the replacement engine. The three sensors are the coolant flow switch, the coolant start aid switch and the engine oil pressure switch that was used to provide power for the service meter. The flow switch is not required on the new engine. The coolant start aid switch is not needed as the operation of the start aid system is triggered through the software of the ECM. The engine oil pressure switch is not required as the service replacement for the service meter is now enabled by the R terminal of the alternator.

4. Replace the original service meter with the 197-8832 Service Meter Gp. The new service meter receives the signal from the alternator instead of an engine oil switch.
   Show/hide table

   Illustration 32	g01435620

5. Install a new backup alarm (1) under the new enclosure.

6. Install an unswitched power breaker.
   Show/hide table

   Illustration 33	g01435621

7. Add four additional connectors (2) between the C9 and the rear radiator guard to assist in removal of the rear radiator guard.
   Show/hide table

   Illustration 34	g01435732

8. Make new longer battery cables using 159-8049 Cable (Red) (3) and 159-8050 Cable (Black) (4). This is required because the starter is located on the opposite side of the original engine.

9. Locate the disconnect switch at the battery box in the negative cable.
   Show/hide table

   Illustration 35	g01435818

10. Install the engine control breaker (5) and the scraper main breaker (6) to the right rear engine cover support post.

11. Mount the primer pump and primer pump switch on the new engine.

    Note: The primer pump start switch will be enabled at any such time the ignition switch in the cab is in the OFF position. When this switch is in the ON position or RUN position a newly added scraper relay will be energized to power elements that will provide the momentary engine start switch at the remote panel to be utilized.

12. Connect the CDL system to the C9 ECM.
    Show/hide table

    Illustration 36	g01436913

13. Install 266-7302 Ether Starting Aid Gp to the support assembly. Refer to Parts Manual, SEBP4242.

Note: The option of throttle lock is configurable with ET and can be operational by controls in the cab.

Note: When repowering a 631E or 633E you will need to connect a 3E-7842 Resistor between "J1", pin 10 on the ECM and ground.

Illustration 37	g01435832

Repowered Machine/Assembled Views

Illustration 38	g01382419

Repower Test

Repowered Machine Stall Speed

Record the stall speed for the repowered machine. Refer to “Techniques for Engine Loading” in Special Instruction, SEHS7050, "Using The 5P2160 Engine Horsepower Meter Arrangement" for techniques for engine loading. Refer to the Service Manual for your machine in order to record the stall speed.