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Producto: NO SE HA ESCOGIDO NINGUN EQUIPO
Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO
Configuración: NO SE HA ESCOGIDO NINGUN EQUIPO
Instrucción Especial
Tier II Level Emissions Engine Repower for a 623B Wheel Tractor-Scraper{1000}
Número de medio -REHS3061-00 Fecha de publicación -10/05/2006 Fecha de actualización -10/05/2006
i02490803
Wheel Tractor-Scraper:
623B (S/N: 46P1-UP)
Introduction
This Special Instruction provides the procedure in order to repower a 623B Wheel Tractor-Scraper. The
replacement engine will be a Tier II level 3406E engine. See table 1 for the engine arrangement numbers. The
623B Wheel Tractor-Scraper 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 II level
replacement engine.
Table 1
Engine Arrangement
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.
Note: This instruction contains some procedures that come from dealer feedback. If errors are found please submit
feedback inSIS Web or contact the Emissions Retrofit Group.
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Safety
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.
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.
NOTICE
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.
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Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the
engine according to the following procedure.
4. Disconnect the engine's electronic components from the wiring harnesses: ECM, throttle actuator, actuator
for the turbocharger compressor's bypass, fuel metering valve and sensors.
5. Protect the wiring harnesses from welding debris and/or from welding spatter.
NOTICE
Do NOT use electrical components (ECM or ECM sensors) or
electronic component grounding points for grounding the welder.
6. Connect the welder's ground cable directly to the engine component that will be welded. Place the clamp as
close as possible to the weld in order to reduce the 5 mm (0.20 inch)possibility of welding current damage to
the engine bearings, to the electrical components, and to other engine components.
Parts Needed
Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list. Refer to
the 623G (S/N: CES) Wheel Tractor-Scraper for the parts that are used to install the replacement engine.
Table 2
Parts for the Exhaust
1 224-4335 shield
1 197-7023 Elbow Gp
Table 3
Parts for the Cooling System
1 170-9237 Bracket
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1 219-3100 Radiator Gp
1 215-5653 Radiator Gp
1 224-2400 Water Lines Gp
Table 4
Parts for the Engine Enclosure
Qty Pt. No. Description
1 215-2128 Hood Gp
Table 5
Parts for the Power train Cooling System (1)
1 166-0552 Tube
1 183-6585 Plate
1 1P-5762 Flange
1 4T-6149 Spacer
1 7X-0326 Grommet
1 8T-4835 Bolt
1 8T-8917 Bolt
1 9K-2522 Clamp
1 166-0551 Tube
(1) The parts in the list are from the 157-2430 Oil Lines .
Table 6
Parts for the Electrical System
1 183-6585 Plate
1 1P-5762 Flange
1 4T-6149 Spacer
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1 5P-8444 Grommet
1 7X-0326 Bolt
1 8T-4835 Bolt
1 8T-8917 Bolt
1 9K-2522 Clamp
1 166-0551 Tube
5 1S-0994 Clip
1 3B-6552 Elbow
1 3B-7721 Bushing
2 3B-7722 Bushing
1 3E-5169 Guard
1 3E-9759 Film
1 3J-7354 Seal
2 3K-8782 Fuse
54 3S-2093 Tie
1 4D-7794 Clip
1 4M-5317 Bushing
1 4P-7582 Clip
4 4P-8134 Clip
15 5M-3062 Bolt
1 5N-2126 Adapter
2 5P-1838 Adapter
1 5P-3413 Sealant
1 5P-3501 Adapter
2 5P-8522 Grommet
1 5P-9297 Clip
1 5S-7379 Bolt
1 6H-4005 Grommet
1 6N-5926 Sender
2 6T-3643 Circuit
1 6V-3265 Clip
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3 6V-8801 Nut
3 7K-1181 Tie
1 7N-3718 Clip
5 7T-1099 Link
1 8B-2664 Bushing
1 8C-6354 Cap
2 8D-8719 Fuse
4 8M-2770 Clip
9 8M-2773 Clip
20 8T-4986 Washer
1 8W-7473 Harness
1 9R-2926 Plate
2 9V-9311 Bracket
1 9W-1494 Meter
1 9W-1951 Receptacle
2 9X-0141 Plug
1 9X-1343 Receptacle
8 102-8802 Receptacle
5 102-8803 Receptacle
2 107-0612 Switch
1 107-0616 Switch
1 111-9563 Switch
1 124-2466 Tachometer
7 130-5300 Clip
1 139-2116 Switch
3 155-2260 Plug
9 155-2270 Plug
1 161-9926 Sensor
1 163-1201 Horn
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1 165-5970 Switch
1 170-4870 Bolt
1 172-6833 Clip
4 174-5907 Clip
1 174-7875 Horn
50 186-3735 Connector
50 186-3736 Socket
1 189-5746 Sensor
1 203-3222 Switch
1 213-8722 Harness
1 214-1720 Film
Table 7
Parts for the Air Conditioning System
Qty Pt. No. Description
1 1P-6356 Plate
1 1S-4698 Rod
1 3E-1906 Compressor
1 4L-6454 Bolt
8 4L-9337 Bolt
1 5C-6565 Bolt
12 5M-3062 Bolt
5 5P-1075 Washer
1 5P-2424 Bolt
1 5S-7379 Bolt
4 5S-7383 Bolt
2 6D-1641 Clip
1 6K-8178 Clip
4 6N-8744 Grommet
1 6V-8188 Nut
10 6V-8801 Nut
1 7C-7595 Bracket
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2 7K-1181 Tie
1 7X-0288 Bolt
2 7X-0448 Nut
1 8C-4436 Bolt
1 8L-8413 Tie
1 8N-3525 Spacer
1 8S-5383 Block
2 8T-4122 Washer
4 8T-4223 Washer
25 8T-4896 Washer
1 8T-6466 Bolt
1 8T-7934 Clamp
1 8X-6263 Hose
2 9B-1722 Screw
4 9B-7237 Bolt
1 9M-7958 Clamp
1 9R-2926 Plate
2 9X-2488 Clamp
2 9X-7385 Seal
1 008-6904 Elbow
1 107-8704 Guard
1 114-0061 Plate
1 130-5300 Clip
1 159-3206 Support
1 159-3207 Bracket
1 159-8320 Plate
1 172-4264 Bracket
1 172-4265 Bracket
1 172-4880 Seal
1 174-9030 V-Belt
4 175-7141 Half Nut
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1 180-7180 Valve
1 180-7181 Valve
1 215-8341 Hose
Table 8
Parts for the Engine Control
1 140-2961 Kit
2 140-2963 Screw
2 160-6365 Screw
2 160-6366 Clip
Table 9
Parts for the Alternator
Qty Pt. No. Description
1 2W-8662 Wire
3 5P-1075 Washer
1 5P-2566 Bolt
1 5S-7382 Bolt
2 5S-7383 Bolt
1 6V-8801 Nut
1 7X-0296 Bolt
1 7X-0345 Bolt
2 7X-0448 Nut
1 8T-4122 Washer
2 8T-4223 Washer
1 9N-1320 V-Belt
1 156-9558 Bracket
1 162-5465 Strap
Table 10
Parts for the Engine Oil Lines
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1 6V-9008 Elbow
2 7M-8485 Seal
34 in 9X-2371 Hose
89 in 9X-2371 Hose
156 in 9X-2372 Hose
4 9X-3808 Coupler
2 9X-3823 Coupler
1 104-7995 Base
84 in 122-6870 Hose
25 in 122-6870 Hose
2 124-1963 Coupler
1 124-2117 Coupler
1 124-2162 Coupler
1 214-5861 Hose
Table 11
Parts for the Hydraulic Tank
Qty Pt. No. Description
1 1A-3709 Gasket
12 1F-0750 Nut
1 1J-8595 Gasket
2 1R-0732 Filter
2 2H-6578 Gasket
1 2M-9189 Gasket
1 2S-4078 Seal
1 3S-1223 Seal
1 4F-7507 Ring
1 4J-0524 Seal
1 5M-3038 Seal
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2 5P-0598 Clamp
2 5P-3092 Seal
1 6G-1249 Gasket
2 6J-1080 Grommet
17 cm 7X-7893 Hose
Illustration 1 g01244936
1. Remove the original engine. Refer to the Service Manual for your particular machine in order to remove the
original engine.
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Illustration 2 g01245420
1. Install fan drive (1) from the original engine on the replacement engine.
Illustration 3 g01245432
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Illustration 4 g01245703
Illustration 5 g01245790
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Illustration 6 g01245804
1. Remove the supports from the 215-5681 Bracket and the 215-5682 Bracket . Mount the supports on the
brackets 76.2 mm (3.0 inch) toward the rear of the radiator. Moving the supports will gain extra clearance
for the fan.
Note: The radiator might need to be removed in order to mount the oil cooler.
Illustration 7 g01248766
Illustration 8 g01248827
Illustration 9 g01248783
Illustration 10 g01248784
9. The side guards will require some modification in order to allow the guard to fit.
Illustration 11 g01245807
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Illustration 12 g01247622
Right Side Lines
Illustration 13 g01245817
Left Side Lines
2. Install the lines for the hydraulic oil cooler. Use the original lines on the frame.
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Illustration 14 g01248585
3. Use the original lines to connect the torque converter and the cooler.
Illustration 15 g01248582
4. Connect the cooler to the lines that are located on the frame.
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Illustration 16 g01247817
Illustration 17 g01248153
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Illustration 18 g01249556
Illustration 19 g01272922
Additional bottom view of air line to precleaner assembly
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Illustration 20 g01248168
Illustration 21 g01248246
3. Weld a plate to the hydraulic tank. Attach the engine oil filter to the block.
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Illustration 22 g01248256
1. Weld blocks to the hydraulic tank in order to mount the fuel filters.
Illustration 23 g01248264
2. Fabricate a bracket in order to mount bulkhead fittings for the fuel lines.
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Illustration 24 g01248493
3. Fabricate a bracket in order to mount fuel fittings on the left side of the engine.
Illustration 25 g01249720
1. Use the original rear hood. Cut new holes for the muffler and the precleaner.
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Illustration 26 g01249761
3. Install a new hinge on the rear hood in order to install the front hood.
Illustration 27 g01250516
4. Fabricate bracket (1) in order to support the front hood while the hood is open.
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Illustration 28 g01250560
Illustration 29 g01250521
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Illustration 30 g01250562
7. Cut the front hood in order to gain clearance for hydraulic filler cap (4). Align the hood with panel (2).
Illustration 31 g01273154
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Illustration 32 g01249543
1. Remove material from the bottom guard in order to gain clearance for the cooling lines.
Illustration 33 g01249538
2. Fabricate a panel that goes between the hood and the cab.
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Illustration 34 g01273422
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Illustration 35 g01273656
Illustration 36 g01273663
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Todos los derechos reservados.
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