Tier II Level Emissions Engine Repower for an 844 Wheel Dozer, 990 Wheel Loader, and a 990 Series II Wheel Loader {1000} Caterpillar

Introduction

This Special Instruction provides the procedure to repower an 844 Wheel Dozer, 990 Wheel Loader, and a 990 Series II Wheel Loader. The replacement engine will be a Tier II level 3412E engine. See table 1 for the engine arrangement numbers. The 844 and 990 were originally equipped with a 3412 engine. The original 3412 engine is not regulated for emissions. This Special Instruction will provide the information to install the Tier II 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. The emissions replacement engine is not a direct replacement. Extra parts and labor hours may be needed to complete this engine replacement. Variations in machine serial number breaks or options could cause discrepancy in the modifications, required parts, and labor hours to complete this procedure. This documentation is a guideline for Cat Dealer personnel to complete the repower procedure. If errors are found, submit feedback in SIS web or contact the Emissions Solutions Group.

The information that follows 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 the Photos After the Proposed Solution

New Engine Information Label

This repower process will require the engine to be reflashed with new software. Use a new engine information label by using the standard process before performing the repower.

Registering the Repower Machine

Reference: Special Instruction, REHS5097, "Instructions to Register the Retrofit"

Document changes to a machine configuration are an advantage to AVSpare 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 AVSpare 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.

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.

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

6. 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 5 mm (0.20 inch) possibility of welding current damage to the engine bearings, to the electrical components, and to other engine components.

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

Original Machine Cycle Times

1. Refer to the Service Manual for your particular machine to record cycle times.

2. Record the cycle times for the original machine.

Original Machine Stall Speeds

Refer to SIS for Techniques for Loading Engines, SEHS7050-00.

1. Refer to the Service Manual for your particular machine to record stall speed.

2. Record the stall speed for the original machine.

Parts Needed

Reference: Parts Manual, SEBP5515

Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list.

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.

The following table shows the optional arrangements that are available for your machine. Before you start, determine the components that are needed for your machine.

Note: Some optional waste handler group parts are replacements for the components that are called out in the standard conversion group.

Procedure to Install the 3412E Repower Engine in the Machine

Preparation of the Machine

1. Wash the machine.

2. Remove the hood and the guards.

3. Reclaim the used engine coolant.

4. Disconnect all water lines.

5. Remove the cooling system.

6. Drain the engine oil into a suitable container.

7. Remove the oil and fuel filters.

8. Remove the air cleaner.

9. Disconnect the remaining lines and electrical wires that are connected to the engine.

Removal of the Original Engine

Note: Before you remove the engine, measure the position of the crankshaft from centerline to the right and left frame rails. Also, measure the height from the centerline of the crankshaft to the top of the main frame. Record all measurements.

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Illustration 1	g01847607

1. Remove the original engine. Refer to Disassembly and Assembly, SENR6643.

2. Remove dirt and grease from the machine.

Preparation of the Engine

Note: The following steps use parts from the original engine. Inspect all components and replace the components that are used from the original engine.

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Illustration 2	g01885716

1. Install the crankshaft pulley from the original engine.
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   Illustration 3	g01885733

2. Install the alternator (1) from the original engine.
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   Illustration 4	g01885720

3. Install the A/C compressor (2) from the original engine.
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   Illustration 5	g01885736

4. Install the rear engine supports (3) from the original engine.
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   Illustration 6	g01885738

5. Install the 194-1604 Fumes Disposal Gp. If the machine is equipped with dual starters, then the tube (4) will need to be secured to the frame.
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   Illustration 7	g01885742

6. Install the starter (5) from the original engine.
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   Illustration 8	g01885777

7. Install the mufflers and the supports (7) from the 193-8597 Muffler Gp.
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   Illustration 9	g01885778

8. Install the exhaust lines (8) from the 196-3813 Air Lines Gp.
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   Illustration 10	g01885815

9. Install the air cleaner adapters (9) and the air cleaner elbows (10) from the original engine.
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   Illustration 11	g01885833

10. Install the air lines (11) from the 192-9010 Air Lines Gp.
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    Illustration 12	g01885854

11. Install the air cleaners (12). Use two 1P-9390 Outlet Gaskets from the original engine.
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    Illustration 13	g01885857

12. Install two 213-6353 Precleaner As (13) from the 206-5087 Air Cleaner Gp onto the engine.
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    Illustration 14	g01886094

13. Install the lines (14) for the dust ejector from the 196-3818 Dust Ejector Gp.
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    Illustration 15	g01886095

14. Install the original torque converter (15).
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    Illustration 16	g01893296

15. Install the original implement pump (16).
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    Illustration 17	g01893297

16. Install the original pilot pump (17).
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    Illustration 18	g01893298

17. Install the original steering pump (18).
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    Illustration 19	g01893300

18. Use two 8T-4779 Bolts (19) to install the 194-6800 Piston Pump Gp (20) on the back of the steering pump. The 194-6800 Piston Pump Gp is found in the 195-3069 Piston Pump Gp.

Frame Modifications

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Illustration 20	g01893373

1. Remove the pad for the radiator from the front right side. After the pad is removed, grind until the area is clean and flat. Inspect the pads after removal. When possible, reuse the pads.
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   Illustration 21	g01893454

2. If the pad is damaged during the removal, then fabricate a new pad.
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   Illustration 22	g01893513

3. Weld the original pad or the fabricated pad using the dimensions shown.
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   Illustration 23	g01893516

4. Remove the remaining pads for the radiator. After the pads are removed, grind until the area is clean and flat. Inspect the pads after removal. When possible, reuse the pads.

5. If the pads are damaged during the removal, then fabricate new pads. Refer to Step 2.
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   Illustration 24	g01893534

6. Use the radiator pad from the front right side (3) to locate the remaining pads.
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   Illustration 25	g01929633

7. Locate the 9C-7863 Block (4). Weld the block onto the frame.
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   Illustration 26	g01893793

8. Fabricate a new mounting block with the dimensions that are shown above.
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   Illustration 27	g01893839

9. Using the dimensions shown above to locate and weld the fabricated 9U-1793 Block (6) on the frame. Refer to Step 8.
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   Illustration 28	g01893858

10. Weld a 9R-2613 Weld Boss onto the front engine support.
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    Illustration 29	g01893973

11. Fabricate a new mounting block with the dimensions that are shown above.
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    Illustration 30	g01893993

12. Use the dimensions that are shown above to locate the fabricated mounting block.

13. Weld the mounting blocks onto the frame.
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    Illustration 31	g01894136
    Use the location (A) to locate the bosses on the frame.

14. Use the dimensions that are shown above to locate the five 9R-2613 Weld Boss (9).

15. Weld the 9R-2613 Weld Bosses onto the frame.
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    Illustration 32	g01904373
    Use the location (A) to locate the blocks and the plates on the frame.

16. Use the dimensions that are shown above to locate the three 9U-1793 Blocks (10) and one 9C-4935 Plate (11) on the frame.

17. Weld the 9U-1793 Blocks (10) and the 9C-4935 Plate (11) onto the frame.
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    Illustration 33	g01904393

18. Remove the two bosses (12) that are shown above.
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    Illustration 34	g01904414
    Use the location (A) to locate the bosses on the frame.

19. Use the dimensions that are shown above to locate the four 9R-4595 Bosses.

20. Weld the four 9R-4595 Bosses onto the frame.
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    Illustration 35	g01904419

21. Fabricate four new hood mounting blocks.
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    Illustration 36	g01904436
    Use the location (A) to locate the mounting blocks on the frame.

22. Use the dimensions that are shown above to locate the four new hood mounting blocks (14).
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    Illustration 37	g01904496

23. The bumper will need to be extended around 144 mm (5.66928 inch) to protect the new cooling system.

Installation of the Engine

Note: Many of the following steps use the parts from the original engine. Inspect all components that are used from the original engine. Repair the damaged components or replace the components.

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Illustration 38	g01904915

1. Install the engine (1).

2. Install the original engine harness and the engine sensors. The original hardware is used to secure the harness onto the engine.

3. Connect the 40-pin connector from the original harness to the 40-pin connector from the new engine harness. The wires may need extended.

4. Inspect the components. Replace the components, if necessary.
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   Illustration 39	g01936758

5. Connect the original harness to the components of the air conditioner. The components are the arc suppressor (4), clutch solenoid (2), and the hi/low pressure switch (3). These components are transferred from the original engine.

6. Attach the403-GN(Green)from the original harness to the Alternator R terminal.
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   Illustration 40	g01937633

7. Attach the 301-BU(Blue) (5), 304-WH(White) (6), and the 207-BK(Black) (7) from the original harness to the starter terminals.
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   Illustration 41	g01915053

8. Install the original fuel lines (8).
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   Illustration 42	g01937777

9. Install the heater lines (9) from the old engine.
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   Illustration 43	g01915116

10. Install the lines for the air conditioner (10) from the 192-7381 Air Conditioner Lines Gp.
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    Illustration 44	g01915120

11. Install the original drive shaft (11).
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    Illustration 45	g01938276

12. Install the original cooler for the power train and torque converter lines.
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    Illustration 46	g01915122

13. Install the original pilot pump lines.
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    Illustration 47	g01915124

14. Install the lines for the original steering pump (13).
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    Illustration 48	g01915133

15. Install the original lines for the implement pump (14).
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    Illustration 49	g01915153

16. Install the hydraulic lines for the fan pump and the motor. The lines are found in the 192-5621 Hydraulic Fan Lines Gp.
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    Illustration 50	g01915515

17. Reuse the original hydraulic oil cooler lines (15) that come from the hydraulic tank. Install the hydraulic lines (16) from the 192-7380 Hydraulic Oil Cooler Lines Gp.
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    Illustration 51	g01915517

18. Install the supports for the firewall (17) from the 193-5494 Firewall.
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    Illustration 52	g01918053

19. Assemble the cooling system, brake lights, and the rear lights from the 191-5212 Cooling Ar, 8R-5645 Stop Lighting Gp, and the 183-3463 Flood Lighting Gp.
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    Illustration 53	g01918494

20. Install the assembled cooling system.
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    Illustration 54	g01943229

21. Cuts may be needed around the bumper to provide clearance.
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    Illustration 55	g01918597

22. Replace the 6-pin plug connector (22) from the 193-0133 Rear Chassis Harness As with the 102-8805 Receptacle Kit. The 102-8805 Receptacle Kit is found in the 193-0115 Rear Wiring Gp. Connect the newly installed 6-pin connector from the rear lighting harness to the original vehicle harness.

    Note: The wires may need extended to complete the connections.

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    Illustration 56	g01918625

23. Install the lines for the Air to Air Aftercooler (23) from the 191-7806 Air Lines Gp.
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    Illustration 57	g01918630

24. Install the water lines (24) from the 191-7811 Water Lines Gp.
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    Illustration 58	g01943658

25. Install the water tank (25) and the water lines (26) from the 194-1016 Water Lines Gp.
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    Illustration 59	g01918632

26. Install the hood (27) from the 192-3808 Hood and Guard Gp.
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    Illustration 60	g01918695

27. Install the remaining lines from the water tank to the radiator (28). The lines are found in the 194-1016 Water Lines Gp.

    Note: The hood is removed in the illustration to show the water lines.

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    Illustration 61	g01918696

28. Install the ether aid (29) from the 194-8726 Ether Starting Aid Gp.
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    Illustration 62	g01918699

29. Install the shield divider (30) from the 192-7358 Engine Compartment Shield Gp.
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    Illustration 63	g01918973

30. Install the firewall (31) from the 193-5494 Firewall Gp.
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    Illustration 64	g01919154

31. Install the exhaust extensions (32) from the 194-7653 Exhaust Extension Gp.

Electrical System

Repower Pinouts

Test and Adjust

Hydraulic Fan Speed

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. In order to prevent possible injury, perform the following procedure before testing and adjusting any of the machine hydraulic systems.

1. Park the machine on a smooth, level surface. Move away from other operating machines and away from personnel. Lower the bucket to the ground. Stop the engine.

2. Permit only one operator on the machine. Keep all other personnel away from the machine or in sight of the operator.

3. Engage the parking brake. Put blocks in front of the wheels and behind the wheels.
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   Illustration 65	g00852083
   Steering frame lock in the LOCKED position

4. Install steering frame lock in the LOCKED position so the machine cannot articulate.

5. Depress the brake pedal repeatedly will relieve any pressure that may be present in the brake hydraulic system.

6. Move the implement control levers through the full range of travel will relieve any pressure that may be present in the implement hydraulic system. Place the lift control lever in the HOLD position. Place the tilt control lever in the HOLD position.

7. Turn the steering controls several times in both directions to relieve the pressure in the steering system.

8. Slowly remove the hydraulic tank cap to relieve any pressure in the hydraulic oil tank.