Rework Procedure for 393-0565 Coolant Tank As for Certain 924G, 928G, 930G Wheel Loader and IT28G Integrated Toolcarrier.{1063, 1353, 1377} Caterpillar

Integrated Toolcarrier:

IT28G (S/N: WAC1-UP; EWF1-UP; DBT1-UP)

Wheel Loader:

924G (S/N: DDA1-UP; EEB1-UP; RBB1-UP; WMB1-UP)

924GZ (S/N: RTA1-UP; WGX1-UP; DFZ1-UP)

928G (S/N: DJD1-UP; WLG1-UP)

930G (S/N: TWR1-UP; TFW1-UP)

Introduction

This Special Instruction will provide the information for the rework procedure to install the 393-0566 Coolant Tank Gp .

Either the new

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

Operation of the machine and the maintenance of the machine must not occur unless the instructions and warnings in the machines Operation and Maintenance Manual have been read and the instructions and the warnings are understood.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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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.

Required Parts

New Shunt Tank Information

Illustration 1	g03843431

Old Tank (with cap)

• 227-0104 Coolant Tank Gp

New Tank (with cap)

• 393-0566 Coolant Tank Gp

Old Tank (tank only)

• 227-0103 Coolant Tank As

New Tank (tank only)

• 393-0565 Coolant Tank As

Rework and Installation

Illustration 2	g03843052
Tank comparison (1) 393-0566 Coolant Tank Gp (A) Previous coolant tank group 227-0104 Coolant Tank Gp (D1) Vent port on previous coolant tank group (D2) Vent port on new tank group (V1) Drain port on previous coolant tank group (V2) Drain port on new tank group

The vent port (D2) on 393-0566 Coolant Tank Gp (1) is on opposite side compared to 227-0104 Coolant Tank Gp (A). Also, drain port (D2) is located in center of 393-0566 Coolant Tank Gp (1). For use in IT28G installation, the 185-1049 Plate bracket assembly must be reworked to accommodate new drain port location.

Illustration 3	g03843076
(2) New longer hose

Install new tank 393-0566 Coolant Tank Gp in machine as shown in picture.

The existing 9X-2133 Hose 107 cm (42.13 inch)(107cm ) will need to be replaced with a longer hose to route around the intake.

Illustration 4	g03843461
(2) 445-0743 Plate

Illustration 5	g03843445

New 445-0743 Plate (2) is required for rework

Illustration 6	g03843457

The turbocharger compressor housing can be rotated to provide additional clearance to the lower hose.

Specifications for Fabrication of 445-0743 Plate

Illustration 7	g03848163
Specifications for fabrication of plate (A) Point A, refer to Table 2 (B) Point B, refer to Table 2 (C) Point C, refer to Table 2 (D) Point D, refer to Table 2 (E) Point E, refer to Table 2 (A1) 40° (A2) 20° (C1) Diameter 11 mm (0.43inch) X 4 (C2) Diameter 50 mm (1.97 inch) (C3) Diameter 13.5 mm (0.53 inch) (D1) 118.9 mm (4.68 inch) X 2 (D2) 173.9 mm (6.85 inch) (D3) 228.9 mm (9.01inch) X 2 (D4) 258.9 mm (10.19 inch) (D5) 28 mm (1.10 inch) (D6) 56 mm (2.20 inch) X 2 (D7) 133 mm (5.24 inch) X 2 (D8) 97 mm (3.82 inch) (D9) 157 mm (6.18 inch) (D10) 151.6 mm (5.97 inch) (D11) 126.6 mm (4.98 inch) (D12) 77 mm (3.03 inch) (D13) 5 mm (0.20 inch) (D14) 78.9 mm (3.11 inch) (D15) 101.1 mm (3.98 inch) (D16) 2.9 mm (0.11 inch) (D17) 90.9 mm (3.58 inch) (D18) 258.9 mm (10.19289 inch) (R1) Radius 5 mm (0.2 inch)