IT28G Integrated Toolcarrier and 924G, 924GZ and 928G Wheel Loaders Engine Supplement Radiator and Fan Group - Remove Caterpillar

Removal Procedure

Start By:

1. Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove".

2. Remove the air cleaner. Refer to Disassembly and Assembly, "Air Cleaner - Remove and Install".

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.

Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. The capacity of the cooling system is approximately 42 L (11.1 US gal). Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

2. Drain the hydraulic tank into a suitable container for storage or disposal. The capacity of the hydraulic tank is approximately 70 L (18.5 US gal). Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change".

3. Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the tools.
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   Illustration 1	g00986846

4. Disconnect hose assemblies (1) and (2).
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   Illustration 2	g00986847

5. Disconnect hose assemblies (3) and (4). Remove bolts (5) and the clamps. Position hose assemblies (1), (2), (3), and (4) out of the way.
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   Illustration 3	g00986849

6. Loosen hose clamps (6) and (7). Disconnect tube assembly (8) and hose (9).
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   Illustration 4	g00986851

7. Remove bolts (10) and remove panel (11).
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   Illustration 5	g00986853

8. Remove bolts (12) and remove panel (13).
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   Illustration 6	g00986867

9. Remove bolts (14) and the clamps. Position harness assembly (15) out of the way.
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   Illustration 7	g00986869

10. Disconnect hose assemblies (16). Remove bolt (17) and the clamp.
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    Illustration 8	g00986870

11. Remove bolts (18) and remove guard (19).
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    Illustration 9	g00986873

12. Disconnect harness assembly (20). Cut and remove cable strap (21) that attaches harness assembly (22) to the machine.
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    Illustration 10	g00986887

13. Disconnect harness assemblies (23). Cut and remove cable straps (24).
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    Illustration 11	g00986894

14. Disconnect harness assembly (25). Cut and remove cable strap (26). Position harness assembly (22) out of the way.
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    Illustration 12	g00986898

15. Cut and remove cable straps (27). Position harness assembly (22) out of the way.
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    Illustration 13	g00986899

16. Disconnect harness assembly (28). Position harness assembly (22) out of the way.
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    Illustration 14	g00986908

17. Disconnect harness assembly (29). Cut and remove cable strap (30). Position harness assembly (22) out of the way.
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    Illustration 15	g00986910

18. Disconnect harness assembly (31). Cut and remove cable straps (32). Position harness assembly (22) out of the way.
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    Illustration 16	g00986911

19. Disconnect hose assemblies (33).
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    Illustration 17	g00986912

20. Loosen hose clamps (34) and disconnect hoses (35).
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    Illustration 18	g00986923

21. Remove nut (37). Position battery disconnect switch (36) out of the way.
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    Illustration 19	g00986924

22. Attach Tooling (A) and a suitable lifting device onto the radiator and fan group. The weight of the radiator and fan group is approximately 340 kg (750 lb).
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    Illustration 20	g00986925

23. Remove bolt (38) and the clamp. Remove bolt (39).
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    Illustration 21	g00986927

24. Remove bolt (40) and the nut. Remove bolt (41).
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    Illustration 22	g00986929

25. Remove bolt (42).
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    Illustration 23	g00986930

26. Remove bolt (43) and the clamp. Remove bolt (44). Remove radiator and fan group (45) from the machine. The weight of radiator and fan group (45) is approximately 340 kg (750 lb).