ENGINE AR-COMPLETE 1399948 - Caterpillar

Illustration 3 g03697818
Illustration 4 g03697819
Drill two holes (F) of diameter (E) of 11 mm (0.4 inch) on the frame as per dimensions shown in Illustration 2.
Illustration 5 g03697820
(G) 206.2 mm (8.12 inch)
(H) 448.8 mm (17.67 inch)
Illustration 6 g03697821
(J) 531 mm (20.9 inch)
(K) 275.8 mm (10.86 inch)
(L) 255.2 mm (10.05 inch)
(M) 81.2 mm (3.20 inch)
(N) Radius of 235 mm (9.3 inch)
(P) Radius of 20 mm (0.8 inch) at four edges
(R) 9.2 mm (0.4 inch)
(S) 125.9 mm (4.96 inch) at two places
Enlarge the size of two areas of the frame as per dimensions shown in Illustration 5 and Illustration 6.Note: Some frames have a smaller hole and some may have a larger hole so the layout might look different than the illustrations but the layout for the dimensions will be correct.
Measurement H and G overlap each other. Use measurement H. Before cutting the hole in the frame in illustration 5, disconnect and cap the hydraulic hoses for the right rear final drive. Remove the clamp and bolt from the L bracket. Cut the L bracket for hydraulic hoses off and save the hardware for later use.
Illustration 7 g03697823
(V) 30 mm (1.2 inch) at four places
(X) Radius of 30 mm (1.2 inch) at four edges
(Y) 120 mm (4.7 inch)
Fabricate a plate (U) of thickness 10 mm (0.4 inch) as per dimensions shown in Illustration 7.
Set the U plate directly in the enlarged hole in the frame. Weld the plate in place. Use the L bracket that was cut off earlier and weld the bracket in the center of the U plate on the backside.
Illustration 8 g03697824
(Z) 98.8 mm (3.89 inch)
(AA) 90 mm (3.5 inch)
(AB) 120 mm (4.7 inch)
Weld the plate (U) into the area of frame as per dimensions shown in Illustration 8.
Illustration 9 g03697825
(W1) 6 mm (0.2 inch) fillet weld
Illustration 10 g03697826
(W1) 6 mm (0.2 inch) fillet weld
Weld new bracket (1) and bracket (2) to the frame as shown in Illustration 9 and Illustration 10.
Remove the existing parts from the old tanks. Install the removed parts on new water tank groups.
Install the 2 elbows, clamps and vent hoses into the new center water tank, and secure them together with zip ties.
Illustration 11 g03778617
434-5082 Water Tank Gp
Illustration 12 g03778618
434-5087 Water Tank Gp
Install one new elbow (3) and one new grommet (4) on top of water tank group (5).
Reuse existing fittings from the old tank on bottom of water tank group (5).
Illustration 13 g03778623
Install new water tank group (5) and water tank (6) to the respective water tank group using the hardware listed in Table 1 as shown in Illustration 11.
After installing the tanks into the machine frame, install new straps to secure the center tank. Reuse the straps from the rear tank to secure the new tank.
Remove both lower supply hoses. Install the hoses on the opposite sides of each other because the hoses are not long enough to reach the lower fittings on the center tank. Route hoses in with the existing P-clips so that the hoses are not rubbing on the frame.