37820-93J03 Suzuki SWITCH ASSY, EMERGENCY

Introduction
This Special Instruction provides the procedure in order to repower a 992D Wheel Loader. The replacement engine will be a Tier I Level 3412 Engine. The 992D Wheel Loader was originally equipped with a 3412 engine. The original 3412 engine is not regulated. This Special Instruction will provide the information in order to install the Tier I Level replacement engine. There will be some modifications to the machine that are not covered in this instruction. If issues are encountered, contact the Caterpillar Emissions Solutions Group for assistance. Photos and the specific details of the issue, along with the information will be appreciated. Once information has been submitted and approved, the changes will be added to these instructions.
Table 1
Engine Arrangement
Original Engine Replacement Engine
1N-4400 293-8251(1)
20R-2517(2)
6N-0204
100-7830
130-1248
(1) New repower engine
(2) Reman repower engineThis 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.Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.The following information includes instructions on registering the updates and retrofits.Register the Retrofit
When performing a retrofit installation, record the vital information in Table 2.Note: If the procedure is performed by the customer, ask the customer to record the proper information.
Table 2
Repair Date
Product Serial Number
Service Hours or Service Meter Units
Removed Component Part Number(1)
Removed Component Serial Number(1)
Installed Component Part Number(2)
Installed Component Serial Number(3)
(1) Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
(2) Record the highest level retrofit kit, arrangement, or group part number.
(3) Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.
Update the product configuration by entering the information from Table 2 into SIMSi and AIMS.Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".
For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".Safety
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.
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.
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.
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.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
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.
Set the engine control to the "STOP" mode.
Turn OFF the fuel supply to the engine.
Disconnect the negative terminal from the battery.
Disconnect the engine electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor bypass, fuel metering valve, and sensors.
Protect the wiring harnesses from welding debris and/or from welding spatter.