Instructions For Installing A Heat Shield For The Battery And Circuit Box On Certain 16M Motor Graders{7513} Caterpillar

Motor Grader:

16M (S/N: B9H1-UP; R9H1-UP)

Introduction

This Special Instruction provides the information about the parts and procedures required to install a heat shield for the circuit breaker box and battery on 16M Motor Graders.

Important Safety Information

Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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 should 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 that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

References

ReferenceRefer to Reuse And Salvage Guidelines, SEBD0512, "Caterpillar Service Welding Guide" for proper cleaning and welding procedures.

ReferenceRefer to Special Instruction, REHS1841, "General Welding Procedures" for additional welding instructions.

ReferenceRefer to Disassembly and Assembly, KENR6018, "16M Motor Grader Machine Systems".

ReferenceRefer to Disassembly and Assembly, KENR6019, "16M Motor Grader Power Train".

Required Parts

Machine Preparation

1. Park on a level surface. If you must park on a grade, chock the machine.

2. Apply the service brake in order to stop the machine. Move the transmission control lever to the NEUTRAL position.

3. Move the speed control lever to the LOW IDLE position and engage the parking brake.

4. Lower all implements to the ground.

5. Turn the engine start switch to OFF position and remove the key.

6. Turn battery disconnect switch to the OFF position.

Hydraulic Tank Breather Rework

1. Remove the muffler to gain access to the front of the service center. Cover the open exhaust elbow.

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Illustration 1	g03746948

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Illustration 2	g03747198

2. Remove existing hydraulic tank breather (A), hose (B), clamps (C) and associated clipping hardware (D) and discard.

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Illustration 3	g03747220

3. Rotate elbow (E) as shown in Illustration 3. Loosen the jamb nut prior to rotating the elbow and tighten when complete.

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Illustration 4	g03747262

4. Install the following components onto elbow (E) as shown in Illustration 4.
   • Hose (1A)

   • Hose (1B)

   • Hose Clamp (2)

   • Breather Filter Element (3)

   • Clip (4)

   • Bolt (5)

   • Nut (6)

   • Washer (7)

   • Clip (8)

Heat Shield Preparation and Retrofit

1. Inspect service center for required mounting bosses, see Illustration 6 and 7. Later units will have these bosses already in place. If bosses are present, skip to Step 5 of this rework procedure.

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Illustration 5	g03747764

2. Remove bosses (F) from the service center plate. Favor the boss when removing. Do not gouge or cut the service center plate. Grind flush the former weld surface.

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Illustration 6	g03747790
Horizontal dimensions for bosses (9) and (10) (G) 233 mm (9.17 inch) (H) 604.7 mm (23.81 inch) (J) 83 mm (3.27 inch) (K) 133 mm (5.24 inch) (L) 614.7 mm (24.17 inch)

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Illustration 7	g03747920
Vertical dimensions for bosses (9) and (10) (M) 445.2 mm (17.53 inch) (N) 185.2 mm (7.29 inch) (P) 55.2 mm (2.17 inch) (R) 606.4 mm (23.87 inch)

3. Clean and prepare service center plate for welding. Weld bosses (9) and (10) according to dimensions in Illustrations 6 and 7 using a 5 mm (0.20 inch) fillet weld all the way around the base of the bosses.

   Note: All dimensions are measured from the edge of the plate to the center of the boss.

4. To protect from corrosion, paint bosses and surrounding area after welding.

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Illustration 8	g03821716

5. Install shield assembly (11) onto service center plate using eight bolts (12) and eight washers (13). Apply Loctite^® 242^TM Blue Threadlocker or equivalent to bolts (12) and tighten to a torque of 15 ± 3 N·m (133 ± 26.5 lb in).

6. Reinstall the muffler.