Usage:
16H (6ZJ, 3JR) Motor Graders
Description of Change: The new engine enclosure design removes the enclosure from the fuel tank and provides a stand-alone support mounted to rear case rails. The door panels and hood go from 2.0 mm (.08 in) to 3.0 mm (.12 in) thick material. The dash goes from 3.0 mm (.12 in) to 5.0 mm (.20 in) thick material. The thicker material allows for improved mounting points for attachments.
Adaptable To: The new 170-7515 Engine Enclosure is a replacement for the former 103-1237 Engine Enclosure. The change is effective with 16H (6ZJ584, 3JR45) Motor Graders. Refer to the chart and procedure that follows to adapt earlier machines.
NOTE: Some components and hardware are used from the former 103-1237 Engine Enclosure in addition to the required parts listed in the chart.
Procedure To Adapt Earlier Machines
Machine Prep Information:
1. Remove the following items from unit:
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- a. 112-6723 Fan Access Panel (left side).
- b. 110-2106 Door As. (left side), will need 113-8457 Retaining Rod and hardware later.
- c. 110-2241 Fan Access Panel (right side).
- d. 110-1266 Door As. (right side), will need 113-8457 Retaining Rod and hardware later.
- e. 2A-7107 Hood As.
- f. (2) 2A-6801 Plates with 8D-3786 Mounts from rear of fuel tank.
- g. Battery boxes with brackets from both sides. (On units 16H (6ZJ1-237, 3JR1-44) Motor Graders, former supports will have to be replaced with (1) 139-3225 Support, (1) 139-3226 Support and (2) 161-4424 Covers).
- h. 112-6721 Plate As. and 112-9807 Plate As. from behind battery boxes.
- i. 110-5735 Plate As. and 110-4811 Plate As. for door hinges, striker and hood bumper from left and right front sides of fuel tank.
- j. 2A-7077 Dash with mounting brackets, 2A-6764 Plate, 129-2034 Plate As. and 8D-3786 Mounts.
- a. 112-6723 Fan Access Panel (left side).
NOTE: The 2A-6381 Plate and the grommets going to engine block will be used during assembly.
2. Remove two (2) bolts from 130-3512 Plate on the fuel tank which holds the disconnect switch and P1, P2 test ports and tie back out of the way.
NOTE: We will assemble later.
3. Remove front two (2) bolts from air cleaner support, loosen the two (2) in back. Using pencil grinder slot front two holes in 100-4099 Plate 1/2 inch towards the front of unit. Assemble cleaner to base with same hardware. This will allow the air cleaner housing to pivot towards the front and provide clearance to remove filter.
NOTE: Use extreme caution not to pull any hoses loose from air cleaner body, which may result in damage to engine.
4. Cut off the 9K-3050 Stud on left rear case rail for battery ground, we will relocate later.
5. Remove bolts from 8X-5444 Brake Valve Relay Brackets on both sides and tie valve back out of the way. Air arc off 7F-3206 Lugs from case rail, we will relocate later.
Installation Of New Material:
Illustration 1.
170-7515 Engine Enclosure Group.
NOTE: During the installation of the new material, the location of the 161-6644 & 160-5495 Blocks is critical. For fore and aft position, use the dash and battery panels as locators for the hood support. For the width position, refer to Dimension C in Illustration 9.
Illustration 2.
View G-G from Illustration 1. Dash Mount Detail.
1. Sub-assemble 160-4177 Dash (Item 25) with 159-8668 Angle As. (LH) (Item 16) and 159-8667 Plate As. (RH) (Item 15) with (4) 8T-2502 Bolts (Item 10), (1) 8N-7837 Plate As. (LH only) (Item 45), and (4) 5P-1075 Washers (Item 6). Assemble dash to front of case with (2) 8C-4436 Bolts (Item 9) and 8T-4223 Washers (Item 11).
NOTE: No rubber mounts required.
Illustration 3.
Section B-B from Illustration 1. Door Mount & Grab Iron and Fan Panel Mount Detail.
2. Assemble to 160-6361 Hood As. (Item 30) with 171-6210 Plate (Item 33) using (5) 4L-6454 Bolts (Item 46) and (5) 5P-1075 Washers (Item 6).
NOTE: Hand tighten only.
Illustration 4.
View E-E from Illustration 1. Support Assembly Detail.
3. Sub-assemble 169-8708 Support As. (RH) (Item 31) and 169-8709 Support As. (LH) (Item 32) with the following hinge parts: (2) 160-3982 Hinge As. (RH) (Item 21), (2) 160-3983 Hinge As. (LH) (Item 22), (4) 8N-7837 Plate As. (Item 45), (8) 4L-6454 Bolts (Item 46) and (8) 5P-1075 Washers (Item 6).
Illustration 5.
Section A-A from Illustration 4. Striker Plate Detail.
4. Sub-assemble supports with (2) 175-4027 Striker As. (Item 36), (4) 5M-3062 Bolts (Item 4) and (4) 5P-1075 Washers (Item 6), (4) 4L-6454 Bolts (Item 46), (2) 175-3529 Plates (Item 35). Apply (4) pieces of 5P-0801 Seal (Item 5) to support, below and above striker.
Illustration 6.
Location of blocks to weld.
5. Assemble 161-6644 Block (LH) (Item 37) and 160-5495 Block (RH) (Item 36) to supports legs with (4) 0S-1585 Bolts (Item 1) and (4) 8T-4223 Washers (Item 11).
NOTE: Hand tighten only.
6. Assemble both support assembly subs (see Step 3) to hood sub with (4) 5S-7379 Bolts (Item 7) and (4) 5P-1075 Washers (Item 6). Transfer the (4) 7I-4995 Grabirons (Item 48) and the (2) 8X-5156 Grabirons (Item 49) from the former hood.
7. Hoist hood sub onto unit and secure to dash with (5) 4L-6454 Bolts (Item 46) and (5) 5P-1075 Washers (Item 6).
NOTE: Hand tighten only.
Illustration 7.
Alternate View of 170-7515 Engine Enclosure.
8. Assemble 159-9369 Plate As. (Item 18) and 159-9371 Plate As. (Item 19) that go behind battery boxes to front dash and horseshoe bracket with (6) 5M-3062 Bolts (Item 4), (2) 5P-1075 Washers (Item 6) and (4) 7X-0578 Washers (Item 14).
NOTE: Hand tighten only.
Illustration 8.
Section N-N from Illustration 1. Engine Tie-In Detail.
9. Center hood with top of radiator support, be sure that dash is 90 degrees to case. Once dash is vertical, secure 2A-6381 Plate (Item 51) with 1P-7115 Grommets (Item 47) from engine to block on dash. Reach inside battery panels and tack weld horseshoe support blocks to case rail. Refer to Illustration 9.
10. Remove bolts from hood to dash, bolts from both support brackets, panels behind battery boxes and lift hood sub assembly back off.
11. Use 160-5696 Shims as required under front of blocks to ensure blocks are flat. Complete the welding of mounting blocks to case rails.
NOTE: Weld only on inside and outside of blocks, do not weld on ends. Refer to Illustration 6 for weld locations.
Illustration 9.
New location of Brake Valve Lug.
12. Relocate 7F-3206 Brake Valve Lug (Item 40) and weld. Assemble valves back to lugs.
NOTE: This may require the rear fitting in valve to be reoriented.
13. Weld the 9K-3050 Stud (Item 41) to left inside rear case rail and reconnect ground cable.
NOTE: Check position of cable for any interference or rubbing.
14. Assemble disconnect switch bracket to fuel tank.
NOTE: Will have to bend back to clear support and may have to remove large boss from fuel tank.
15. Install hood sub assembly to dash and bolt to blocks previously welded on. Use 160-3986 Plates (Item 23) and 160-3987 Plates (Item 24), as required, between mounting block and vertical support to get the proper height of hood relative to the radiator cowl.
Illustration 10.
Section T-T from Illustration 1.
16. Assemble the 159-9371 Plate As. (Item 19) and the 159-9369 Plate As. (Item 18) to front dash and supports. Assemble 159-8677 Small Plate As. (Item 17) for battery cables to panel with (2) 6V-8801 Nuts (Item 8), (2) 5M-3062 Bolts (Item 4) and (4) 5P-1075 Washers (Item 6). Route cable through opening and clip.
17. Assemble battery boxes and covers to unit.
NOTE: On the 16H (6ZJ1-237, 3JR1-44) Motor Graders, new supports and covers listed in Step 1-G of Machine Prep Information are required.
Illustration 11.
Section D-D from Illustration 1. Door Latch Detail.
18. Sub-assemble 160-5106 Door As. (LH) (Item 28) and 160-5108 Door As. (RH) (Item 29) with the following: (2) 160-3958 Pawl-latch (Item 20), (2) 8Y-6400 Latch (Item 13), (4) 8T-2502 Bolts (Item 10), (4) 5P-1075 Washers (Item 6), (4) 8T-9496 Locknuts (Item 12) and (4) 3K-6060 Locknuts (Item 2).
19. Assemble both doors to dash with (10) 4L-6454 Bolts (Item 46), (10) 5P-1075 Washers (Item 6) and hold open rods.
Illustration 12.
Section C-C from Illustration 1. Fan Panel Mount Detail.
20. Assemble (2) 173-0080 Plate As. (Item 34) to rear case rail.
NOTE: Replaces 7I-4983 Plate As.
21. Assemble (2) 5H-9743 Grommets (Item 3) to 160-4913 Rear Fan Panel Door (Item 26) and 160-4915 Rear Fan Panel Door (Item 27).
22. Assemble fan panels to hinges on supports; adjust hinges for alignment with radiator support. Use (2) 7X-0578 Washers (bottom) (Item 14), (2) 5P-1075 Washers (Item 6), and (4) 9B-7237 Bolts (Item 50) to secure door.
23. Apply films to unit.
Refer to Service Magazine, October 6, 1997, Page 44, "Proper Welding Procedure On Machines And Engines With Electronic Controls".
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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 kill.
Read and understand the manufacturer's instructions and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and general area. Wear correct eye, ear, and body protection. Do not touch live electrical parts.
Refer to the American National Standard Z49.1 "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CRF 1910, available from U.S. Dept. of Labor, Washington, D.C. 20408.
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Weld Specifications And Parameters
NOTE: Welding operator personal protection should be provided to assure that total weld fume in the operators breathing zone does not exceed OSHA limits.
All repair welding operators must be qualified for groove and fillet welding, as outlined the current ANSI/AWS D14.3. The qualification will be for the SMAW (Shielded Metal Arc Welding) process in the vertical welding positions. The welding operator must also have used this welding process during the last six months or be re-certified for this process before welding. Documentation must be maintained of the weld operators qualifications. The alternate process for this repair could be FCAW (Flux Cored Arc Welding).
The area to be welded and the surrounding area must be at a minimum temperature of 16° C (60° F) before and during welding.
NOTE: Since weld distortion is a possibility, minimizing the heat is important.
The SMAW process shall be used with E7018 (ANSI/ AWS A5.5) welding electrode in open environments. The GMAW or the FCAW (Flux Cored Arc Welding) should be used in enclosed environments. The weld deposited by these electrodes will have the following minimum mechanical properties:
- 500 MPa (72 KSI) Tensile Strength
- 420 MPa (60 KSI) Yield Strength
- 22% elongation in 50 mm (2 in)
- 27 J (20 ft lb) Notch Toughness at -29° C (-20° F)
- 420 MPa (60 KSI) Yield Strength
These are low hydrogen electrodes and must be stored in an electrode oven at 120° C (250° F) when not in use. If the electrodes get damp, scrap or recondition them to the manufacturer's specifications.
Where possible, welds should be made in the flat or horizontal position.
The following chart relates to the electrodes diameter and approximate current settings for welding:
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass size shall not exceed two times the electrode diameter.
Welding parameters will vary due to weld position and manufacturer of the welding electrode.
Clean the metal of oil, grease, paint, and dirt in the area to be welded. Attach the welding ground cable directly to the area to be welded. Protect all machined surfaces from sparks or splatter produced by the welding, chipping, and/or grinding operations.
The welds shall be free from cracks, porosity, undercut, and incomplete fusion. All weld quality shall conform to ANSI/AWS D14.3.