Relocation of the Rear Disconnect Switch {1411} Caterpillar


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Relocation of the Rear Disconnect Switch {1411} [REHS4878]
ELECTRICAL AND STARTING SYSTEM
SWITCH GP
1.1. Introduction
2.1. Important Safety Information
3.1. Required Parts for the Two Battery Configuration
4.1. Relocate the Rear Disconnect Switch for the Two Battery Configuration
5.1. Required Parts for the Four Battery Configuration
6.1. Relocate the Rear Disconnect Switch for the Four Battery Configuration
Wheel Tractor-Scraper:
637G (S/N: DEX1-UP; DFJ1-UP; DEY1-UP)

Introduction

This Special Instruction provides information about relocating the rear disconnect switch. The present location of the rear disconnect switch for the scraper engine can obstruct a clear line of sight to the rear hydraulic tank sight gauge.

The procedure that is discussed in this Special Instruction will involve a modification and a new location for the support plate that is used for the rear disconnect switch. The support plate that is used for the rear disconnect switch will be positioned 100 mm (4 inches) forwards from the original location. Also, new battery cables are to be installed.

Do not perform any procedure that is outlined in this special instruction, or order any parts until the entire special instruction has been read and understood.

Important Safety Information

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. AVSpare 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. If a tool, a procedure, a work method or operating technique that is not specifically recommended by AVSpare is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance or the repair procedures that are used.

Required Parts for the Two Battery Configuration

The parts that are listed in Table 1 are for the 228-6965 Battery and Wiring Group two battery configuration.

Table 1
Required Parts    
Qty     Part Number     Description    
1     312-4603     Cable Assembly    
1     317-6836     Cable Assembly    
1     237-0982     Cable Assembly    
1     111-1374     Bracket    
2     4L-6454     Bolt    
2     174-5907     Clip    
4     8T-4896     Washer    
2     6V-8801     Nut    
1     2W-7940     Bracket    
1     8T-4192     Bolt    
1     8T-4223     Washer    

Relocate the Rear Disconnect Switch for the Two Battery Configuration

  1. Move the machine to a safe location. Secure the machine. Place the disconnect switch for the tractor and the scraper in the OFF position.

  1. Make two alignment marks for the support block that is used for the scraper disconnect switch. The original location must be marked before the support block is removed. The marks will serve as reference points in order to relocate the support block.

  1. Remove the battery cables. Remove the cables that are used for the disconnect switch. Discard the battery cables. Discard the cables that are used for the disconnect switch. Refer to Table 2 for the list of parts that are to be removed and that are to be discarded. Save the hardware, the grommets, and the clips.

    Table 2
    Parts to be Removed and Discarded    
    Qty     Part Number     Description    
    1     239-6895     Cable Assembly    
    1     236-8020     Cable Assembly    
    1     236-8017     Cable Assembly    

  1. Remove the disconnect switch from the support plate. Set the disconnect switch aside.

  1. Remove the disconnect switch support plate from the fender.

    Note: Use caution not to destroy or distort the support plate. The plate will be used again.

  1. Use the reference marks that were made in Step 2 in order to mark the new location for the disconnect switch support plate. The marks for the new location must be 100 mm (4 inches) forward (toward the front of machine) from original mounting location.

  1. Weld the support plate into position. Use a 3 mm (0.11811 inch) (1/8 inch) fillet weld. Use AVSpare weld specification code 1E0099R. The weld must be made along both sides of the support.

  1. Clean the welded areas and paint the welded areas.

  1. Install the disconnect switch. Use the hardware that was saved.

  1. Install the batteries (1) according to Illustration 1. Install the 237-0982 Cable Assembly (2) in order to connect the batteries in "series".



    Illustration 1g01901090

    (1) Batteries

    (2) 237-0982 Cable Assembly

    (3) "+" Battery Cable 312-4603 Cable Assembly

    (4) "-" Battery Cable 317-6836 Cable Assembly

    (5) Hold Down Clip Assembly

    (6) Hold Down Clip Assembly

    (7) Disconnect Switch Assembly

    (8) Positive Cable to Starter

    (9) Disconnect Switch End of Positive Battery Cable

    (10) Disconnect Switch End of Negative Battery Cable

  1. Assemble the "+" battery cable 312-4603 Cable Assembly (3) to the positive terminal on the rear battery.

  1. Route the positive cable (12) out of the battery box through the bottom hole of the grommet (13). Refer to Illustration 2.



    Illustration 2g01902333

    (12) Positive Battery Cable

    (13) Grommet

    (14) Negative Battery Cable

  1. Connect the disconnect switch end of the "+" cable (9) to the disconnect switch (7) .

  1. Tighten the connectors. The connector for the disconnect switch must be torqued to 50 ± 10 N·m (37 ± 7 lb ft). Torque the bolts for the battery post to 7.2 ± 1.5 N·m (5 ± 1 lb ft).

  1. Assemble the "-" battery cable 317-6836 Cable Assembly (4) to the negative terminal of the front battery. Refer to Illustration 1.

  1. Route the negative battery cable (14) out of the battery box through the top hole of the grommet (13). Refer to Illustration 2.

  1. Connect the disconnect switch end of the "-" battery cable (10) to the disconnect switch (7) .

  1. Tighten the connectors. The connector for the disconnect switch must be torqued to 50 ± 10 N·m (37 ± 7 lb ft). Torque the bolts for the battery posts to 7.2 ± 1.5 N·m (5 ± 1 lb ft).

  1. Secure the battery cables to the fender. Use the hardware, the grommets, and the clips that were saved in Step 3.

  1. Secure the "+" cable to the battery hold down (6). Use the clip, grommet, bolt and washer that were removed in Step 3.

  1. Secure the "-" battery cable to the battery cable hold down (5). Use one clip, one grommet, one nut, and one washer. Assemble the hold down (5) to the existing mounting stud.

  1. Remove the "+" cable from the starter. Remove the battery cable from the clip, that is closest to the starter, that is used to attach the battery cable to the frame rail.

  1. Secure the starter cable (18) to the flywheel housing (19) with the bracket assembly (20). The parts for the bracket assembly (20) are listed in Table 3. Refer to Illustration 3.

    Table 3
    Starter Cable Mounting Hardware for Flywheel Housing    
    Qty     Part Number     Description    
    1     2W-7940     Bracket    
    1     174-5907     Clip    
    1     8T-4192     Bolt    
    1     8T-4223     Washer    
    1     4L-6454     Bolt    
    2     8T-4896     Washers    
    1     6V-8801     Nut    



    Illustration 3g01901092

    (18) Starter Cable

    (19) Flywheel Housing

    (20) Bracket Assembly

    (21) Bracket for the ECM

    (22) Bracket Assembly

    (23) Starter

  1. Secure the starter cable (18) to the ECM bracket (21) that is above starter (23). Use the bracket assembly (22) in order to secure the starter cable to the ECM bracket. The parts for the bracket assembly (22) are listed in Table 4. Refer to Illustration 3.

    Table 4
    Starter Cable Mounting Hardware for ECM Bracket    
    Qty     Part Number     Description    
    1     111-1374     Bracket    
    1     174-5907     Clip    
    1     4L-6454     Bolt    
    2     8T-4896     Washers    
    1     6V-8801     Nut    

  1. Connect the starter cable to the starter.

    Note: If the starter cable will not reach the starter, then there may be a need to loosen some of the battery cable clips, that are on the frame, in order to allow the battery cable to be moved enough in order to reach to the starter.

  1. Return the machine to service.

Required Parts for the Four Battery Configuration

The parts that are listed in Table 5 are for the 271-3333 Battery and Wiring Group four battery configuration.

Table 5
Required Parts    
Qty     Part Number     Description    
1     310-9250     Cable Assembly    
1     317-6837     Cable Assembly    
2     170-6929     Cable Assembly    
1     111-1374     Bracket    
2     4L-6454     Bolt    
2     174-5907     Clip    
4     8T-4896     Washer    
2     6V-8801     Nut    
1     2W-7940     Bracket    
1     8T-4192     Bolt    
1     8T-4223     Washer    

Relocate the Rear Disconnect Switch for the Four Battery Configuration

  1. Move the machine to a safe location. Secure the machine. Place the disconnect switch for the tractor and the scraper in the OFF position.

  1. Make two alignment marks for the support block that is used for the scraper disconnect switch. The original location must be marked before the support block is removed. The marks will serve as reference points in order to relocate the support block.

  1. Remove the battery cables. Remove the disconnect switch cables. Discard the battery cables. Discard the disconnect switch cables. Refer to Table 6 for the list of parts that are to be removed and that are to be discarded. Save the hardware, the grommets, and the clips.

    Table 6
    Parts to be Removed and Discarded    
    Qty     Part Number     Description    
    2     239-6895     Cable Assembly    
    1     271-3334     Cable Assembly    
    1     271-3335     Cable Assembly    

  1. Remove the disconnect switch from the support plate. Set the disconnect switch aside.

  1. Remove the disconnect switch support plate from the fender.

    Note: Use caution not to destroy or distort the support plate. The plate will be used again.

  1. Use the reference marks that were made in Step 2 in order to mark the new location for the disconnect switch support plate. The marks for the new location must be 100 mm (4 inches) forward (toward the front of machine) from original mounting location.

  1. Weld the support plate into position. Use a 3 mm (0.11811 inch) (1/8 inch) fillet weld. Use AVSpare weld specification code 1E0099R. The weld must made along both sides of the support.

  1. Clean the welded areas and paint the welded areas.

  1. Install the disconnect switch. Use the hardware that was saved.

  1. Install the batteries (30) according to Illustration 4. Install two 170-6929 Cable Assemblies (31) in order to connect the batteries in "series".



    Illustration 4g01901135

    (30) Batteries

    (31) 170-6929 Cable Assemblies

    (32) "+" Battery Cable 317-6837 Cable Assembly

    (33) Battery Cable 310-9250 Cable Assembly

    (34) Disconnect Switch Assembly

  1. Assemble the "+" battery cable 317-6837 Cable Assembly (32) to the two positive terminals on the batteries as shown in Illustration 4.

  1. Route the positive cable (32) out of the battery box through the bottom hole of the grommet (35). Refer to Illustration 5.



    Illustration 5g01903542

    (32) Positive Battery Cable

    (33) Negative Battery Cable

    (35) Grommet

  1. Connect the disconnect switch end of the "+" cable (32) to the disconnect switch (34). Refer to Illustration 4.

  1. Tighten the connectors. The connector for the disconnect switch must be torqued to 50 ± 10 N·m (37 ± 7 lb ft). Torque the bolts for the battery posts to 7.2 ± 1.5 N·m (5 ± 1 lb ft).

  1. Assemble the "-" battery cable 310-9250 Cable Assembly (33) to the two negative terminals of the batteries. Refer to Illustration 4.

  1. Route the negative battery cable (33) out of the battery box through the top hole of the grommet (35). Refer to Illustration 5.

  1. Connect the disconnect switch end of the "-" battery cable (33) to the disconnect switch (34). Refer to Illustration 4.

  1. Tighten the connectors. The connector for the disconnect switch must be torqued to 50 ± 10 N·m (37 ± 7 lb ft). Torque the bolts for the battery posts to 7.2 ± 1.5 N·m (5 ± 1 lb ft).

  1. Secure the battery cables to the fender. Use the hardware, the grommets, and the clips that were saved in Step 3.

  1. Remove the "+" cable from the starter. Remove the battery cable from the clip, that is closest to the starter, that is used to attach the battery cable to the frame rail.

  1. Secure the starter cable (40) to the flywheel housing (41) with the bracket assembly (42). The parts for the bracket assembly (42) are listed in Table 7. Refer to Illustration 6.

    Table 7
    Starter Cable Mounting Hardware for Flywheel Housing    
    Qty     Part Number     Description    
    1     2W-7940     Bracket    
    1     174-5907     Clip    
    1     8T-4192     Bolt    
    1     8T-4223     Washer    
    1     4L-6454     Bolt    
    2     8T-4896     Washers    
    1     6V-8801     Nut    



    Illustration 6g01901136

    (40) Starter Cable

    (41) Flywheel Housing

    (42) Bracket Assembly

    (43) ECM Bracket

    (44) Bracket Assembly

    (45) Starter

  1. Secure the starter cable (40) to the ECM bracket (43) that is above starter (45). Use the bracket assembly (44) in order to secure the starter cable to the ECM bracket (43). The parts for the bracket assembly (44) are listed in Table 8. Refer to Illustration 6.

    Table 8
    Starter Cable Mounting Hardware for ECM Bracket    
    Qty     Part Number     Description    
    1     111-1374     Bracket    
    1     174-5907     Clip    
    1     4L-6454     Bolt    
    2     8T-4896     Washers    
    1     6V-8801     Nut    

  1. Connect the starter cable to the starter.

    Note: If the starter cable will not reach the starter, then there may be a need to loosen some of the battery cable clips, that are on the frame, in order to allow the battery cable to be moved enough in order to reach to the starter.

  1. Return the machine to service.

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