Procedure To Install the New Air Baffle Gp and Cab Insulation{1806} Caterpillar

Introduction

This publication contains information to install the new air baffle group, insulation, and engine software. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for the standard machine.

Read the entire Special Instruction. Understand the information before performing any procedures. Understand the information before ordering any parts.

ReferenceDisassembly and Assembly, KENR6707.

Safety Section

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.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by AVSpare. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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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. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Parts Required

Procedure

1. Move the machine to a hard level surface away from operating machines and personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Turn the key start switch and battery disconnect switch to the OFF position.

4. Remove the radiator header tank. Refer to Disassembly and Assembly, "Radiator Tank (Header) - Remove".

5. Remove the bottom engine guard. Refer to Disassembly and Assembly, "Bottom Guard (Engine) - Remove and Install".

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Illustration 1	g02125916

6. Remove and retain covers (1) for installation purposes.

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Illustration 2	g02126395

7. Remove and discard plate (2) .

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Illustration 3	g02125918

8. Remove and retain clip (3) for installation purposes.

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Illustration 4	g02125915

9. Loosen two hose clamps (4) and two hose clamps (5) .

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Illustration 5	g02125921

10. Loosen two hose clamps (7) .

11. Remove and retain clamp assembly (10) and tube assembly (8) for installation purposes.

12. Loosen two hose clamps (11) .

13. Remove and retain clamp assembly (6) and tube assembly (9) for installation purposes.

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Illustration 6	g02125922

14. Remove and retain clip (12) for installation purposes. Disconnect harness assembly (13) and move aside.

15. Remove and discard clip (17) .

16. Remove and retain clip (14) for installation purposes.

17. Disconnect 326-6690 Hose As (15) and 217-9917 Hose As (16) if equipped.

18. Remove 326-6690 Hose As (15) and remove 100 mm (3.93 inch) from the hose length.

19. Remove 217-9917 Hose As (16) and remove 150 mm (5.90 inch) from the hose length.

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Illustration 7	g02125417

20. Remove and retain clip (18), clip (19) and the bolt and washer for installation purposes.

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Illustration 8	g02125416

21. Install clip (19), the bolt, and washer retained in Step 20 and 291-9502 Spacer (20) .

    Note: Ensure clip (19) is installed as shown.

22. Install clip (18) retained in Step 20, 8T-4136 Bolt (21) and 5P-1075 Hard Washer .

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Illustration 9	g01964814
(23) 346-2182 Strip (A) 930 mm (36.6 inch) (B) 184 mm (7.24 inch)

23. Weld 346-2182 Strip (23) into position on plate (22). Refer to Table 3 and Illustration 9.
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    Table 3

    Item	Dimension
    L1	50 mm (1.97 inch)
    N1	100 mm (3.94 inch)
    W1	3 mm (0.12 inch)

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Illustration 10	g01964815
(24) 9R-2613 Weld Boss (C) 39.5 mm (1.55 inch) (D) 21 mm (0.83 inch)

24. Weld 9R-2613 Weld Boss (24) into position on 306-2229 Tank As (25). Refer to Table 4 and Illustration 10.
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    Table 4

    Item	Dimension
    W2	3 mm (0.12 inch)

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Illustration 11	g02126397
(E) 110 mm (4.33 inch) (26) 351-1371 Plate (27) 8T-4189 Bolt (28) 351-1434 Baffle (29) 351-1433 Plate

25. Weld plate 351-1371 Plate (26) to the underside of the radiator header tank. Refer to Table 5 and Illustration 11.
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    Table 5

    Item	Dimension
    L2	50 mm (1.97 inch)
    N2	100 mm (3.94 inch)
    W3	5 mm (0.19 inch)
    W4	5 mm (0.19 inch)

26. Install 351-1434 Baffle (28), 351-1433 Plate (29), two 8T-4189 Bolt (27) and 8T-4224 Hard Washer .

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Illustration 12	g01964816
Plan view of the front frame (30) 9R-2613 Weld Boss (F) 27 mm (1.06 inch) (G) 102 mm (4.0 inch)

27. Weld 9R-2613 Weld Boss (30) into position on the front frame. Refer to Table 6 and Illustration 12.
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    Table 6

    Item	Dimension
    W5	3 mm (0.12 inch)

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Illustration 13	g01966234
(31) 344-8794 Baffle (32) 346-2179 Baffle (33) 346-2246 Retainer As (34) (37) (38) 344-8792 Cover (35) 346-2248 Retainer As (36) 344-8791 Cover

28. Assemble items (31) , (35) , (36) , three 8T-4189 Bolts and 8T-4224 Hard Washers .

29. Assemble items (36) , (33) (not shown), (32) , five 8T-4189 Bolts and 8T-4224 Hard Washer .

30. Install item (34), (37), (38), 12 8T-4189 Bolts and 8T-4224 Hard Washer .

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Illustration 14	g01966253
(39) 344-8793 Baffle (40) 344-8789 Cover (41) 346-2244 Retainer As

31. Assemble items (39), (40), (41), six 8T-4189 Bolts and 8T-4224 Hard Washers .

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Illustration 15	g02127717
Rear view of the radiator

32. Remove and retain two bolts (42) and the hard washers for installation purposes.

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Illustration 16	g01959377
(36) 344-8791 Cover (40) 344-8789 Cover (44) 344-8790 Cover

33. Install 344-8789 Cover (40), two 8T-4137 8T-4137 Bolts (43) and 5P-1075 Hard Washer .

34. Install 344-8790 Cover (44), six 8T-4189 Bolts (45) and 5P-4116 Hard Washer .

35. Install 344-8791 Cover (36) .

    Note: Do not install bolts at this stage.

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Illustration 17	g02125926

36. Install tube assembly (9) and clamp assembly (6) retained in Step 13. Tighten two hose clamps (11) .

37. Install tube assembly (8) and clamp assembly (10) retained in Step 11. Tighten two hose clamps (7) .

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Illustration 18	g02125927

38. Tighten two hose clamps (4) and two hose clamps (5) .

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Illustration 19	g02127737

39. Install two bolts (42) retained in Step 32.

40. Install two 8T-4137 Bolt (47) and 5P-1075 Hard Washer .

41. Install two 106-6553 Bumper (46) .

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Illustration 20	g01965113
(48) 8T-4136 Bolt (49) 321-4443 Bracket (50) 8T-4137 Bolt

42. Install items (48), (49), 5P-1075 Hard Washer and 8T-4133 Nut .

43. Install items (50) and 5P-1075 Hard Washer .

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Illustration 21	g02118918

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Illustration 22	g02127773

44. Drill and tap four M10X1.5 holes using 351-1304 Cover As (52) as a template.

45. Install 351-1304 Cover As (52), four 8T-4195 Bolt (51) and 5P-1075 Hard Washer . Position 346-2179 Baffle (32) as shown in Illustration 21 and Illustration 22.

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Illustration 23	g02123333

46. Assemble items 351-1314 Plate (53), 351-1312 Baffle (54), 351-1313 Cover As (56), four 8T-4136 Bolt (55) and 8T-4121 Hard Washer .

    Note: If 351-1313 Cover As (56) requires modification in order to adapt to after market fire suppression system, ensure that any opening is properly sealed. Failure to properly seal will affect the performance of the cooling system.

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Illustration 24	g02125393

47. Drill and tap two M10X1.5 holes (57) using 351-1313 Cover As (56) as a template.

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Illustration 25	g02118933

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Illustration 26	g02123334

48. Install 351-1313 Cover As (56) assembled in Step 46, four 8T-4136 Bolt (58) and 8T-4121 Hard Washer .

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Illustration 27	g02123355
Left side view of the cooling package (H) 222 mm (8.74 inch) (J) 168 mm (6.61 inch) (K) 475 mm (18.7 inch)

49. Drill and tap two M10X1.5 holes (59) .

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Illustration 28	g02125334
(60) 351-1298 Plate (61) 8T-4136 Bolt (63) 351-1299 Cover As

50. Install items (60), two 8T-4136 Bolt (61) and 8T-4121 Hard Washer .

51. Install 351-1299 Cover As (63) .

52. Weld 351-1299 Cover As (63) at three positions (62). Refer to Table 7 and Illustration 28.
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    Table 7

    Item	Dimension
    W6	3 mm (0.12 inch)

53. Install the radiator header tank. Refer to Disassembly and Assembly, "Radiator Tank (Header) - Install".

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Illustration 29	g01966273
(64) 8T-4137 Bolt

54. Install 8T-4137 Bolt (64) and 5P-1075 Hard Washer .

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Illustration 30	g02126381
Typical example

55. Connect harness assembly (13) .

56. Install clip (12) retained in Step 14.

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Illustration 31	g02126429
Right side view of the operator station (65) 212-0501 Cover As (66) 11 mm (0.43 inch) (L) 20 mm (0.78 inch) (M) 36 mm (1.42 inch)

57. Drill hole (66) in 212-0501 Cover As (65) .

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Illustration 32	g02126398

58. Connect hose assembly (15) and hose assembly (16) disconnected in Step 17.

59. Install clip (14) retained in Step 18, 8T-4137 Bolt , 8T-4121 Hard Washer and 8T-4133 Nut .

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Illustration 33	g02125918

60. Install clip (3) retained in Step 8.

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Illustration 34	g02125916

61. Install covers (1) retained in Step 6.

62. Install the bottom engine guard. Refer to Disassembly and Assembly, "Bottom Guard (Engine) - Remove and Install".

Procedure to Install Insulation

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Illustration 35	g02139553
(A) Location for 338-6710 Lining As

1. Remove coat hook (1) .

2. Using Bostik 9913 Solvent clean surface (A) of any dirt and grease.

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Illustration 36	g02139556
(2) 338-6710 Lining As

3. Apply Bostik 2402 Solvent Based Adhesive and Bostik 9105 Curing Agent to 338-6710 Lining As (2) .

4. Install 338-6710 Lining As (2) as shown in Illustration 36.

5. Install coat hook (1) .

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Illustration 37	g02139555
(B) Location for 338-6711 Lining As

6. Remove storage door (3) .

7. Using Bostik 9913 Solvent clean surface (B) of any dirt and grease.

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Illustration 38	g02139554
(4) 338-6711 Lining As

8. Apply Bostik 2402 Solvent Based Adhesive and Bostik 9105 Curing Agent to 338-6711 Lining As (4) .

9. Install 338-6711 Lining As (4) as shown in Illustration 38.

10. Install storage door (3) .

Updating the Software

1. Flash the engine with the applicable software listed in Table 9.
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   Table 8

   Model	Effective with	Adaptable to
   AD55B	S/N:JNW178-UP	S/N:JNW1-177

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   Table 9

   New Part Number	Description	Former Part Number
   361-2101	Engine Ratings Electronic Software Gp	345-9668

   The improved software is available in the form of a flash file through the AVSpare Service Information System (SIS).