Improved Fuse Block Assembly Is Now Used in the Steering Console Wiring Group on Certain Motor Graders {1408, 5258, 7451} Caterpillar

Reference: Operation and Maintenance Manual, SEBU8250, "120K Motor Grader", "Prepare the Machine for Maintenance"

Reference: Operation and Maintenance Manual, SEBU8724, "120K Series 2 Motor Grader", "Prepare the Machine for Maintenance"

Reference: Operation and Maintenance Manual, SEBU8249, "12K140K160K Motor Graders", "Prepare the Machine for Maintenance"

Reference: Operation and Maintenance Manual, SEBU8725, "140K Series 2 Motor Grader", "Prepare the Machine for Maintenance"

Description Of Change: The improved fuse block assembly in the steering console wiring group has two new cap nuts to cover the terminal threads of the fuse block assembly.

The new cap nuts avoids hard rubbing of steering hose to the fuse block terminal threads.

Adaptable To: The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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Personal injury or death can result from sudden movement. Prevent possible injury by performing the following procedures before work begins: Move the product or equipment to a smooth, level surface. When applicable, lower equipment/work tools to the ground. Engage the parking brake, system brakes and/or hydraulic lockout control. When applicable, stop the engine and remove the ignition key. Release system pressure from pressurized systems. If applicable, block the wheels/tracks. Turn the battery disconnect switch to the OFF position and if applicable, remove the battery disconnect key. If not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps.  Attach a “Do Not Operate” or similar warning tag at the battery disconnect switch location and as defined by site rules and/or local regulations.

Illustration 1	g06276183

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Shock/Electrocution Hazard – Do not operate this equipment or work on this equipment unless you have read and understand the instructions and warnings in the Service Manual. Failure to follow the instructions or heed the warnings will result in serious injury or death.

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Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.

Machine Preparation

Refer to Operation and Maintenance Manual , "Prepare the Machine for Maintenance" for your machine.

Rework Procedure

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Illustration 2	g06613455
(A) 512-5907 Plate (B) 9X-2042 Screw

1. Remove and retain plate (A) and two screws (B) from the operator console group.
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   Illustration 3	g06613462
   (B) 9X-2042 Screw (C) 490-1097 Plate

2. Remove and retain plate (C) and three screws (B) from the operator console group.
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   Illustration 4	g06613468
   (A) 512-5907 Plate (B) 9X-2042 Screw

3. Remove and retain plate (A) and two screws (B) from the operator console group.
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   Illustration 5	g06613470
   (B) 9X-2042 Screw (C) 490-1097 Plate

4. Remove and retain plate (C) and three screws (B) from the operator console group.
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   Illustration 6	g06613447
   (1) 195-3699 Nut (D) 347-4716 Fuse Block As

5. Install two nuts (1) on the terminal threads of fuse block assembly (D). Refer to Illustration 6.

   Tighten two nuts (1) to a torque of 28 ± 7 N·m (248 ± 62 lb in).

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   Illustration 7	g06613907
   Typical example (1) 195-3699 Nut

   1. A typical example of nuts (1) installed on the fuse block assembly is shown in Illustration 7.
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      Illustration 8	g06613914
      Typical example (1) 195-3699 Nut (E) 306-9556 Hose As

   2. Inspect to ensure that steering hose assembly (E) has adequate slack, so that hose assembly (E) does not rub on the fuse block tabs.

      Refer to Illustration 8.

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   Illustration 9	g06613470
   (B) 9X-2042 Screw (C) 490-1097 Plate

6. Install plate (B) and three screws (C) that were retained in Step 4 to the operator console group.

   Tighten three screws (C) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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   Illustration 10	g06613468
   (A) 512-5907 Plate (B) 9X-2042 Screw

7. Install plate (B) and two screws (C) that were retained in Step 3 to the operator console group.

   Tighten two screws (C) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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   Illustration 11	g06613462
   (B) 9X-2042 Screw (C) 490-1097 Plate

8. Install plate (B) and three screws (C) that were retained in Step 2 to the operator console group.

   Tighten three screws (C) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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   Illustration 12	g06613455
   (A) 512-5907 Plate (B) 9X-2042 Screw

9. Install plate (B) and two screws (C) that were retained in Step 1 to the operator console group.

   Tighten two screws (C) to a torque of 6 ± 1 N·m (53 ± 9 lb in).