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Installation of the Hydraulic Auto Lube System on Certain 16M Motor
Graders{7510, 7540}
SMCS - 7510; 7540
Motor Grader:
16M (S/N: B9H1-UP; R9H1-UP)
Introduction
A hydraulic auto lube system is now available for the machines that are listed above. The new hydraulic system
will replace the electrical system. The new hydraulic system will have longer service life and lower maintenance
than the existing electrical system.
References
ReferenceRefer to Troubleshooting, UENR1988, "16M and 24M Motor Graders Automatic Lubrication System".
This can be used to diagnose issues with the electrical auto lube system before installing this hydraulic system.
Safety Section
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.
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.
Welding Details
ReferenceRefer to Special Instructions, REHS1841, "General Welding Procedures" for additional welding
instructions.
Shielded Metal Arc Welding
The Shielded Metal Arc Welding (SMAW) process may be used with the E7018 (ANSI/AWS A5.1) welding
electrode. The weld that will be deposited by these electrodes will have the following mechanical properties.
Table 1
Tensile strength 480 MPa (69600 psi)
Yield strength
400 MPa (58000 psi)
Elongation 22%
Impact toughness
27 N·m (20 lb ft)
These low hydrogen electrodes must be stored in an electrode oven at 120 °C (248 °F) when the electrodes are not
being used. Scrap the electrodes if the electrodes get damp.
Note: Welding parameters will vary due to the position of the weld and the parameters will vary due to the
manufacturer of the welding electrode.
The following chart relates to the electrode diameter and approximate current settings for welding.
Table 2
Diameter Current
70-140
3.2 mm (0.1260 inch)
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110-180
4 mm (0.16 inch)
190-270
4.8 mm (0.19 inch)
The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass. Weld all joints
from the bottom upward. The number of weld passes will depend on the width of the weld joint. Remove all slag
after welding. Inspect the weld for low areas. Grind high spots in the weld with a coarse pad. Be sure not to grind
out any base material. Finish blending the weld with a fine pad. No sharp edges are acceptable.
Flux Cored Arc Welding
The Flux Cored Arc Welding (FCAW) process may be used with the E71T-1 (AWS A5.20) welding electrode.
The FCAW process may also be used with shielding gas. The weld that will be deposited by these electrodes will
have the following mechanical properties.
Table 3
Tensile strength
480 MPa (69600 psi)
Yield strength
400 MPa (58000 psi)
Elongation 22%
Impact toughness
27 N·m (20 lb ft)
Note: Welding parameters will vary due to the position of the weld and the parameters will vary due to the
manufacturer of the welding electrode.
For a 1.1 mm (0.045 inch) electrode, the typical welding parameters should be the following.
Table 4
Wire Feed Speed Voltage Approximate Amperage
MIN 175 Inches Per Minute. 22-24 130
MID 350 Inches Per Minute. 26-28 210
MAX 425 Inches Per Minute. 29-31 275
For a 1.3 mm (0.052 inch) electrode, the typical welding parameters should be the following.
Table 5
Wire Feed Speed Voltage Approximate Amperage
MIN 200 Inches Per Minute. 22-24 185
MID 300 Inches Per Minute. 25-27 245
MAX 425 Inches Per Minute. 28-30 295
The welder should be set to use the DC reverse polarity setting. Remove all slag after every pass. Weld all joints
from the bottom upward. The number of weld passes will depend on the width of the weld joint. Remove all slag
after welding. Inspect the weld for low areas. Grind high spots in the weld with a coarse pad. Be sure not to grind
out any base material. Finish blending the weld with a fine pad. No sharp edges are acceptable.
Table 6
Weld Specifications
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Weld Item Weld Description
W1
10 mm (0.39 inch) fillet weld
Note: All vertical welds will be welded with a vertical up technique.
Rework Procedure
Table 7
Required Parts
Item Qty Part Number Description
1 4 8X-5957 Block
2 1 395-3689 Plate As
3 4 108-3589 Spacer
4 16 5P-1076 Hard Washer
5 8 8T-4194 Bolt
6 1 395-3528 Plate As
7 13 8T-4121 Hard Washer
8 10 8T-4195 Bolt
9 1 377-2072 Lubrication Tank and Pump Gp
10 1 098-5687 Tee
11 4 3K-0360 O-Ring Seal
12 8 6V-8397 O-Ring Seal
13 1 8C-8988 Elbow
14 1 160-4128 Pressure Reducing Valve
15 1 6V-8723 Elbow
16 1 6V-8634 Connector
17 2 8T-4185 Bolt
18 1 396-7044 Hose As
19 1 396-7046 Hose As
20 2 8M-2773 Clip
21 3 8T-4137 Bolt
22 1 8T-7546 Elbow
23 1 3J-7354 O-Ring Seal
24 1 6V-8636 Connector
25 1 3J-1907 O-Ring Seal
26 1 6V-9746 O-Ring Seal
27 1 5K-9090 O-Ring Seal
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28 1 7M-8485 O-Ring Seal
29 1 8T-6356 O-Ring Port Tee
30 1 6V-8556 Nut
31 1 6V-8941 Reducer
32 1 372-3841 Tube As
33 1 396-7048 Hose As
34 3 8T-1889 Clip
35 3 8T-1890 Clip
36 3 5G-3676 Grommet
37 1 268-6052 O-Ring Tee
38 2 7J-9108 O-Ring Seal
39 2 6V-8938 O-Ring Reducer
40 1 9X-6581 O-Ring Seal Nut
41 1 396-7050 Hose As
42 1 396-7047 Hose As
43 6 6D-4244 Clip
44 1 396-0775 Hose As
45 1 396-0776 Hose As
46 3 242-1583 Stud
47 5 8T-4133 Nut
48 2 8T-4935 Weld Boss
49 1 379-3374 Tube As
50 1 6V-9844 Swivel Tee
51 1 344-1950 Clip
52 1 344-1951 Clip
53 1 5P-8939 Grommet
54 1 122-9709 Block
1. Remove all the hoses and harnesses from the existing Autolube tank.
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Illustration 1 g02840057
2. Remove the front frame control valve covers (A) .
Illustration 2 g02840079
3. Remove the Autolube tank mounting bolts and remove the Autolube tank. Take care not to scratch the
machine frame while removing the tank.
Note: Retain one of the 194-5336 Swivels from the tank.
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Illustration 3 g02841817
4. Remove the tank support bracket (B) .
Illustration 4 g03319598
(C) 1239 mm (48.8 inch)
(D) 745 mm (29.3 inch)
Illustration 5 g03319646
(E) 88.2 mm (3.5 inch)
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5. Weld (W1) four blocks (1) to the inside of the drawbar frame as shown Illustration 4 and Illustration 5 .
Illustration 6 g03318883
6. Install plate assembly (2) onto block (1) using two spacers (3) eight washers (4), and four bolts (5) .
Illustration 7 g02843016
7. Install plate assembly (6) onto block (1) with two spacers (3) eight washers (4), and four bolts (5). Secure
the front of plate assembly (6) to plate assembly (2) using four washers (7) and four bolts (8) .
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Illustration 8 g02843296
8. Install lubrication tank and pump group (9) to plate assembly (6). Orient the pump group as shown in
Illustration 8. Secure lubrication tank and pump group (9) to plate assembly (6) with six bolts (8) and six
washers (7) .
Illustration 9 g02847790
9. Assemble tee (10) to pressure reducing valve (14). Use one o-ring (11) and two o-rings (12). Assemble
elbow (13) to tee (10). Use one o-ring (12). Assemble elbow (15) to pressure reducing valve (13). Use one o-
ring (11) and one o-ring (12). Assemble elbow (13) to elbow (15) using one o-ring (12). Assemble connector
(16) to pressure reducing valve (14) using one o-ring (12) .
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Illustration 10 g03319597
(F) 142 mm (5.6 inch)
(G) 202 mm (7.95274 inch)
10. Weld (W1) block (54) as shown Illustration 10.
Illustration 11 g02848604
11. Install pressure reducing valve (14) onto plate (54) using two washers (7) and two bolts (17) .
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Illustration 12 g02848668
12. Install hose (18) onto tee (16) and hose (19) onto connector (10). Use two clips (20), one washer (7), and one
bolt (21) .
Illustration 13 g02843337
13. Install elbow (22) onto lubrication tank and pump group (9) using one o-ring (12) and one o-ring (23). Install
connector (24) onto lubrication tank and pump group (9) using one o-ring (12) and one o-ring (25). Install
hose (18) onto elbow (22). Install hose (19) onto connector (24) .
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Illustration 14 g02849897
14. Remove the existing tube on top of the front frame that is connected to the front valve assembly. Install a
new tee (29). Use three o-rings, (26), (27), and (28). Install a reducer (31). Use an o-ring (12) and a swivel
nut (30) .
Illustration 15 g02849916
15. Install a new tube (32) to the top of the front frame. Use the factory installed clamps to retain the tube.
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Illustration 16 g02849977
16. Install a new hose (33). Use clips (34) and (35) as well as a grommet (36) to secure the new hose.
Illustration 17 g02850279
17. Install a new tee (37). Use two o-rings (38) and one o-ring (11). Install a reducer (39). Use an o-ring (12) and
a swivel nut (40) .
Illustration 18 g02850324
18. Install a new hose (41). Use clips (34) and (35) as well as a grommet (53) to secure the new hose.
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Illustration 19 g02850771
19. Replace existing hose on the right side of the machine with a new hose (42) and secure with clip (43),
washer (7), and bolt (21) .
Illustration 20 g02851276
20. Install two new hoses (44) and (45). Secure the new hoses to the left side of the drawbar with six clips (43),
three studs (46) and three nuts (47) .
Illustration 21 g02850838
(H) 82.5 mm (3.2 inch)
(J) 95.2 mm (3.7 inch)
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(K) 127.3 mm (5 inch)
21. Weld (W1) two new bosses (48) onto the front bulkhead. Refer to Illustration 21 for clarification.
Illustration 22 g02851116
22. Install a new tube (49). Reuse the existing clip on the right side of the machine. Install a tee (50). Use two o-
rings (39). Reuse the previously saved 194-5336 Swivel from Step 3. Use two o-rings (39). Secure the new
tube (49) and the opposite tube with two new clips (51), two new clips (52), bolts (21), and washers (7) .
Illustration 23 g02850817
23. Connect hose (44) and hose (45) to the swivels.
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