Usage:
Introduction
This instruction provides the information for the installation of emergency starting receptacles on various machines. A typical installation of a starting receptacle is shown on Page 2. To install a receptacle group on a specific Caterpillar machine, see the page reference in the chart below.
Use 9S3664 Jumper Cables for a machine-to-machine start, or 8S2632 Jumper Cables for a battery pack-to-machine start.
Installation of Emergency Starting Receptable (Typical)
1. Drill four holes and make the opening for the receptacle at a practical location, or as given for a specific machine.
2. Install receptacle (1) with bolts (2), lockwashers and plates (3).
3. Fasten wire (4) to a bolt and install cover (5).
4. Connect red cable (6) to the solenoid and connect black cable (7) to the starter.
Locations and Diagrams for Specific Machines
Use the following location diagrams along with the typical instructions above for receptacle installation and connection on specific machines. Where the installation is different, additional instructions are given.
D7F (91E, 92E, 93N, 94N), D7G (64V, 65V, 91V, 92V)
D8H (22A, 36A, 46A, 68A)
D8K (66V, 76V, 77V)
583 (61A680-Up, 78V)
DD9G (90J)
D9G (66A), DD9G (91J)
594 (62H59-Up, 96V)
572 (96N, 40U)
571 (95N, 16W)
D7G (64V, 65V, 91V, 92V)
Weld plate (A) to the engine left side guard (B), with a 3.048 mm (0.12") fillet weld on both sides.
D8K (66V, 76V, 77V)
Weld plate (A) to the engine left side guard (B), with a 3.048 mm (0.12") fillet weld on both sides.
D9H (90V), DD9H (97V, 98V)
Weld plate (A) to the engine left side guard (B), with a 3.048 mm (.12") fillet weld on both sides.
983 (38K)
Mount receptacle (1) as shown. Secure routed lines with clip (2).
988 (87A2385-Up), 824 (36H581-Up), 825 (43N), 834 (43E423-Up), 835 (44N)
Bolt bracket (1) to right front handrail (2), so receptacle (3) will be under the platform.
992 (25K1-382)
1. Make opening (1) in the right bumper.
Section A-A.
2. Weld bracket (2) inside opening (1) with 4.826 mm (0.19") fillet welds.
Section B-B.
3. Put lug (3) in position so the cables will go through the triangle between the frame and the bumper.
4. Weld lug (3) with a 4.826 mm (0.19") fillet weld on one side.
5. Fasten the cables to lug (3) with the clip.
992 (25K383-1169)
1. Install the receptacle as shown for machines 25K1-382.
2. Weld lugs (1) and (2) with 4.826 mm (0.19") fillet welds.
3. Remove the section from the bumper and the grating as shown.
4. Fasten the cables to lugs (1) and (2).
992B (25K1170-Up)
1. Bolt bracket (1) to the plate on the timing gear housing of the engine.
2. Weld lug (2) and (3) to the frame with 3.048 mm (.12") fillet welds.
3. Fasten the cables to lugs (2) and (3) with clips.
16 (49G)
1. Remove four bolts (1).
2. Install bracket (2) with four spacers (3) and new bolts.
14G (96U), 16G (93U)
1. Install receptacle (1) in plate (2).
2. Put plastic tape around red cable (3) so there is a 1.524 mm (0.06") gap between turns.
769 (99F2287, 35W)
1. Weld bracket (1) at the location shown with a 4.826 mm (0.19") fillet weld on two sides.
2. Install the receptacle to bracket (1).
3. Fasten the cables with the ties and clip.
631 (67M4581-Up), 633 (66M782-Up), 637 (65M430-Up, 79P527-Up)
1. Weld plate (1) to step (2) with a 4.826 mm (0.19") fillet welds.
2. Weld lug (3) to the frame with 3.048 mm (0.12") fillet welds.
3. Put plastic tape around the red cable so there is a 1.524 mm (.06") gap between turns.
4. Fasten the cables to lug (3) and the pan with clips.
613 (71M)
Drill four holes in the frame and bolt bracket (1) to the frame.
621B (45P, 35V), 623B (46P), 627B (14S, 15S, 34V, 56V)
1. Bolt bracket (1) in place as shown.
2. Bolt receptacle (2) to bracket (1).
3. Put plastic tape around the red cable so there is a 1.524 mm (0.06") gap between turns.
4. Fasten the cables to existing cables near the oil pan with clips.
621 (23H4454-Up, 15U), 623 (52U310-Up)
1. Fasten plate (1) over the opening in plate (2) with bolts (3).
2. Weld plate (1) with 4.826 mm (0.19") fillet welds on top and bottom edges.
3. Weld lugs (4) to the frame with 4.826 mm (0.19") fillet welds as shown.
4. Put plastic tape around the red cable so there is a 1.524 mm (0.06") gap between the turns.
5. Fasten the cables to lugs with clips.
650B (58K), 660B (58K), 666B (66K)
1. Weld plate (1) to the cowl as dimensioned from the door assembly (2) with a 4.826 mm (0.19") fillet weld on both sides.
2. Fasten the cables to the front of the cowl with clip (3).
641 (65K), 651 (67K), 657 (68K)
1. Weld gusset (1) and bracket (2) together and then weld them to the inside of the operator's platform with 4.826 mm (0.19") fillet welds.
2. Put plastic around the red cable so there is a 1.524 mm (0.06") gap between turns.
3. Install grommet (3).
4. Fasten the cables with clips (4).
613B (38W)
1. Remove plate (1).
2. Install receptacle (2) with two plates (3) and four bolts (4) and washers.
D9H (90V), SXSD9H (12U, 99V)
Weld plate (1) to support (2) with 3.048 mm (0.12") fillet welds on both sides at the dimensions shown.
824C (85X), 825C (86X), 826C (87X), 980C (63X)
1. Remove disconnect switch (1) from plate (2) and remove plate (2) from the frame.
2. Install plate (3) to the frame and install disconnect switch (1) to plate (3).
3. Fasten receptacle (4) to plate (3) with two 8S4211 Plates, four bolts and washers.
988B (50W)
1. Remove disconnect switch (1) from plate (2) and remove plate (2) from the frame.
2. Install plate (3) to the frame and install disconnect switch (1) to plate (3).
3. Fasten receptacle (4) to plate (3) with two 8S4211 Plates (5), four bolts and washers.
4. Use straps (6) as needed to hold the cables.
5. Cut panel (7) to the dimensions shown for access to receptacle (4).
992C (42X)
1. Weld strip (1) to brace (2) to the dimensions shown with 6.350 mm (0.25") fillet welds all around.
2. Fasten bracket (3) to strip (1) with two bolts and washers.
3. Install receptacle (4) to bracket (3).
4. Fasten the cables to the existing cables with four straps (5).
631D (24W, 66W), 633D (25W), 637D (26W, 27W, 71W)
1. Put the plastic tape (1) around the red cable so there is a 1.524 mm (0.06") gap between turns and cover 50.8 mm (2") of each end of the cable with plastic tape.
2. Install receptacle (2) to step (3) with four bolts, nuts and washers.
3. Put cables (4) and (5) through tube (6).
4. Remove two bolts and fasten tube (6) to the platform with two clips (7), spacers (8) and the two bolts that were removed.
5. Fasten cables (4) and (5) with two 2G1476 Clamps (9) and plate (10) to the inside of the right frame.
6. Remove four clips and fasten the cables with four new clips (11).
621B (45P1985-Up), 627B (14S765-Up, 15S900-Up)
1. Weld lug (1) to hydraulic tank (2); if equipped with hood and door attachment, weld to bracket (3).
NOTE: For machines that are not equipped with 8F9836 Lug (1), order the lug from the Parts Department.
2. Use 5.080 mm (0.20') fillet welds to fasten lug (1) to hydraulic tank (2) or bracket (3), at the dimensions shown.
3. Install 6G6043 Bracket (4), under handle (5); fasten 4N6579 Receptacle (6) and 8S2634 Cover (7) to bracket (4) with four 2J3118 Bolts, 5M2894 Washers and 1D4717 Nuts.
4. Put 5P0706 Wrap (8) around the red cable.
5. Fasten the cables with 6G2256 Clamps (9), 6G2263 Spacer, two 2G8767 Washers, 5D9844 Bolt and 5M2894 Washers.
621B (45P1985-Up), 627B (14S765-Up)
6. Connect the black cable to starter (10) and the red cable to solenoid (11).
7. The cables are fastened to the frame of the 621B with one clamp (9), spacer, washer, bolts and washers, and to the 627B with three clamps (9), spacers, washers, bolts and washers.
627B (15S900-Up)
6. Connect the black cable to starter (10) and the red cable to solenoid (11).
7. The cables are fastened to the frame of the 627B with three clamps (9), spacers, washers, bolts and washers.
245 (94L497-Up, 84X397-Up)
3. Fasten 9S9312 Receptacle (4) and 8S2634 Cover to plate (2) with two 8S4211 Plates, four S1594 Bolts and 5P1075 Washers.
4. Move the cables to the starter along the frame, then connect the red cable to solenoid (5) and the black cable to starter (6).
5. Put hoses (1) in position as shown and fasten the cables with 3P9847 Clamps (7), S1594 Bolts and 5P1075 Washers.
6. Use two 4D7733 Clips (8), S1594 Bolts, and one 1D4717 Nut (9) to fasten the cables to plate (10).
657B (47M291-Up, 53K1074-Up)
1. Fasten 8S2633 Receptacle (1) to panel (2) with four 5D0353 Bolts, 5M2894 Washers and 1D4717 Nuts.
2. Connect the red cable to the solenoid and the black cable to the starter.
130G (74V)
1. Install 8S2633 Receptacle at the location shown on the fuel tank left side plate (1).
2. Drill the four holes and make the opening for the receptacle as shown on Page 3.
227 (10W174-Up)
Section A-A
1. Fasten 9S9016 Receptacle (1) and 8S4211 Plate (2) to the cover on the 7V4971 Bracket Assembly with four 5M3062 Bolts and 8T4896 Washers.
2. Fasten 8S2634 Cover Assembly (3) to receptacle (1).
3. Connect the red cable to the solenoid and the black cable to the starter.