CAB AR 3692466 - Caterpillar

Introduction
This Special Instruction provides the information necessary to rework the battery cover on the machines listed above. The rework procedure resolves the issues of electrolyte leakage and shell bulging failures.Read the entire Special Instruction and understand the information before you perform any procedures.Safety
Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. 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. Do not allow battery electrolyte to contact with the skin or with the eyes. Battery electrolyte is an acid. In case of contact with battery electrolyte, immediately wash the skin with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention. Rework Procedure for Battery Covers in Machine Inventory
Illustration 1 g03868601
(1) 238-2501 Knob (2) 8T-4133 Nut (3) 5I-8270 Battery Cover (4) 6W-6005 Battery Hold-Down
Remove the 238-2501 Knob and 5I-8270 Battery Cover .
Remove the 8T-4133 Nut and the 6W-6005 Battery Hold-Down . Place the battery hold-down on a table in a secure position.
Illustration 2 g03868603
Drill two 5 mm (0.2 inch) diameter holes in the battery hold down as shown in Illustration 2.
Illustration 3 g03868606
Illustration 4 g03868611
View of area A
Illustration 5 g03868613
View of area A
Turn over the battery hold down as shown in Illustration 5. Use a proper tool to grind the cover profile around the center hole as shown in Illustration 5. Currently the profile is 7.5 mm (0.3 inch). Trim to 0 to 1 mm (0.00000 to 0.04 inch) of the base to provide clearance to the vent opening on the battery. Refer to Illustration 4 and 5 for detailed dimensions.
Clean the plastic powder thoroughly.
Install the battery hold down and nut. Torque the nut to 20 5 N m (177 44 lb in).
Install the dust cover and knob.Rework Procedure for Battery Covers Not on Machines
Illustration 6 g03868756
Put the battery hold down on a table in order to be reworked. Drill two 5 mm (0.2 inch) diameter holes in the battery hold down. Detailed dimensions are shown in Illustration 6.
Illustration 7 g03868757
Illustration 8 g03868778
View of area B
Illustration 9 g03868780
View of area B
Turn over the battery hold down as shown in Illustration 7. Use a proper tool to grind the cover profile around the center hole as shown in Illustration 7. Currently the profile is 7.5 mm (0.3 inch). Trim to 0 to 1 mm (0.00000 to 0.04 inch) of the base to provide clearance to the vent opening on the battery. Refer to Illustrations 8 and 9 for detailed dimensions.
Clean the plastic powder thoroughly and install the battery hold down in place.