Procedure to Install Secondary Steering on Certain 631K and 637K Wheel Tractor-Scrapers {1408, 4304, 4324, 4334, 7960} Caterpillar


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Procedure to Install Secondary Steering on Certain 631K and 637K Wheel Tractor-Scrapers {1408, 4304, 4324, 4334, 7960} [M0121047]
ELECTRICAL AND STARTING SYSTEM
ELECTRONICS GP-MACHINE
Procedure to Install Secondary Steering on Certain 631K and 637K Wheel Tractor-Scrapers {1408, 4304, 4324, 4334, 7960}
1.1. Introduction
2.1. Reference Section
3.1. Safety Section
4.1. Required Parts
5.1. Required Tools
6.1. Machine Preparation
7.1. Procedure
Wheel Tractor-Scraper
631K (S/N: WTR114-117)
637K (S/N: WTS119-122)

Introduction

Secondary steering was an attachment on early production 631K and 637K Wheel Tractor-Scrapers. This Special Instruction outlines the procedure to update the secondary steering on machines that did not order the attachment for the factory to the latest design available for secondary steering.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference Section

Reference: Specifications, SENR3130, "Torque Specifications"

Reference: Combined Manual, UENR4608, "631K and 637K Wheel Tractor-Scraper", "Machine Preparation for Testing and Adjusting"

Reference: Operation and Maintenance Manual, SEBU9132, "637K Wheel Tractor-Scraper", "System Pressure Release"

Safety Section

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.

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 must also have the necessary training, skills, and tools 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 of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by AVSpare.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

------ WARNING! ------

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.


------ WARNING! ------

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.


------ WARNING! ------

When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.


------ WARNING! ------

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.


------ WARNING! ------

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 1g06276183

------ WARNING! ------

Access to this service point may require climbing on the equipment. Slipping or falling while climbing on the equipment could result in personal injury or death. Refer to the Operation and Maintenance Manual, Mounting and Dismounting topic for safety information.


------ WARNING! ------

Failure to use an approved access system during installation and removal of components could result in slipping and falling which could result in personal injury or death. To prevent injury or death, use an approved access system to reach the appropriate mounting locations of the components. Do not climb on the machine. Maintain three-points of contact and/or use a safety harness.


------ WARNING! ------

Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment required to do the job.

Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.


------ WARNING! ------

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.


------ WARNING! ------

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.


------ WARNING! ------

Hot hydraulic oil under high pressure can remain in the components of the hydraulic system or the power train system after the engine has been stopped. The uncontrolled release of the hydraulic oil can cause sudden machine movement and can also result in the following conditions:

  • Burns

  • The penetration of body tissue

  • Other personal injury

  • Death

If hydraulic oil penetrates body tissue, the injury must be treated immediately by a doctor who is familiar with this type of injury. Use a board or a piece of cardboard to check for a hydraulic oil leak. Make sure that all of the attachments have been lowered to the ground and that all trapped pressure has been released from the hydraulic system and the power train system. Also, make sure that the hydraulic oil is cool before the removal of any components or lines. Remove the hydraulic oil filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "AVSpare Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in AVSpare machines.

Dispose of all fluids according to local regulations and mandates.


Required Parts

Table 1
Required Parts 
Item  Qty  Part Number  Part Name 
396-7616  Tube As 
1P-3708  Rectangular Seal 
8T-0646  Bolt 
13  8T-4223  Hard Washer 
289-9520  Bracket As 
8T-4137  Bolt 
10  8T-4121  Hard Washer 
5P-1293(1)  Hose 
396-7620  Tube 
10  8T-4984  Hose Clamp 
11  9D-6196  Clip 
12  9D-6197  Clip 
13  8T-4196  Bolt 
14  7X-7729  Washer 
15  382-4297  Bracket As 
16  8T-4192  Bolt 
17  459-7438  Tube As 
18  6V-8641  Connector 
19  3J-1907  O-Ring Seal 
20  574-2812  Tube As 
21  239-5032  Connector 
22  228-7094  O-Ring Seal 
23  417-0163  Check Valve As 
24  574-2811  Hose As 
25  5K-9090  O-Ring Seal 
26  6V-8400  O-Ring Seal 
27  178-3620  Strap 
28  574-2814  Hose As 
29  574-2815  Hose As 
30  4J-5477  O-Ring Seal 
31  5p-9299  Clip 
32  344-5675  Nut 
33  3E-6909  Clip 
34  9S-3582  Bearing Cone 
35  542-1715  Bevel Pinion 
36  3D-8352  Retaining Ring 
37  2J-3118  Locking Bolt 
38  5T-4784  Shaft 
39  5F-3999  O-Ring Seal 
40  488-0014  Gear Pump Gp 
41  8T-4193  Bolt 
42  198-4780  Hard Washer 
43  505-7833  Hub 
44  505-7834  Retainer 
45  6V-3938  Bolt 
46  505-7745  Plate-Sensor 
47  8T-1159  Bolt 
48  9X-2027  Washer 
49  7K-1181  Cable Strap 
50  8T-4194  Bolt 
51  142-3331  Bracket As 
52  6V-8627  Elbow 
53  6V-9008  Elbow 
54  7M-8485  O-Ring Seal 
55  6V-9009  Elbow 
56  2S-4078  O-Ring Seal 
57  6V-3965  Fitting 
58  214-7568  O-Ring Seal 
59  395-0275  Unloading Valve 
60  6V-0852  Dust Cap 
61  7X-2543  Bolt 
62  132-7551  Spacer 
63  8T-4136  Bolt 
64  459-7439  Hose As 
65  391-0113  Hose As 
66  8X-4886  Elbow 
67  4J-0522  O-Ring Seal 
68  8T-4172  Bolt 
69  8T-6466  Bolt 
70  564-4793  Hose As 
71  6V-0397  Half Flange 
72  8T-4183  Bolt 
(1) Cut 2 sections of bulk hose 18 cm (7.1 inch)

Required Tools

Table 2
Required Tools 
Item  Qty  Part Number  Part Name 
T1  —  3/8 /16 Partially threaded dowel 
T2  —  10M Threaded rod 
T3  —  10m Nut 
T4  —  Large washer 

Machine Preparation

  1. Operate the machine until the differential oil is warm. Park the machine on a level surface. Lower the bowl.

  2. Engage the parking brake. Stop the engine.

  3. Refer to Operation and Maintenance Manual, SEBU9132, "637K Wheel Tractor-Scraper", "System Pressure Release" for more information.

  4. Perform lockout tag-out procedures on the operator controls in the cab of the machine.

Refer to Combined Manual, UENR4608, "631K and 637K Wheel Tractor-Scraper", "Machine Preparation for Testing and Adjusting" for more information.

Procedure



    Illustration 2g06566030
    Location of differential and transmission drains

  1. Drain the differential oil into a suitable container that will allow the oil to be reused.

  2. Drain the hydraulic oil into a suitable container to be reused.


    Illustration 3g06566064
    Location of the belly pans

  3. Use a suitable lifting/ lowering device and remove the center and rear belly pans from under the machine.

    The belly pans weigh 151.3 kg (334 lb) and 152.5 kg (336 lb).



    Illustration 4g06572460
    Side of the hydraulic tank
    (A) Flange cover
    (B) Split flange
    (C) Mounting hardware

  4. Remove flange cover (A), two split flanges (B), and mounting hardware (C) from the rear of the hydraulic tank. Discard the components.


    Illustration 5g06572883
    View of tube assembly
    (1) 396-7616 Tube As
    (2) 1P-3708 Rectangular Seal
    (3) 8T-0646 Bolt
    (4) 8T-4223 Hard Washer

  5. Install tube assembly (1) onto the hydraulic tank flange with one seal (2), four bolts (3), and four hard washers (4).


    Illustration 6g06572488
    Bracket location
    (5) 289-9520 Bracket As
    (6) 8T-4137 Bolt
    (7) 8T-4121 Hard Was\her

  6. Install bracket assembly (5) to the frame using one bolt (6) and one hard washer (7).


    Illustration 7g06572919
    View towards the front
    (1) 396-7616 Tube As
    (8) 5P-1293 Hose
    (9) 396-7620 Tube
    (10) 8T-4984 Hose Clamp

  7. Install hose (8) onto tube (9) with two hose clamps (10).

  8. Install tube (9) and hose (8) built in Step 7 onto tube assembly (1) with two hose clamps (10). Leave the hose clamps loose until the secondary steering pump is installed.


    Illustration 8g06573029
    Clamp location
    (5) 289-9520 Bracket As
    (9) 396-7620 Tube
    (11) 9D-6196 Clip
    (12) 9D-6197 Clip
    (13) 8T-4196 Bolt
    (14) 7X-7729 Washer

  9. Secure tube (9) to bracket assembly (5) with one clip (11) , one clip (12) , one bolt (13) , and one washer (14).


    Illustration 9g06573078
    View from the right -hand side
    (4) 8T-4223 Hard Washer
    (9) 396-7620 Tube
    (11) 9D-6196 Clip
    (12) 9D--6197 Clip
    (13) 8T-4196 Bolt
    (14) 7X-7729 Washer
    (15) 382-4297 Bracket As
    (16) 8T-4192 Bolt

  10. Install bracket (15) to the differential case with one bolt (16) and one washer (4).

  11. Secure tube (9) to bracket (15) with one clip (11), one clip (12), one bolt (13), and one washer (14).


    Illustration 10g06594435
    View from right-side
    (8) 5P-1293 Hose
    (9) 396-7620 Tube
    (10) 8T-4984 Hose Clamp
    (17) 459-7438 Tube As

  12. Install hose (8) onto tube (17) with two clamps (10). Leave the clamps loose until the secondary steering pump is installed.

  13. Install tube assembly (17) and hose (8) assembled in Step12 onto the tube (9) with two hose clamps (10). Leave the clamps loose until the secondary steering pump is installed.


    Illustration 11g06573443
    View from left side
    (D) 5P-7468 Clip
    (E) 5P-7469 Clip
    (F) 5P-8444 Grommet
    (G) 8T-4121 Hard Washer
    (H) 344-5675 Nut
    (J) 8T-4195 Bolt
    (K) 3E-6909 Clip
    (L) 455-7356 Hose As

  14. Remove and retain the existing clip (D), clip (E), grommet (F), hard washers (G), nut (H), and bolt (J) from hose (L).

  15. Remove and retain clip (K) from the small hose.

  16. Disconnect hose (L) from the adapter.


    Illustration 12g06573854
    View towards the rear
    (M) 7N-8374 Pump Cover
    (N) 6V-9833 Cap
    (P) 6V-9828 Cap

  17. Remove and discard the existing cover (M) and hardware along with cap (N), and cap (P).


    Illustration 13g06579178
    View of the adapter plate and sensors
    (R) Cable straps
    (S) Transmission output sensors
    (T) Mounting hardware
    (U) Adapter plate

  18. Cut cable ties (R) for the Transmission Output Speed (TOS) Sensors (S), disconnect the connectors. Remove hardware (T), and remove adapter plate (U) along with the TOS sensors (S). Retain adapter plate (U) and hardware (T). The two ladder style clips are bolted onto the actual adapter plate and do not need to be removed.


    Illustration 14g06574497
    View from left-hand side
    (V) 178-3620 Strap
    (W) 374-1638 Hose As
    (X) 9V-5382 Grommet

  19. Remove strap (V) securing the electrical harness to hose (W).

  20. Disconnect hose (W) from the steering pump and check valve. Retain existing grommet (X) and discard hose (W).


    Illustration 15g06574786
    View from the left
    (Y) 8S-0023 Clip
    (Z) 8S-0024 Clip
    (AA) - Hardware
    (AB) 455-7355 Tube As
    (AC) 3E-6909 Clip

  21. Remove clip (Y), clip (Z), and hardware (AA) from tube assembly (AB) that is used to secure the existing hose assembly. Retain clips (Y), (Z) and hardware (AA).

    Note: Leave clip (AC) on the existing hose.



    Illustration 16g06579263
    Left-hand side view
    (AB) 455-7355 Tube As
    (AD) 344-5675 Nut
    (AE) 8T-4121 Hard Washer
    (AF) 3E-6909 Clip
    (AG) 136-4992 Spacer
    (AH) 8S-0023 Clip
    (AJ) 8S-0024 Clip

  22. Remove existing nut (AD), hard washer (AE), clip (AF), and spacer (AG) from the mounting stud. Retain the existing hardware, clip (AF), and spacer (AG).

    Note: Leave clip (AF) on the existing hose.

  23. Remove clip (AH) and clip (AJ) from tube assembly (AB).


    Illustration 17g06575071
    Left-hand view
    (AB) 455-7355 Tube As
    (AK) 5P-7468 Clip
    (AL) 5P-7469 Clip
    (AM) 5P-8444 Grommet
    (AN) 8T-4121 Hard Washer
    (AP) 8T-4195 Bolt
    (AR) 455-7356 Hose As
    (AS) 3E-6909 Clip

  24. Remove and discard the existing clip (AK), clip (AL), grommet (AM), hard washers (AN), and bolt (AP) that secures hose assembly (AR).

    Note: Leave clip (AS) on the existing hose.

  25. Disconnect hose assembly (AR) from tube assembly (AB). Remove and discard hose (AR).


    Illustration 18g06575336
    View from the rear
    (AB) 455-7355 Tube As
    (AT) 8T-6466 Bolt
    (AU) 7X-7729 Washer
    (AV) 133-6934 Spacer
    (AW) 8K-4691 Half Clamp

  26. Remove bolts (AT), washers (AU), and spacers (AV) securing two half clamps (AW) to the machine.

  27. Remove the existing tube assembly (AB) from the machine. Retain both existing clips (AW) that secure the rear of the tube, along with clip (AH) and clip (AJ) from Step 23 that secure the front of the tube.


    Illustration 19g06575415
    View of the 574-2812 Tube As
    (18) 6V-8641 Connector
    (19) 3J-1907 O-Ring Seal
    (20) 574-2812 Tube As
    (21) 239-5032 Connector
    (22) 228-7094 O-Ring Seal
    (23) 417-0163 Check Valve As

  28. Install adapter (18) with one O-ring (19) into tube assembly (20).

  29. Install connector (21) onto tube assembly (20) with one O-ring (22).

  30. Install one check valve assembly (23) onto connector (21).


    Illustration 20g06575808
    View from rear of scraper
    (AH) 8S-0023 Clip
    (AJ) 8S-0024 Clip
    (AT) 8T-6466 Bolt
    (AU) 7X-7729 Washer
    (AV) 133-6934 Spacer
    (AW) 8K-4691 Half Clamp
    (20) 574-2812 Tube As

  31. Install tube (20) to the machine using the existing clamps, hardware, and spacers removed in Step 26.


    Illustration 21g06576642
    View from left-side rear of scraper
    (AD) 344-5675 Nut
    (AE) 8T-4121 Hard Washer
    (AF) 3E-6909 Clip
    (AG) 136-4992 Spacer
    (AH) 8S-0023 Clip
    (AJ) 8S-0024 Clip
    (20) 574-2812 Tube As

  32. Secure tube assembly (20) to the existing mounting stud using retained clip (AH) and clip (AJ). Secure the existing hose with the existing spacer (AG), clip (AF), hard washer (AE), and nut (AD) removed in Steps 22 and 23.


    Illustration 22g06576681
    View from the left-side
    (Y) Clip
    (Z) Clip
    (AA) Retained hardware
    (AC) Clip
    (20) 574-2812 Tube As

  33. Secure tube (20) to the existing hose using clip (AC), clip (Y), clip (Z), and retained hardware (AA) removed in Step 21.


    Illustration 23g06577043
    View towards rear of scraper
    (X) 9V-5382 Grommet
    (20) 574-2812 Tube As
    (24) 574-2811 Hose As
    (25) 5K-9090 O-Ring Seal
    (26) 6V-8400 O-Ring Seal
    (27) 178-3620 Strap

  34. Install hose assembly (24) to tube assembly (20) with one O-ring (25).

  35. Install hose assembly (24) to the steering pump with one O-ring (26).

  36. Secure the electrical harness using the existing grommet (X) removed in Step 20 and one strap (27).


    Illustration 24g06577184
    left side of machine
    (18) 6V-8641 Connector
    (20) 574-2812 Tube As
    (23) 417-0163 Check Valve As
    (28) 574-2814 Hose As
    (29) 574-2815 Hose As
    (30) 4J-5477 O-Ring Seal

  37. Install hose assembly (28) to check valve (23) .

  38. Install hose assembly (29) to connector (18) on tube assembly (20) with one O-ring (30).


    Illustration 25g06577216
    left side of machine
    (7) 8T-4121 Hard Washer
    (11) 9D-6196 Clip
    (12) 9D-6197 Clip
    (13) 8T-4196 Bolt
    (29) 574-2815 Hose As
    (31) 5P-9299 Clip
    (32) 344-5675 Nut

  39. Secure hose assembly (29) to the existing tube with one clip (11), one clip (12), one clip (31), two hard washers (7), one bolt (13), and one nut (32).


    Illustration 26g06577614
    View of left side of machine
    (7) 8T-4121 Hard Washer
    (11) 9D-6196 Clip
    (12) 9D-6197 Clip
    (13) 8T-4196 Bolt
    (14) 7X-7729 Washer
    (17) 459-7438 Tube As
    (29) 574-2815 Hose As
    (31) 5P-9299 Clip
    (32) 344-5675 Nut
    (33) 3E-6909 Clip

  40. Secure lower hose to tube assembly (17) using one clip (11), one clip (12), one clip (33), one hard washer (7), one washer (14), one bolt (13), and one nut (32).

  41. Secure hose assembly (29) to tube assembly (17) using one clip (11), one clip (12), one clip (31), one hard washer (7), one washer (14), one bolt (13), and one nut (32).


    Illustration 27g06582104
    View of 574-2814 Hose As connection
    (D) 5P-7468 Clip
    (E) 5P-7469 Clip
    (F) 5P-8444 Grommet
    (G) 8T-4121 Hard Washer
    (H) 344-5675 Nut
    (J) 8T-4195 Bolt
    (K) 3E-6909 Clip
    (25) 5K-9090 O-Ring Seal
    (28) 574-2814 Hose As

  42. Install hose assembly (28) to the existing fitting with one O-ring (25).

  43. Secure existing hose to hose assembly (28) with clip (D), one clip (E), one grommet (F), two hard washers (G), one nut (H), one bolt (J) and one clip (K) removed in Step 14 and 15.


    Illustration 28g06578009
    few of the tone wheel and cage assembly
    (T1) Dowels

  44. Remove the bolt and washer from the center two holes on the top and bottom of the cage assembly.

  45. Install four 100 mm (4 inch) long partially threaded dowels (T1) with 3/8"-16 threads into the four holes.

  46. Remove the remaining hardware and remove the tone wheel assembly from the differential. Leave the existing shims in place on the partially threaded dowel. Discard the eight bolts but retain the eight washers.

    Note: Count the shims to ensure that there are an equal number of shims on the top and the bottom. Shims may stick to the cage when removed so ensure that the shims are counted and returned to the correct location.

  47. Apply heat to the tube of the tone wheel and remove the tone wheel from the bevel gear assembly. Retain the cage assembly with bearing cup and discard the tone wheel and bevel gear.


    Illustration 29g06578025
    Pinion gear
    (34) 9S-3582 Bearing Cone
    (35) 542-1715 Bevel Pinion

  48. Using an induction heater, heat two bearing cones (34) and install bearing cones (34) onto pinion gear (35).


    Illustration 30g06578060
    Pinion gear
    (35) 542-1715 Bevel Pinion
    (36) 3D-8352 Retaining Ring

  49. Install one retaining ring (36) into pinion gear (35).


    Illustration 31g06578097
    View of differential
    (35) 542-1715 Bevel Pinion (gear)
    (37) 2J-3118 Locking Bolt
    (38) 5T-4784 Shaft

  50. Install bevel pinion gear (35) into the differential using the existing cage assembly, the existing shims, and secure the cage on the corners with four locking bolts (37) and four of the existing washers.

  51. Remove the four partially threaded dowels (T1) installed in Step 45 and install four locking bolts (37) with the remaining four existing washers.

  52. Install shaft (38) into bevel pinion gear (35).


    Illustration 32g06578145
    Pump and mounting plate
    (S) - TOS sensor
    (U) - Adapter assembly
    (39) 5F-3999 O-Ring Seal
    (40) 488-0014 Gear Pump Gp
    (41) 8T-4193 Bolt
    (42) 198-4780 Hard Washer

  53. Install one O-Ring (39) onto gear pump group (40). Attach gear pump group (40) to existing adapter assembly (U) with two bolts (41) and two hard washers (42). The weight of the pump is 34.4 kg (75 lb).

  54. Loosen the retaining nut on the TOS sensors and remove the sensors (S). Retain the sensors (S) for installation.


    Illustration 33g06578620
    View of hub
    (36) 3D-8352 Retaining Ring
    (43) 505-7833 Hub

  55. Install one retaining ring (36) into hub (43).


    Illustration 34g06578680
    Hub and tool
    (T2) M10 Threaded rod
    (T3) Large washer
    (T4) M10 Nut
    (43) 505-7833 Hub

  56. Press hub (43) onto the secondary steering pump shaft using a simple tool made out of a length of M10 threaded rod (T2), large washer (T3), and a M10 nut (T4).


    Illustration 35g06578695
    Cut away view of hub
    (36) 3D-8352 Retaining Ring
    (43) 505-7833 Hub
    (44) 505-7834 Retainer
    (45) 6V-3938 Bolt

  57. Remove the press tool and secure hub (43) to the secondary steering pump shaft with one retainer (44) and one bolt (45).

  58. Install one retaining ring (36) into hub (43).


    Illustration 36g06578754
    View of sensor plate
    (S) - TOS sensor
    (U) - Adapter assembly
    (43) 505-7833 Hub
    (46) 505-7745 Plate Sensor
    (47) 8T-1159 Bolt
    (48) 9X-2027 Washer

  59. Mount sensor plate (46) to hub (43) with six bolts (47) and six washers (48).

  60. Install the existing TOS sensors (S) into the existing adapter assembly (U). Set the gap using the following procedures.

    1. Apply Loctite 536 sealant to the thread of the sensor. Using a feeler gauge, hand tighten the sensor until a gap of 2.4 mm (0.09 inch) is achieved. Tighten the lock nut to 25 ± 5 N·m (18 ± 4 lb ft). Repeat for the remaining sensor.


    Illustration 37g06592074
    View in front of transfer case
    (2) 1P-3708 Rectangular Seal
    (17) 459-7438 Tube As

  61. Install one rectangular seal (2) into tube assembly (17).


    Illustration 38g06581033
    Secondary steering pump
    (T) Existing mounting hardware
    (U) Adapter plate
    (40) 488-0014 Gear Pump Gp
    (49) 7K-1181 Cable Strap

  62. Attach a suitable lifting device and install the secondary steering pump (40) and tone wheel assembly to the front of the differential case with existing hardware (T) from Step 18. The weight of the secondary steering pump is 34.4 kg (76 lb).

  63. Connect the existing electrical connectors and secure each connector to the ladder clips with cable straps (49).


    Illustration 39g06581054
    View of tube assembly
    (4) 8T-4223 Hard Washer
    (17) 459-7438 Tube As
    (40) 488-0014 Gear Pump Gp
    (50) 8T-4194 Bolt
    (51) 142-3331 Bracket As

  64. Secure tube assembly (17) to pump group (40) with four bolts (50), four hard washers (4), and one bracket assembly (51).


    Illustration 40g06581115
    View of valve group
    (19) 3J-1907 O-Ring Seal
    (52) 6V-8627 Elbow
    (53) 6V-9008 Elbow
    (54) 7M-8485 O-Ring Seal
    (55) 6V-9009 Elbow
    (56) 2S-4078 O-Ring Seal
    (57) 6V-3965 Fitting
    (58) 214-7568 O-Ring Seal
    (59) 395-0275 Unloading Valve
    (60) 6V-0852 Dust Cap

  65. Install two adapters (52) with two O-rings (19), one adapter (53) with one O-ring (54), an adapter (55) with one O-ring (56), and one adapter (57) with an O-Ring (58) to valve group (59).

  66. Install one dust cap (60) onto adapter (57).


    Illustration 41g06581155
    View of valve and secondary steering pump
    (40) 488-0014 Gear Pump Gp
    (59) 395-0275 Unloading Valve
    (61) 7X-2543 Bolt
    (62) 132-7551 Spacer

  67. Install unloading valve (59) to gear pump group (40) with four bolts (61) and four spacers (62).


    Illustration 42g06581183
    Install hose
    (7) 8T-4121 Hard Washer
    (29) 574-2815 Hose As
    (30) 4J-5477 O-Ring Seal
    (31) 5P-9299 Clip
    (51) 142-3331 Bracket As
    (59) 395-0275 Unloading Valve
    (63) 8T-4136 Bolt

  68. Install hose assembly (29) to unloading valve (59) with one O-ring (30).

  69. Secure hose assembly (29) to bracket assembly (51) with one clip (31), one bolt (63), and one hard washer (7).


    Illustration 43g06581398
    View of hose assembly
    (30) 4J-5477 O-Ring Seal
    (59) 395-0275 Unloading Valve
    (64) 459-7439 Hose As

  70. Install hose (64) to unloading valve (59) with one O-ring (30) and to the steering lines adapter with one O-ring (30).


    Illustration 44g06581444
    View of hose and unloading valve
    (25) 5K-9090 O-Ring Seal
    (59) 395-0275 Unloading Valve
    (65) 391-0113 Hose As

  71. Install hose assembly (65) to unloading valve (59) with one O-ring (25) and on to steering the adapter assembly with one O-ring (25).


    Illustration 45g06581513
    view of manifold group
    (AX) 1P-4578 Half Flange
    (AY) 391-0095 Manifold

  72. Remove flanges (AX) and hardware from the top of manifold (AY) and discard.


    Illustration 46g06581595
    View of manifold and elbow
    (AY) 391-0095 Manifold
    (AZ) 4P-7581 Clip
    (7) 8T-4121 Hard Washer
    (66) 8X-4886 Elbow
    (67) 4J-0522 O-Ring Seal
    (68) 8T-4172 Bolt
    (69) 8T-6466 Bolt

  73. Install elbow (66) to manifold (AY) with one O-ring (67), two bolts (68), two bolts (69), and four hard washers (7). Secure the existing ladder clip (AZ) for the harness.


    Illustration 47g06581665
    View of hose
    (4) 8T-4223 Hard Washer
    (26) 6V-8400 O-Ring Seal
    (59) 395-0275 Unloading Valve
    (66) 8X-4886 Elbow
    (67) 4J-0522 O-Ring Seal
    (70) 564-4793 Hose As
    (71) 6V-0397 Half Flange
    (72) 8T-4183 Bolt

  74. Install hose (70) to elbow (66) with one O-ring (67), two half flanges (71), four bolts (72), and four hard washers (4).

  75. Install hose (70) to unloading valve (59) with one O-ring (26).


    Illustration 48g06581972
    View of clamp positions
    (1) 396-7616 Tube As
    (8) 5P-1293 Hose
    (9) 396-7620 Tube
    (10) 8T-4984 Hose Clamp
    (17) 459-7438 Tube As

  76. With the secondary steering pump in place and tube (17) bolted up, tighten clamps (10) installed on hose (8) in Steps 7- 8 and 12-13.

  77. Fill the differential and hydraulic oil with existing oil.

  78. install the belly guard and pans.


    Illustration 49g06582064
    Cat ET screen

  79. Connect to the machine with Cat ET, go into the configuration screen for the Transmission ECM, and change the status of the "Secondary Steering Pump Installation Status" from "Not Installed" to "Installed".

Information System:

Oil Leaks May Occur Behind the Alternator Pulley On Certain 3512C Well Service Engines {1205, 1207, 1425}
966 GC Wheel Loader Power Train Output Transfer Gears - Assemble
966 GC Wheel Loader Power Train Output Transfer Gears - Disassemble
C15 and C18 Engines for Caterpillar Built Machines Camshaft
Certain Cat<SUP>&reg; Electronic Control Modules (ECMs) May Have Vulnerabilities If Not Connected Through Cat<SUP>&reg; Gateways {1926, 7490, 7606, 7610}
Procedure to Install <NOBR>590-1140</NOBR> Work Tool Lines Gp on Certain Compact Wheel Loaders to Connect Hydromechanical Tools {5057, 6129}
C15 and C18 Engines for Caterpillar Built Machines Valve Mechanism Cover
D6 GC Track-Type Tractor Power Train Transmission - Assemble
Improved Engine Oil Cooler for Certain C7.1 Machine Engines {1378}
A New Actuator Group for the Governor Control Group is Now Used on Certain Compact Wheel Loaders {1265, 1276}
New Torque Converter and Housing Group and Torque Converter Group Are Available for Certain 854K Wheel Dozers and 992K Wheel Loaders {3101, 3105}
Improved Mast Hose Guardrail Group Is Now Used on Certain MD6200 Rotary Drills {79NS}
D7 Track-Type Tractors Information Display Diagnostic Operation
D7 Track-Type Tractors Information Display Display Features - Start-Up Procedure
D7 Track-Type Tractors Information Display Performance Pages
D7 Track-Type Tractors Information Display Display Settings
D7 Track-Type Tractors Information Display Menu Navigation
D7 Track-Type Tractors Information Display Machine Settings Menu
D7 Track-Type Tractors Information Display Functions Menu
D7 Track-Type Tractors Information Display System Information Menu
D7 Track-Type Tractors Information Display Service Menu
D7 Track-Type Tractors Information Display Service Test Menu
D7 Track-Type Tractors Information Display ECM Summary Menu
D7 Track-Type Tractors Information Display Operator Menu