12M Motor Grader Machine Systems Caterpillar

Steering Cylinder - Remove and Install

Usage:

12M B92

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	311-1362	Vacuum Cap	1

Start By:

Connect the steering frame lock.
Release the system pressure.

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Cylinders equipped with lock valves can remain pressurized for very long periods of time, even with the hoses removed.
Failure to relieve pressure before removing a lock valve or disassembling a cylinder can result in personal injury or death.

Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component.
Lower all attachments to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the attachment in the raised position, the attachments and lift cylinders must be supported properly.

Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

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Illustration 1	g01368952

Install Tooling (A) onto the hydraulic tank. Attach an air supply hose onto Tooling (A). Apply 138 kPa (20 psi). This procedure will pull a vacuum on the hydraulic system.

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Illustration 2	g01344371

Disconnect fitting (1). Disconnect hose assembly (2) .

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Illustration 3	g01344386

Remove cover (3). Disconnect harness assembly (4). Disconnect clips (5) .

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Illustration 4	g01344395

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Illustration 5	g01344413

Attach a suitable lifting device onto steering cylinder (6). The weight of steering cylinder (6) is approximately 20 kg (44 lb). Remove pin assembly (7) .

Remove cotter pin (8). Remove nut (9). Remove steering cylinder (6) .

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Illustration 6	g01491113

Remove retaining ring (10). Remove cap assembly (11). Remove O-ring seal (12). Remove boot (13) .

Repeat Step 1 through Step 6 for the remaining steering cylinder.

Installation Procedure

Install steering cylinder (6) in the reverse order of removal.
1. Tighten nut (9) to 220 ± 14 N·m (162 ± 10 lb ft). Align nut (9) with the hole that is in the rod end.
1. THE PARAMETERS FOR THE LENGTH OF THE CYLINDER AND THE TRIM FILES FOR THE POSITION SENSOR FOR BOTH OF THE STEERING CYLINDERS MUST BE CONFIGURED IN THE ECM BEFORE OPERATING THE MACHINE. Refer to Testing and Adjusting, "Electronic Control Module (ECM) - Configure" and Testing and Adjusting, "Electronic Control Module (ECM) - Replace".
1. Check the hydraulic oil level. Refer to Operation and Maintenance Manual, "Hydraulic System Oil Level - Check".

Sensor Removal Procedure

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Table 2
Required Tools
Tool	Part Number	Part Description	Qty
B	4C-5649	Threaded Adapter	1
B	1P-0074	Slide Hammer Puller Gp	1

Note: The Illustrations that are shown in the following Steps demonstrate the correct removal procedure for the sensor assembly. The Illustrations may not represent the exact cylinder that is on your machine.

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Illustration 7	g01151971

Remove bolts (2) and cover (1) .

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Illustration 8	g01151970

Remove connector assembly (3) and sleeve (4) from the harness assembly.

Remove plate (5) and grommet (6) .

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Illustration 9	g01370084

Install Tooling (B) to sensor assembly (7) .

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Illustration 10	g01151955

Remove screw (8) and discard screw (8) .

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Illustration 11	g01152067

Remove sensor assembly (7) .

Remove O-ring seal (9) and backup ring (10) from sensor assembly (7) .

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Illustration 12	g01154825

Remove retainer (11) and magnet (12) from carrier (13) .

Remove carrier (13) from rod (14) .

Sensor Installation Procedure

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Table 3
Required Tools
Tool	Part Number	Part Description	Qty
C	265-4177	Installation Kit ⁽¹⁾	1
D	264-4181	Sleeve ⁽¹⁾	1
E	265-4208	Wire Assembly ⁽¹⁾	1
F	-	Loctite 271	-
G	-	Loctite Low Breakloose PST	-

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^( 1 )

Part of 265-4177 Installation Kit

Note: The Illustrations that are shown in the following Steps demonstrate the correct installation procedure for the sensor assembly. The Illustrations may not represent the exact cylinder that is on your machine.

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Illustration 13	g01152067

Lubricate backup ring (10) and O-ring seal (9) with the lubricant that is being sealed. Install backup ring (10) and O-ring seal (9) on sensor assembly (7) .
Note: Install backup ring (10) so the split in backup ring (10) is in alignment with the slotted notch on the side of sensor assembly (7) .

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Illustration 14	g01370088

Assemble Tooling (C), as shown. Refer to Tool Operating Manual, NEHS0935.

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Illustration 15	g01370090

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Illustration 16	g01370093

Install sensor assembly (7) into Tooling (C) .

Slide Tooling (D) over sensor assembly (7) until Tooling (D) has cleared the dimple in the side of sensor assembly (7), as shown.
Note: If Tooling (D) is installed to the point which exposes the O-ring seal on sensor assembly (7), continue pulling sensor assembly (7) through Tooling (D). Repeat Steps 3 and 4. This will help prevent cutting the O-ring seal with Tooling (D) .

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Illustration 17	g01151972

Install sleeve (4) over the harness assembly.

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Illustration 18	g01370094

Start by threading Tooling (E) through the wire passage of the cylinder. Continue threading Tooling (E) through the cylinder and secure Tooling (E) to the wires of sensor assembly (7), as shown.

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Illustration 19	g01370099

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Illustration 20	g01370102

With the help of another person, use Tooling (C) and Tooling (E) to guide the sensor assembly into position.
Note: Use the alignment marks on Tooling (C) to ensure proper alignment of the sensor assembly into the counterbore. The sensor assembly should be installed with the alignment marks that are found on Tooling (C) toward the top, or in line with the wire passage in the cap if the wire passage is not in a vertical position.

Use Tooling (C) to push the sensor assembly into the counterbore until the pin engages the slot on the side of the sensor assembly. Make sure that the sensor assembly has engaged the counterbore correctly. Gently try to rotate Tooling (C) in both directions in order to ensure proper engagement of the sensor assembly.

Use a suitable mallet and Tooling (C) to tap the sensor assembly into the counterbore. Install the sensor assembly until the sensor assembly rests against the face of the counterbore.

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Illustration 21	g01151955

Install set screw (8). Tighten set screw (8) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

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Illustration 22	g01151970

Install grommet (6) .

Apply Tooling (F) to the mating surface of plate (5) and install plate (5) .

Install sleeve (4) and connector assembly (3) .

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Illustration 23	g01151971

Install cover (1) and bolts (2).

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Illustration 24	g01154825

Apply Tooling (G) to the threads of carrier (13) and install carrier (13) into rod (14). Tighten carrier (13) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

Install magnet (12) into carrier (13) .

Apply Tooling (G) to retainer (11) and install retainer (11) into carrier (13). Tighten retainer (11) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

Disassembly and Assembly Information

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Table 4
Required Tools
Tool	Part Number	Part Description	Qty
F	-	Locttie 271	-
G	-	Loctite Low Breakloose PST	1
H	127-4904	Repair Stand	1
J	195-4609	Seal Pick	1
K	-	Loctite 609	-
L	1P-0808	Multipurpose Grease	-
M	9U-7868	Spanner Wrench	1
M	127-8064	Adjustable Plate	1
N	8T-3198	Sleeve	1

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Ensure all pressure is relieved before removing a lock valve or disassembling a cylinder.

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Illustration 25	g01367442

(1) Tighten the set screw to a torque of 25 ± 3 N·m (221 ± 27 lb in).

(2) Apply Tooling (G) to the carrier and the retainer prior to installation. Tighten the carrier to a torque of 35 ± 5 N·m (310 ± 44 lb in). Tighten the retainer to a torque of 35 ± 5 N·m (310 ± 44 lb in).

(3) Lubricate the seals with the lubricant that is being sealed.

(4) Apply Tooling (K) to the wiper seal prior to installation.

(5) Tighten the nut to a torque of 600 ± 20 N·m (443 ± 15 lb ft).

(6) Use a suitable press to remove the bearing and the ball stud. Use a suitable press and Tooling (N) to install the bearing and the ball stud.

(7) Apply Tooling (F) to the bottom of the plate prior to installation.

(8) Apply Tooling (L) to the threads of the head prior to installation. Use Tooling (M) to tighten the head to a torque of 600 ± 130 N·m (443 ± 96 lb ft).