Procedure to Install STIC Lockout Control Limit Switch on R1600G, R1600H, and R1700G Load Haul Dump Machines{1435, 3034, 4343} Caterpillar

Load Haul Dump:

R1600G (S/N: 9YZ1-UP)

R1600H (S/N: 9SD1-182)

R1700G (S/N: SBR1-1067)

Introduction

This special instruction covers the procedure to install a new STIC lockout control limit switch, on the above R1600G, R1600H and R1700G Load Haul Dump machines. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Safety Section

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 should also have the necessary training, skills, and tools in order 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. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Show/hide table

Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

ReferenceDisassembly and Assembly, KENR8508, "R1600G Load Haul Dump Machine Systems".

ReferenceDisassembly and Assembly, UENR1457, "R1600H Load Haul Dump Machine Systems".

ReferenceDisassembly and Assembly, KENR6271, "R1700G Load Haul Dump Machine Systems".

ReferenceSystems Operation, Testing & Adjusting, KENR6826, "R1600G Load Haul Dump Power Train".

ReferenceTroubleshooting, Testing & Adjusting, UENR1448, "R1600H Load Haul Dump Power Train".

ReferenceTroubleshooting Testing and Adjusting, KENR6256, "R1700G Load Haul Dump Power Train".

Parts Required

Machine Preparation

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".

5. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

Removal Procedure

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

Show/hide table



Illustration 1	g03663957
(1) Cap (2) Bolt (3) Washer (4) Cover assembly

1. Remove and retain Item (1) through Item (4) .

Show/hide table



Illustration 2	g03663958
(5) Cap (6) Bolt (7) Washer (8) Cover assembly

2. Remove and retain Item (5) through Item (8) .

Show/hide table



Illustration 3	g03676419
(9) Cap (10) Bolt (11) Washer (12) Cover

3. Remove and retain three caps (9), three bolts (10), three washers (11), and cover (12) .

Show/hide table



Illustration 4	g03663961
(13) Bolt (14) Housing

4. Remove and retain two bolts (13) and housing (14) .

Show/hide table



Illustration 5	g03663962
(15) Locknut (16) Handle assembly

5. Remove and discard locknut (15).

6. Remove and retain handle assembly (16) .

Show/hide table



Illustration 6	g03795952
(17) Bolt (18) Washer (19) Nut (20) Bracket assembly (21) Bracket assembly

7. Remove and discard two bolts (17) and washers (18) .

8. Remove and retain three nuts (19) .

9. Remove and discard bracket assembly (20) .

10. Remove and retain bracket assembly (21) .

Show/hide table



Illustration 7	g03795547
(21) Bracket Assembly (22) 4E-8557 Shaft As (23) 8T-4133 Nut (24) 151-6427 Bearing (25) 204-3611 Plate As (26) 6L-8598 Retaining Ring (27) 4E-8560 Square Key (28) 4E-8561 Cam (29) 8C-3442 Coil Spring

11. Assemble Item (21) through Item (29). Refer to Illustration 7.

    Note: Apply Loctite 263 to the thread of 8T-4133 Nut (23) .

Show/hide table



Illustration 8	g03795548
(30) 353-5983 Limit Switch As (31) 6V-9325 Screw (32) 1P-7326 Washer

12. Install 353-5983 Limit Switch As (30) using two 6V-9325 Screws (31) and two 1P-7326 Washers (32) .

    Note: Apply Loctite 263 to the thread of two 6V-9325 Screws (31) .

Show/hide table



Illustration 9	g03795967
(19) Nut (33) 130-5300 Clip (34) 454-5032 Harness As

13. Install the assembly, assembled in Step 11 and Step 12, using three nuts (19) that were retained in Step 7, 130-5300 Clip (33), and 454-5032 Harness As (34) .

Show/hide table



Illustration 10	g03795970
(16) Handle assembly (27) 4E-8560 Square Key (35) 6V-7744 Locknut

14. Install handle assembly (16) that was retained in Step 6, using 4E-8560 Square Key (27), and 6V-7744 Locknut (35) .

15. Install two bolts (13) and housing (14) that were retained in Step 4. Refer to Illustration 4.

16. Install three caps (9), three bolts (10), three washers (11), and cover (12) that were retained in Step 3. Refer to Illustration 3.

17. Install Item (5) through Item (8) that were retained in Step 2. Refer to Illustration 2.

18. Install Item (1) through Item (4) that were retained in Step 1. Refer to Illustration 1.

Procedure to Check the STIC Lockout Control Limit Switch

Show/hide table

Personal injury or death can result from machine movement. Place blocks in front of and behind the wheels to make sure the machine does not move while the parking brakes are disengaged.

Note: Permit only one operator on the machine. Keep all other personnel away from the machine or in the operators sight.

1. Move the machine to a smooth, level location that is away from operating machines and personnel.

2. Engage the parking brake and stop the engine.

3. Install the steering frame lock.

4. Place blocks behind the wheels and in front of the wheels.

5. Start the engine.

Show/hide table



Illustration 11	g03679333
(1) Steering and transmission lock lever (2) Transmission direction control

6. Move direction control (2) to the NEUTRAL position. Move steering and transmission lock lever (1) to the LOCKED position.

7. Raise the work tool clear of the ground.

8. Disengage the parking brake.

9. With steering and transmission lock lever (1) in the LOCKED position, move direction control (2) to the FORWARD position or the REVERSE position. The transmission should not engage in either direction.

10. Engage the parking brake, lower the work tool to the ground, and stop the engine.

    Note: The lock limit switch is non-adjustable.

Procedure to Check the STIC Lockout Control

1. Refer to Systems Operation Testing and Adjusting, "STIC lockout control - Check and Adjust" for the machine that is being serviced.