Procedure to Upgrade Certain R2900G Load Haul Dump Machines {1408, 3101, 3159, 7000}
- Load Haul Dump
- R2900G (S/N: JLK1-1202,1204-1207)
Introduction
This special instruction covers the procedure to upgrade R2900G S/N:JLK1-1202,1204-1207Load 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.
Reference: Schematic, UENR6129, "R2900G Load Haul Dump Electrical System"
Reference: Disassembly and Assembly, RENR8556, "R2900G Load Haul Dump Machine Systems"
Reference: Disassembly and Assembly, RENR8558, "R2900G Load Haul Dump Power Train"
Reference: Disassembly and Assembly, RENR8559, "R2900G Load Haul Dump C15 Engine Supplement"
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.
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. |
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
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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. |
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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas. |
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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of LaborWashington, D.C. 20210 |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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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. |
Parts Required
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| Parts Required | ||
|---|---|---|
| Qty | Part Number | Description |
| 2 | Elbow | |
| 2 | Elbow | |
| 2 | Flared Tee | |
| 2 | Flared Elbow | |
| 1 | Connector | |
| 1 | Connector | |
| 8 | Bolt | |
| 1 | Bolt | |
| 22 | Bolt | |
| 1 | Clip | |
| 5 | Clip | |
| 3 | Elbow | |
| 1 | O-Ring Tee | |
| 1 | Plate As | |
| 8 | Clip | |
| 1 | Clip | |
| 1 | Oil Filter Housing Assembly | |
| 1 | Retainer | |
| 1 | Spring | |
| 2 | Bracket | |
| 1 | Boss | |
| 1 | Brake Control Valve Gp | |
| 1 | Connector As | |
| 1 | Elbow As | |
| 1 | O-Ring Seal | |
| 10 | Cable Tie | |
| 1 | Information Plate | |
| 2 | Half Flange | |
| 4 | Spacer | |
| 3 | Rectangular Seal | |
| 4 | Rectangular Seal | |
| 4 | Half Flange | |
| 1 | Power Train Filter Base | |
| 1 | Relief Valve As | |
| 1 | Manifold | |
| 2 | Shuttle Valve | |
| 1 | Relay As | |
| 2 | Solenoid Valve Gp | |
| 1 | Modulating Valve Gp | |
| 2 | Plug As | |
| 1 | Bracket As | |
| 1 | Film | |
| 2 | Solenoid Valve Gp | |
| 4 | Bolt | |
| 1 | O-Ring Seal | |
| 3 | O-Ring Seal | |
| 1 | Elbow | |
| 2 | Adapter | |
| 1 | O-Ring Seal | |
| 1 | Electronic Control Module | |
| 1 | Block | |
| 1 | Plug As | |
| 1 | Clip | |
| 1 | Film | |
| 1 | Oil Filter Element | |
| 1 | Pressure Sensor Gp | |
| 2 | Pressure Sensor Gp | |
| 1 | Toggle Switch | |
| 4 | Elbow As | |
| 1 | Identification Plate | |
| 1 | Cab Harness As | |
| 1 | Control Valve Gp | |
| 1 | Cover As | |
| 1 | Drive Shaft Gp | |
| 1 | Torque Converter and Updrive Ar | |
| 1 | Transmission Ar | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Tube As | |
| 1 | Tube | |
| 1 | Tube As | |
| 1 | Adapter | |
| 1 | Tube As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Pipe As | |
| 1 | Manifold Block | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 2 | Push Button Switch | |
| 1 | Manifold | |
| 1 | Hose As | |
| 1 | O-Ring Seal | |
| 1 | Switch Guard | |
| 8 | Hard Washer | |
| 24 | O-Ring Seal | |
| 15 | O-Ring Seal | |
| 1 | Spring | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Pressure Sensor | |
| 1 | Mount As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 2 | Tube As | |
| 1 | Tube | |
| 1 | Sensor Harness As | |
| 2 | Film | |
| 1 | Wire As | |
| 1 | Wiring Harness | |
| 1 | Rear Harness As | |
| 1 | Lighting Harness As | |
| 1 | Cab to Hitch Harness As | |
| 1 | Rear Harness As | |
| 1 | Engine Harness As | |
| 1 | Cab Harness As | |
| 1 | Cab Harness As | |
| 1 | Cab Harness As | |
| 1 | Cab Harness As | |
| 1 | Front Harness As | |
| 1 | Lighting Harness As | |
| 1 | Lighting Harness As | |
| 1 | Hitch Harness As | |
| 1 | Rear Lighting Harness As | |
| 1 | Switch Panel Gp | |
| 1 | Bracket | |
| 1 | Plate | |
| 1 | Plate | |
| 1 | Plate | |
| 1 | Warning Indicator Module Gp | |
| 1 | Plate As | |
| 1 | Mount As | |
| 1 | Control Harness As | |
| 2 | Solenoid Harness As | |
| 1 | Panel Harness As | |
| 1 | Handle Control Gp | |
| 1 | Plate As | |
| 1 | Information Plate | |
| 1 | Hose As | |
| 1 | Mount As | |
| 1 | Power Train Software Gp | |
| 1 | Monitor Software Gp | |
| 1 | Machine Software Gp | |
| 1 | Engine Software | |
| 1 | Engine Software | |
| 4 | Drive Screw | |
| 4 | Washer | |
| 2 | Bracket | |
| 3 | O-Ring Seal | |
| 15 | O-Ring Seal | |
| 10 | O-Ring Seal | |
| 2 | O-Ring Seal | |
| 2 | Clip | |
| 8 | Bolt | |
| 1 | Bolt | |
| 1 | Clip | |
| 4 | Clip | |
| 1 | Bolt | |
| 2 | O-Ring Seal | |
| 1 | O-Ring Seal | |
| 1 | O-Ring Seal | |
| 2 | Bolt | |
| 2 | Bolt | |
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Hose | |
| 1 | Adapter | |
| 4 | Bolt | |
| 2 | Clip | |
| 1 | Clip | |
| 1 | Clip | |
| 1 | Clip | |
| 1 | Hard Washer | |
| 13 | Bolt | |
| 8 | Bolt | |
| 25 | Strap | |
| 3 | Bolt | |
| 8 | Clip | |
| 5 | Clip | |
| 10 | Clip | |
| 4 | Dowel | |
| 4 | Spacer | |
| 4 | Pop Rivet | |
| 1 | Clip | |
| 1 | Spool | |
| 1 | Grommet | |
| 1 | Clip | |
| 4 | Bolt | |
| 2 | Locknut | |
| 1 | Boss Adapter | |
| 13 | Nut | |
| 1 | Drive Screw | |
| 50 | Cable Strap | |
| 1 | Bolt | |
| 2 | Bolt | |
| 2 | Bolt | |
| 8 | Bolt | |
| 4 | Bolt | |
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Hose | |
| 2 | Bolt | |
| 2 | Clip | |
| 4 | Adapter | |
| 1 | Flared Elbow | |
| 1 | Retaining Ring | |
| 1 | Clip | |
| 1 | Angle | |
| 1 | Clip | |
| 4 | Bolt | |
| |
Hose | |
| 14 | Hard Washer | |
| 10 | Hard Washer | |
| 2 | Washer | |
| 3 | Bolt | |
| 4 | Bolt | |
| 1 | Bolt | |
| 12 | Bolt | |
| 2 | Bolt | |
| 4 | Bolt | |
| 1 | Bolt | |
| 4 | Bolt | |
| 5 | Hard Washer | |
| 2 | Plated Washer | |
| 35 | Hard Washer | |
| 2 | Hard Washer | |
| 1 | Bolt | |
| 4 | Screw | |
| 4 | Bolt | |
| 60 | Hard Washer | |
| 4 | Bolt | |
| 4 | Hose Clamp | |
| 8 | Hose Clamp | |
| 4 | Hose Clamp | |
| 4 | Bolt | |
| 38 | Washer | |
| 8 | Bolt | |
| 8 | Hard Washer | |
| 4 | Bolt | |
| 16 | Bolt | |
| 1 | Bolt | |
| 4 | Bolt | |
| 8 | Isolation Mount | |
| 7 | Bolt | |
| 1 | Breather As | |
| 1 | O-Ring Seal | |
| 4 | Hard Washer | |
| 2 | Clip | |
| 1 | Spacer | |
| 3 | Clip | |
| 1 | Spacer | |
| 4 | Hard Washer | |
| 4 | Plug | |
| 6 | O-Ring Plug | |
| 2 | Sleeve | |
| 2 | Washer | |
| 2 | Mount As | |
| 4 | Screw | |
| 4 | Washer | |
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| (1) | Required for Tier 3 engines |
| (2) | Required for Ventilation Reduction (VR) engines |
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| Parts Required - Wiring Gp Transmission | ||
|---|---|---|
| Machines Fitted without Remote Control | ||
| Qty | Part Number | Part Description |
| 1 | Grommet | |
| 5 | Bolt | |
| 1 | Wire As | |
| 1 | Mount As | |
| 1 | Plate As | |
| 2 | Hard Washer | |
| 1 | Clip | |
| 1 | Hard Washer | |
| 2 | Washer | |
| 1 | Bolt | |
| 2 | Bolt | |
| 1 | Clip | |
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| Parts Required - Wiring Gp Transmission | ||
|---|---|---|
| Machines Fitted with Remote Control | ||
| Qty | Part Number | Part Description |
| 1 | Clip | |
| 4 | Bolt | |
| 6 | Clip | |
| 2 | Cable Tie | |
| 1 | Wire As | |
| 1 | Mount As | |
| 1 | Plate As | |
| 1 | Transmission Remote Harness As | |
| 1 | Bolt | |
| 5 | Hard Washer | |
| 1 | Spacer | |
| 1 | Clip | |
| 1 | Nut | |
| 1 | Clip | |
| 1 | Hard Washer | |
| 2 | Washer | |
| 1 | Bolt | |
| 2 | Bolt | |
| 1 | Hard Washer | |
| 1 | Bolt | |
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| Parts Required - Lines Gp Oil Cooler | ||
|---|---|---|
| Machines Fitted with Axle Cooling | ||
| Qty | Part Number | Part Description |
| 1 | Hose As | |
| 2 | Hose As | |
| 1 | Hose As | |
| 1 | Bracket As | |
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| Parts Required - Lines Gp Pilot | ||
|---|---|---|
| Machines Fitted with Standard Bucket Control | ||
| Qty | Part Number | Part Description |
| 1 | Identification Plate | |
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| Parts Required - Lines Gp Pilot | ||
|---|---|---|
| Machines Fitted with 90 Degree Rotation | ||
| Qty | Part Number | Part Description |
| 1 | Identification Plate | |
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| Parts Required - Lighting Gp | ||
|---|---|---|
| For Machines Requiring the Truck Loading Light Installation | ||
| Qty | Part Number | Part Description |
| 3 | Bolt | |
| 3 | Hard Washer | |
| 3 | Hard Washer | |
| 3 | Bolt | |
| 1 | Flood Lamp Gp | |
| 1 | Guard As | |
| 1 | Mount As | |
| 1 | Plate | |
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| Parts Required - Lines Gp Steering | ||
|---|---|---|
| Machines Fitted with Secondary Steering | ||
| Qty | Part Number | Part Description |
| 2 | Half Flange | |
| 1 | Hose As | |
| 2 | O-Ring Seal | |
| 4 | Hard Washer | |
| 4 | Bolt | |
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| Parts Required - Fire System | ||
|---|---|---|
| Machines Fitted with the Dry Powder Fire System | ||
| Qty | Part Number | Part Description |
| 1 | Hose As | |
Machine Preparation
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.
- Move the machine to a hard level surface away from operating machines and away from personnel.
- Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
- Stop the engine.
- Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".
- 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.
- Release system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".
Rear Frame - Modification
Note: Required in order to install the 211-7068 Manifold. Refer to "Manifold Assemblies - Install".
- Drill and tap four holes (1). Refer to Illustration 1.
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| Illustration 1 | g03880240 |
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View of the left side torque converter compartment (1) Thread 3/8 - 16 (A) (B) (C) (D) | |
Plate - Install
Note: Required in order to install the 444-5921 Front Harness As.
- Weld in position 445-6266 Plate (1). Refer to Illustration 2 and Table 10.
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Table 10 Item Dimension W1 3 mm (0.12 inch) Fillet weld.20 mm (0.75 inch) -40 mm (1.50 inch) Show/hide table
Illustration 3 g03786316 View from the right side of the front frame
(2)446-0659 Plate
(B)145 mm (5.75 inch)
(C)8.5 mm (0.35 inch) - Weld in position 446-0659 Plate (2). Refer to Illustration 3 and Table 11.
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Table 11 Item Dimension W2 6 mm (0.25 inch) Fillet weld
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| Illustration 2 | g03786296 |
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View of the front frame (1) (A) | |
For Machines Requiring the Truck Loading Light Installation
Note: Required in order to install the loading light.
- Weld in position 444-3866 Plate (1). Refer to Illustration 4 and Table12.
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Table 12 Item Dimension W1 6 mm (0.25 inch) Fillet weld all around.
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| Illustration 4 | g03797661 |
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View of the front frame (1) (A) (B) | |
Power Train
Note: Where parts are not called out, use existing parts.
Torque Converter - Remove and Install
- Remove the engine, torque converter, and updrive gears. Refer to Disassembly and Assembly, "Engine, Torque Converter and Updrive Gears - Remove".
- Separate the engine from the torque converter and updrive gears. Refer to Disassembly and Assembly, "Engine from Torque Converter and Updrive Gears - Separate".
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Illustration 5 g03760561 (1) Implement pump
(2) Steering, pilot, and braking pump
(3) Torque converter scavenge pump
(4) Torque converter assembly - Remove and retain Item (1) through Item (3).
- Discard torque converter assembly (4).
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Illustration 6 g03690836 (1) Implement pump
(2) Steering, pilot, and braking pump
(3) Torque converter scavenge pump
(5)5F-3106 O-Ring Seal
(6)380-4670 Torque Converter Gp - Install Item (1) through Item (3) to 380-4670 Torque Converter Gp (6) using two 5F-3106 O-Ring Seals (5).
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Illustration 7 g03691437 (6) 380-4670 Torque Converter Gp
(7)0T-0768 Bolt
(8)8T-5360 Washer
(9)9H-0846 O-Ring Seal
(10)416-6595 Hose As
(11)4J-0524 O-Ring Seal - Connect the engine to 380-4670 Torque Converter Gp (6), using Item (7) through Item (11). Refer to Disassembly and Assembly, "Engine to Torque Converter and Updrive Gears - Connect" and Illustration 7.
Note: Tighten 0T-0768 Bolts (7) to a torque of
74 ± 8 N·m (55 ± 6 lb ft) . - Install the engine, torque converter, and updrive gears. Refer to Disassembly and Assembly, "Engine, Torque Converter and Updrive Gears - Install".
Machines Fitted with the Ansul Fire System
- Remove and discard hose assembly (1). Retain Item (2) through Item (8) for assembly purposes.
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Illustration 9 g03801545 (2) Clip
(3) Clip
(4) Grommet
(5) Bracket
(6) Bolt
(7) Nut
(8) Washer
(9)387-0232 Hose As - Install 387-0232 Hose As (9) using Item (2) through Item (8) retained in Step 1.
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| Illustration 8 | g03801543 |
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(1) Hose assembly
(2) Clip (3) Clip (4) Grommet (5) Bracket (6) Bolt (7) Nut (8) Washer | |
Transmission - Remove and Install
- Remove and discard the transmission and output transfer gears. Refer to Disassembly and Assembly, "Transmission and Output Transfer Gears - Remove".
- Install the electrical harness to the 382-8140 Transmission Ar. Refer to "Wiring Group - Transmission".
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Illustration 10 g03766937 View of the rear of the transmission
(1)8C-8478 Bolt
(2)9W-6584 Washer
(3)449-9281 Mount As
(4)9W-6582 Sleeve
(5)9W-9930 Mount As
(6)453-1704 Mount As
(7)7X-0345 Bolt
(8)8T-4122 Hard Washer
(9)6F-7054 Dowel
(10)6V-7688 Locknut
(11)8T-4123 Washer
(12)382-8140 Transmission Ar - Install 382-8140 Transmission Ar (12) using Item (1) through Item (11). Refer to Disassembly and Assembly, "Transmission and Output Transfer Gears - Install" and Illustration 10.
Drive Shaft and Drive Shaft Guard - Install
- Install Item (3) through Item (5). Refer to Illustration 11.
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Illustration 12 g03772596 (1) Transmission
(2) Torque converter and updrive
(6)5S-7379 Bolt
(7)8T-4896 Hard Washer
(8)379-9964 Cover As - Install Item (6) through Item (8). Refer to Illustration 12.
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| Illustration 11 | g03772576 |
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(1) Transmission
(2) Torque converter and updrive (3) (4) (5) | |
Braking System
Note: Where parts are not called out, use existing parts.
Lines Gp - Parking Brake
- Install Item (1) through Item (6). Refer to Illustration 13.
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| Illustration 13 | g03780198 |
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(1) (2) (3) (4) (5) (6) | |
Electrical System
Refer to the electrical system schematic in order to identify wire colors.
Note: Where parts are not called out, use existing parts.
- Install 444-5910 Engine Harness As (1) using Item (2) through Item (17). Refer to Illustration 14 through Illustration 22.
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| Illustration 14 | g03787739 |
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View of the left side of the engine (1) | |
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| Illustration 15 | g03787740 |
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View of the front of the engine (1) (2) (3) (4) (5) | |
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| Illustration 16 | g03789158 |
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View of the right side of the engine (1) (3) (4) | |
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| Illustration 17 | g03788499 |
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View of the left side of the engine (1) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) | |
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| Illustration 18 | g03787756 |
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View of the left side of the engine (1) (15) (16) (17) | |
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| Illustration 19 | g03788518 |
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View of the torque convertor and up-drive gears (1) (17) | |
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| Illustration 20 | g03802747 |
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Harness connector identification View of the right side of the engine (18) Coolant temperature sensor connector (two pins) (19) Alternator R terminal connector (two pins) (20) Torque convertor oil temperature sensor connector (three pins) (21) Ground (22) Ground (23) Air filter pressure sensor connector (three pins) (24) Torque convertor output speed sensor connector (two pins) (25) Rear main harness connector (70 pins) (26) Secondary steering speed sensor connector (two pins) (27) Suppressor harness connector for compressor clutch (four pins) (28) Lockup clutch connector (two pins) (29) Coolant flow switch connector (two pins) (30) Ground (31) Refrigerant pressure switch connector (two pins) | |
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| Illustration 21 | g03802748 |
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Harness connector identification View of the left front of the engine (32) Boost pressure sensor connector (three pins) (33) Coolant level sensor connector (three pins) (34) Rear light harness connector (24 pins) (35) Timing calibration harness connector (two pins) (36) Secondary speed/timing sensor connector (two pins) (37) Rear axle oil temperature switch (two pins) (38) Front axle oil temperature switch (two pins) (39) Primary speed/timing sensor connector (two pins) (40) Rear brake oil pressure switch connector (two pins) (41) Front brake oil pressure switch connector (two pins) | |
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| Illustration 22 | g03802753 |
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Harness connector identification View of the left side of the engine (42) Fuel primer switch connector (three pins) (43) Fuel flow sensor connector (two pins) (44) Fuel sensor resistor connector (three pins) (45) Splice receptacle connector (eight pins) (46) Splice receptacle connector (eight pins) (47) ARC suppressor connector (two pins) (48) Fuel prime pump connector (two pins) (49) Fuel temperature sensor (two pins) (50) Injector harness connector (12 pins) (51) Inlet air temperature sensor (two pins) (52) Splice receptacle connector (eight pins) (53) Splice connector (12 pins) (54) Ground (55) Atmospheric pressure sensor connector (three pins) (56) On board radio connector (four pins) (57) Battery isolation harness connector (12 pins) (58) Engine oil pressure sensor (three pins) (59) J2 connector (120 pins) (60) Resistor harness connector (two pins) (61) J1 connector (70 pins) | |
- Install 439-0816 Wiring Harness (1) and 438-5675 Wire As (2). Using Item (3) through Item (6), and securing with 7K-1181 Cable Straps as required. Refer to Illustration 23 through Illustration 25.
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| Illustration 23 | g03789420 |
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View of the left side of the engine (1) | |
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| Illustration 24 | g03789421 |
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View of the left side of the engine (2) (3) (4) (5) (6) | |
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| Illustration 25 | g03803656 |
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Harness connector identification View of the left side of the engine (1) (2) (7) Start relay (8) Start relay (9) 80 Amp circuit breaker (10) 80 Amp circuit breaker (11) Starter motor solenoid (12) Starter motor battery terminal | |
Machines Fitted without Remote Control
Note: Where parts are not called out, use existing parts.
- Install Item (1) through Item (12). Refer to Illustration 26 and Illustration 27.
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| Illustration 26 | g03773124 |
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View of the left side of the transmission (1) (2) (3) (4) (5) (6) (7) (8) (9) | |
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| Illustration 27 | g03774803 |
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View of the right side of the transmission (3) (4) (10) (11) (12) | |
Machines Fitted with Remote Control
Note: Where parts are not called out, use existing parts.
- Install Item (11) through Item (30). Refer to Illustration 28 and Illustration 30.
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| Illustration 28 | g03808524 |
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Harness connector identification (1) Splice connector (six pins) (2) Splice connector (12 pins) (3) Transmission solenoid connector (14 pins) (4) Splice connector (four pins) (5) Remote logic box connector (40 pins) (6) Cab harness connector (40 pins) (7) Splice connector (12 pins) (8) MAS harness connector (two pins) (9) Transmission speed sensor connector (two pins) (10) Ground | |
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| Illustration 29 | g03774808 |
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(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) | |
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| Illustration 30 | g03775845 |
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View of the left side of the transmission (13) (17) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) | |
- Install Item (1) through Item (14). Refer to Illustration 31 through Illustration 33.
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| Illustration 31 | g03786977 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) | |
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| Illustration 32 | g03786996 |
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(10) (12) (13) (14) | |
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| Illustration 33 | g03803715 |
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Harness connector identification (12) (16) Rear harness connector (40 pins) (17) Ground (18) J2 connector (70 pins) (19) Splice connector (six pins) (20) J1 connector (70 pins) | |
- Install 444-5905 Rear Harness As (1) using Item (2) through Item (7). Refer to Illustration 34 through Illustration 42.
- Secure 444-5905 Rear Harness As (1) using 7K-1181 Cable Straps as required.
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| Illustration 34 | g03782457 |
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Harness location (1) | |
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| Illustration 35 | g03783037 |
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View of the transmission compartment (1) | |
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| Illustration 36 | g03783056 |
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(1) (2) (3) (4) (5) (6) | |
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| Illustration 37 | g03783057 |
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View of the parking brake control valve (1) | |
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| Illustration 38 | g03784356 |
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View of the engine over speed brake control valve (1) (7) | |
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| Illustration 39 | g03783058 |
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View of the engine compartment (1) | |
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| Illustration 40 | g03803730 |
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Harness connector identification View of the left side of the transmission compartment (1) (8) Ground (9) Pressurizer fan motor connector (two pins) (10) Cab harness connector (70 pins) (11) Cab harness connector (24 pins) (12) Linear cable connector (two pins) (13) Main relay magnetic switch connector (two pins) (14) Splice connector (12 pins) (15) Splice connector (six pins) (16) Remote control connector (two pins) (17) Transmission oil pressure sensor connector (three pins) (18) Ground (19) Control harness connector to Machine ECM (40 pins) (20) Machine automated system connector (40 pins) | |
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| Illustration 41 | g03803743 |
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Harness connector identification View of the left side of the torque convertor and up-drive compartment (1) (7) (21) Ground (22) Ground (23) Parking brake solenoid one (two pins) (24) Parking brake solenoid three (two pins) (25) Parking brake solenoid two (two pins) (26) Rear service brake EOC pressure sensor connector (three pins) (27) Brake accumulator oil pressure switch connector (three pins) (28) Implement and steering solenoid connector (three pins) (29) Parking brake oil pressure switch connector (three pins) (30) Front EOC supply solenoid connector (two pins) (31) Front service brake EOC pressure sensor connector (three pins) (32) Parking brake low-pressure switch connector (three pins) (33) Ground (34) Ground (35) Rear EOC supply solenoid connector (two pins) (36) Brake accumulator oil pressure switch connector (three pins) (37) Front EOC control solenoid harness connector (two pins) (38) Rear EOC control solenoid harness connector (two pins) (39) Rear EOC control solenoid connector (two pins) (40) Front EOC control solenoid connector (two pins) | |
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| Illustration 42 | g03804580 |
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Harness connector identification View of the left side of the torque convertor and up-drive compartment (1) (41) Ansul pressure switch connector (three pins) (42) Remote fire suppression system connector (two pins) (43) Ansul pressure switch connector (two pins) (44) Engine harness connector (70 pins) | |
- Install 444-5908 Rear Harness As (1) using Item (10), Item (18), and existing parts. Refer to Illustration 43 through Illustration 47.
- Secure with 7K-1181 Cable Straps as required.
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| Illustration 43 | g03783656 |
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Harness location (1) | |
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| Illustration 44 | g03783657 |
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View of the transmission compartment (1) (2) Main cab harness connector (40 pins) (3) Splice connector (12 pins) (4) Transmission harness connector (40 pins) (5) Ground (6) Ground (7) Hitch harness connector (six pins) (8) Remote/hydraulic interface harness connector (12 pins) | |
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| Illustration 45 | g03783660 |
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View of the hydraulic tank compartment (1) (9) VIMS harness connector (12 pins) (10) (11) Ground (12) Hydraulic control module connector (12 pins) (13) MAS interface harness connector (two pins) (14) Ground | |
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| Illustration 46 | g03783676 |
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View of the hydraulic tank compartment (1) (15) Secondary steering flow switch connector (two pins) (16) Hydraulic oil level sensor connector (three pins) (17) Hydraulic oil temperature sensor connector (three pins) (18) (19) Window washer harness connector (three pins) | |
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| Illustration 47 | g03783678 |
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View of the transmission compartment (1) (20) Primary steering flow switch connector (two pins) | |
- Install 444-5907 Cab to Hitch Harness As (1). Refer to Illustration 48 through Illustration 50.
- Secure with 7K-1181 Cable Straps as required.
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| Illustration 48 | g03784338 |
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Harness connector identification (1) (2) Cab harness connector (24 pins) (3) Transmission harness connector (six pins) (4) CAN tee connector (two of - three pins) (5) Reverse steering solenoid connector (two pins) (6) Front frame harness connector - Black (12 pins) (7) Front frame harness connector - Gray (12 pins) (8) Ground | |
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| Illustration 49 | g03784339 |
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(1) | |
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| Illustration 50 | g03784340 |
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(1) | |
- Install 444-5906 Lighting Harness As (1). Refer to Illustration 51 through Illustration 60.
- Secure with 7K-1181 Cable Straps as required.
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| Illustration 51 | g03784357 |
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Harness location View of the rear of the machine (1) | |
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| Illustration 52 | g03784358 |
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View of the left side radiator compartment (1) | |
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| Illustration 53 | g03784376 |
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View of the radiator compartment (1) | |
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| Illustration 54 | g03784396 |
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View of the right side radiator compartment (1) | |
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| Illustration 55 | g03785016 |
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View of the right side radiator and engine compartment (1) | |
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| Illustration 56 | g03785022 |
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View of the left side rear of the machine (1) | |
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| Illustration 57 | g03785023 |
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View of the right side rear of the machine (1) | |
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| Illustration 58 | g03805276 |
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Harness connector identification View of the left side of the machine (1) (2) Left headlight connector (two pins) (3) Splice connector (three pins) (4) Left floodlight connector (two pins) (5) Ground (6) Ground (7) Emergency stop connector (12 pins) (8) Battery isolation switch connector - spare (two pins) (9) Splice connector (12 pins) (10) Ground (11) Backup alarm connector (two pins) | |
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| Illustration 59 | g03805279 |
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Harness connector identification View of the right side of the machine (1) (12) Engine harness connector (24 pins) (13) Red autonomous control light connector (two pins) (14) Amber MAS warning light connector (two pins) (15) Right headlight connector (two pins) (16) Splice connector (three pins) (17) Ground (18) Right floodlight connector (two pins) | |
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| Illustration 60 | g03805280 |
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Harness connector identification View of the right side of the machine (1) (19) Ground (20) Ground (21) Battery isolation switch connector - spare (two pins) (22) Emergency stop connector (12 pins) (23) Grease pump connector (two pins) (24) Fuel level sensor connector (two pins) (25) Splice connector (six pins) (26) Splice connector (three pins) (27) Splice connector (six pins) (28) Autonomous control enable switch connector (six pins) (29) Loop receptacle connector (two pins) | |
Switch Gp - Shutdown
- Install two 392-8100 Push Button Switches using Item (2) and Item (3). Refer to Illustration 61 and Illustration 62.
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| Illustration 61 | g03785036 |
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View from the right side of the machine (1) (2) (3) | |
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| Illustration 62 | g03785056 |
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View from the left side of the machine (1) (2) (3) | |
Pressure Sensor - Service Brake
Prior to installing the pressure sensor, replace the control valve. Refer to "Control Group - Service Brake".
- Install Item (1) and Item (2).
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| Illustration 63 | g03797658 |
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View from below the operator station (1) (2) | |
- Install 444-5912 Cab Harness As (1). Refer to Illustration 64 through Illustration 69.
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| Illustration 64 | g03791479 |
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Harness location View of the operator station (1) | |
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| Illustration 65 | g03791536 |
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Harness connector identification View A-A (2) Splice receptacle (12 pins) (3) Convertor connector (six pins) (4) Upper cab harness connector (eight pins) (Connects to (5) Fuse connector (two pins) (6) 12 VDC outlet connector (1 pins) (7) Fire system connector (eight pins) (8) Upper cab harness connector (12 pins) (Connects to (9) Main power diode harness connector (four pins) (10) Ground (12 VDC outlet connector) | |
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| Illustration 66 | g03793216 |
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Harness connector identification View B-B (11) Splice connector (12 pins) (12) Splice connector (12 pins) (13) Splice connector (12 pins) (14) Splice connector (12 pins) (15) Splice connector (12 pins) (16) Circuit breaker connector (40 pins) (17) Ground x3 (18) Splice connector (12 pins) (19) Splice connector (eight pins) (20) Splice connector (eight pins) (21) Splice connector (eight pins) (22) Splice connector (eight pins) (23) Splice connector (eight pins) (24) Ground x6 (25) Splice connector (12 pins) (26) J2 Power train ECM connector (70 pins) (27) J1 Power train ECM connector (70 pins) | |
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| Illustration 67 | g03793156 |
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Harness connector identification View C-C (28) Rear harness connector (24 pins) (29) Hitch harness connector (24 pins) (30) Transmission / remotes connector (40 pins) (31) Rear main connector (70 pins) (32) Cab to upper cab harness connector (12 pins) (33) Battery isolation switch connector (six pins) (34) Cab harness connector (40 pins) (Connects to (35) Attachment relay connector (four pins) (36) Parking brake switch harness connector (three pins) (37) Main power relay connector (two pins) (38) Key start switch connector (21 pins) (39) Action alarm connector (two pins) (40) Cab harness connector (two pins) (Connects to (41) Switch panel connector (40 pins) (42) Fault alarm (Hydraulic oil level) connector (two pins) (43) ECM monitoring system connector (40 pins) (44) Auto/Manual switch connector (six pins) | |
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| Illustration 68 | g03793217 |
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Harness connector identification View D-D (45) ET survive port connector (nine pins) (46) Splice connector (three pins) (47) Indicator light panel connector (two pins) (48) Exhaust back pressure connector (four pins) (49) Service tool port connector (nine pins) (50) Remote loop plug connector (four pins) (51) CAN resistor connector (two pins) (52) Indicator light panel connector (12 pins) (53) Harness code connector (two pins) | |
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| Illustration 69 | g03791488 |
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Harness connector identification View E-E (54) Air seat connector (two pins) (55) Ground (56) Communication control connector (three pins) (57) Lower cab lamp (four pins) (58) Health monitoring connector (six pins) | |
Instrument Panel Gp
- Install Item (1) and Item (2) using existing parts. Refer to Illustration 70.
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| Illustration 70 | g03797656 |
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(1) (2) | |
- Install 444-5913 Cab Harness As (1). Refer to Illustration 71 through Illustration 75.
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| Illustration 71 | g03789434 |
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Harness location View of the operator station (1) | |
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| Illustration 72 | g03789435 |
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Harness connector identification View from below the operator station (2) Front brake pressure switch connector (two pins) (3) Rear brake pressure switch connector (two pins) (4) Service brake oil pressure sensor connector (four pins) (5) Throttle connector (three pins) (6) Ground (7) Splice receptacle (three pins) (8) Neutralizer switch connector (four pins) | |
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| Illustration 73 | g03790753 |
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(9) Residual brake oil pressure switch for the rear service brake circuit
(10) Residual brake oil pressure switch for the front service brake circuit (11) Service brake oil pressure sensor | |
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| Illustration 74 | g03790016 |
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Harness connector identification (1) (6) Ground (12) Shift control connector (eight pins) (13) Door light connector (two pins) (14) Splice receptacle (three pins) (15) Steering lock connector (four pins) (16) Horn harness connector (eight pins) (17) Fire pressure switch connector (three pins) | |
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| Illustration 75 | g03790776 |
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Harness connector identification (1) (6) Ground (18) Loadrite connector (six pins) (19) Truck payload measurement system (TPMS) connector (two pins) (20) Splice receptacle (12 pins) (21) Payload control harness connector (12 pins) (22) Cab harness connector (40 pins) (23) Gauge harness connector (12 pins) (24) Cab harness connector (two pins) | |
- Install 444-5914 Cab Harness As (1). Secure with 5W-2226 Straps as required. Refer to Illustration 76 through Illustration 79.
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| Illustration 76 | g03790779 |
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Harness location View of the lower operator station (1) | |
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| Illustration 77 | g03795111 |
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View from below the operator station seat (1) (2) (3) (4) | |
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| Illustration 78 | g03790784 |
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Harness connector identification View of the lower operator station (1) (5) Air seat connector (two pins) (6) Engine shutdown switch connector (three pins) (7) Lower cab light connector (two pins) (8) Ground | |
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| Illustration 79 | g03790785 |
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Harness connector identification View of the lower operator station (1) (9) Cab harness (two pins) (10) Cab harness (four pins) | |
- Install 444-5915 Cab Harness As (1). Refer to Illustration 80 and Illustration 81.
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| Illustration 80 | g03790789 |
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Harness location View of the lower operator station (1) | |
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| Illustration 81 | g03791416 |
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Harness connector identification View of the lower operator station (2) Joystick connector (eight pins) (3) Ground (4) Splice receptacle (eight pins) (5) Front cab harness connector (eight pins) (6) Diode connector (two pins) (7) Relay connector (five pins) | |
Circuit Breaker Panel
- Install 450-4591 Panel Harness As (16) to panel (15). Refer to Illustration 82 through Illustration 84, and Table 13.
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Table 13 Circuit Breaker Panel Wiring Circuit Breaker Number of Wires Wire Color Identification Number 1 2 OR(Orange)
OR(Orange)113
1132 1 OR(Orange) EL132 3 3 OR(Orange)
GY(Grey)
GY(Grey)127
146
1464 5 PK(Pink)
PK(Pink)
PK(Pink)
PK(Pink)
GN(Green)128
128
128
128
1385 2 BR(Brown)
BR(Brown)EL705
EL7056 2 GN(Green)
GN(Green)124
1247 3 GN(Green)
GN(Green)
GN(Green)114
114
1148 4 GY(Grey)
GY(Grey)
GY(Grey)
GY(Grey)118
118
118
1189 1 WH(White) 164 10 1 PK(Pink) 119 11 4 RD(Red)
RD(Red)
RD(Red)
RD(Red)102
102
102
15012 4 RD(Red)
RD(Red)
RD(Red)
RD(Red)101
101
101
11513 4 BU(Blue)
BU(Blue)
BU(Blue)
BU(Blue)104
104
104
10414 4 BU(Blue)
BU(Blue)
BU(Blue)
BU(Blue)102
102
102
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Illustration 85 g03800097 (17) 452-8546 Information Plate
(18)4B-4158 Drive Screw
(A)40 mm (1.60 inch) - Install 452-8546 Information Plate (17). Refer to Illustration 85.
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| Illustration 82 | g03799192 |
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Location of the circuit breaker panel | |
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| Illustration 83 | g00945903 |
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(1) Caterpillar Monitoring System – 15 Amp
(1) Instrument Illumination – 15 Amp (1) Monitor, Telemetry Port, Electronic Access Module (EAM) – 15 Amp (2) Remote Control System (If Equipped) – 15 Amp (3) Spare (24v) – 15 Amp (3) Autodig (If Equipped) – 15 Amp (4) Payload Control System (If Equipped) – 15 Amp (5) Remote Control System (If Equipped) – 15 Amp (5) Service Port – 15 Amp (6) Air Conditioner (If Equipped) – 15 Amp (7) Automatic Lubrication System (If Equipped) – 15 Amp (7) Exhaust Gas Pressure (If Equipped) – 15 Amp (7) Horn – 15 Amp (8) 24V to 12V Converter – 15 Amp (8) Instrument Illumination – 15 Amp (8) Radio (Accessories) (If Equipped) – 15 Amp (9) Power Train Electronic Control Module (ECM) – 15 Amp (10) Front Window Washer and Wiper – 15 Amp (10) Side Window Washer and Wiper – 15 Amp (10) Rear Window Washer and Wiper – 15 Amp (11) Key switch – 15 Amp (11) Service Port – 15 Amp (11) Remote Control System (If Equipped) – 15 Amp (11) Engine Electronic Control Module (ECM) – 15 Amp (11) Monitor, Telemetry Port, Electronic Access Module (EAM) – 15 Amp (12) 24V to 12V Converter – 15 Amp (12) Dome Lamp (If Equipped) – 15 Amp (12) Power Train Electronic Control Module (ECM) – 15 Amp (13) Right Front Lights – 30 Amp (Automatic) (13) Right Rear Lights – 30 Amp (Automatic) (14) Left Front Lights – 30 Amp (Automatic) (14) Left Rear Lights – 30 Amp (Automatic) | |
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| Illustration 84 | g03799213 |
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(15) Panel
(16) | |
- Install 366-4033 Cab Harness As (1). Refer to Illustration 86 through Illustration 89.
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| Illustration 86 | g03798053 |
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Harness location (1) | |
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| Illustration 87 | g03798056 |
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Harness connector identification (1) (2) Front light connector (two pins) (3) Front LADAR connector (four pins) (4) (5) (6) | |
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| Illustration 88 | g03798058 |
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Harness connector identification (1) (7) Spare (two pins) (8) Ground (9) Ground (Wiper motor) (10) Idle timer control connector (eight pins) | |
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| Illustration 89 | g03798067 |
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Harness connector identification (1) (8) Ground (9) Ground (Wiper motor) (10) Idle timer control connector (eight pins) (11) (12) Rear cab light harness connector (12 pins) (13) Cab harness connector (eight pins) (14) (15) Cab harness connector (12 pins) | |
- Install 444-5926 Rear Lighting Harness As (1). Refer to Illustration 90 through Illustration 92.
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| Illustration 90 | g03798072 |
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Harness location (1) | |
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| Illustration 91 | g03798621 |
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Harness connector identification (2) Ground (3) Rear light connector (two pins) (4) Remote control brake light connector (three pins) (5) Horn connector (two pins) (6) Tail/Stop light connector (three pins) (7) Remote control activation light connector (two pins) (8) Tail/Stop light connector (three pins) (9) Splice receptacle connector (six pins) (10) Rear LADAR connector (four pins) (11) Connects to (12) | |
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| Illustration 92 | g03798632 |
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(10) Rear LADAR connector (four pins)
(13) (14) (15) (16) | |
- Install 444-5921 Front Harness As (1) using Item (2) through Item (16). Refer to Illustration 93 through Illustration 99.
Note: 231-3930 Relay As (7) and 446-0660 Plate (12) are installed to plates welded on in "Front Frame - Modification".
- Secure with 5W-2226 Straps (5) as required.
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| Illustration 93 | g03785076 |
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Harness location View of the front frame (1) | |
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| Illustration 94 | g03785077 |
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View of the front frame (1) (2) (3) (4) (5) | |
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| Illustration 95 | g03785636 |
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View from the front of the machine (1) (5) (6) (7) (8) (9) | |
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| Illustration 96 | g03785619 |
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View of the front frame (1) (5) | |
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| Illustration 97 | g03785639 |
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View of the rear of the front frame Rear of the front frame removed for illustration purposes (1) (4) (5) (9) (10) (11) (12) (13) (14) (15) (16) | |
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| Illustration 98 | g03805726 |
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Harness connector identification View of the front frame (1) (17) Right corner light connector (two pins) (18) Loadrite connector (two pins) (19) Sensor power connector (four pins) (20) Ground (21) Bucket position switch connector (three pins) (22) CAN tee connector (two of, three pins) (23) Right lift arm light harness connector (two pins) (24) PCS lift arm position sensor connector (three pins) (25) Splice connector (12 pins) (26) Left lift arm light harness connector (two pins) (27) Splice connector (six pins) (28) Ground (29) Ground | |
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| Illustration 99 | g03805728 |
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Harness connector identification View of the front frame (1) (30) Hitch harness connector - Gray (12 pins) (31) Relay connector (five pins) (32) Ride control solenoid connector (two pins) (33) Loading light connector (two pins) (34) Hitch harness connector - Black (12 pins) (35) PCS lift cylinder pressure sensor connector (three pins) (36) Ground (37) Lift arm position solenoid connector (two pins) (38) Fuse connector (two pins) (39) Ground | |
- Install 444-5922 Lighting Harness As (1) and 444-5923 Lighting Harness As (2). Refer to Illustration 100.
- Secure with 5W-2226 Straps (3) as required.
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| Illustration 100 | g03786236 |
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View of the front frame (1) (2) (3) | |
- Install 444-5924 Hitch Harness As (6) using Item (8) and Item (9). Refer to Illustration 101 and Illustration 102.
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| Illustration 101 | g03786256 |
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Harness connector identification (1) Front frame harness connector - Gray (12 pins) (2) Front frame harness connector - Black (12 pins) (3) Ground (4) Cab harness connector - Black (12 pins) (5) MAS articulation sensor connector (six pins) (6) (7) Cab harness connector - Gray (12 pins) | |
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| Illustration 102 | g03786257 |
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View of the articulation hitch area (6) (8) (9) | |
For Machines Requiring the Truck Loading Light Installation
- Install Item (1) through Item (7). Refer to Illustration 103 and Illustration 104.
- Connect loading light connector (32) to 386-1722 Flood Lamp Gp (7). Refer to Illustration 99 and Illustration 104.
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| Illustration 103 | g03798050 |
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(1) (2) (3) | |
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| Illustration 104 | g03798051 |
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(4) (5) (6) (7) | |
Hydraulic System
Note: Where parts are not called out, use existing parts.
Torque Converter and Transmission - Hydraulic Lines
Lines Group - Hydraulic
- Install Item (1) through Item (15). Refer to Illustration 105 and Illustration 106.
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| Illustration 105 | g03767117 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) | |
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| Illustration 106 | g03767136 |
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(12) (15) | |
Transmission Filter - Assemble
- Assemble Item (1) through Item (24). Refer to Illustration 107 and Illustration 108.
Note: Finger tighten 8T-4196 Bolts (19) and 6V-5815 Bolts (24) in order to install hosing in a later step.
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| Illustration 107 | g03769416 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) | |
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| Illustration 108 | g03770116 |
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(10) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) | |
Lines Group - Transmission
- Install Item (1) through Item (30). Refer to Illustration 109 through Illustration 112.
Note: Transmission filter assembly (6) was assembled in "Transmission Filter - Assemble".
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| Illustration 109 | g03768776 |
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(1) (2) (3) (4) (5) (6) Transmission filter assembly (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) | |
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| Illustration 110 | g03768836 |
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(1) (2) (3) (4) (5) (6) Transmission filter assembly (7) (8) (13) (14) (19) | |
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| Illustration 111 | g03769360 |
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View A-A (8) (20) (21) (22) | |
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| Illustration 112 | g03769376 |
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View B-B (23) (24) (25) (26) (27) (28) (29) (30) | |
Transmission Oil Level Gauge
- Install Item (1) through Item (6). Refer to Illustration 113.
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| Illustration 113 | g03772559 |
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View inside the transmission compartment (1) (2) (3) (4) (5) (6) | |
Control Group - Service Brake
- Disconnect hose assembly (2) through hose assembly (5) from valve assembly (1).
- Remove two nuts and valve assembly (1).
- Remove and retain the hydraulic fittings from valve assembly (1). Discard valve assembly (1).
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Illustration 115 g06173817 (6) 143-5605 Brake Control Valve Gp
(7)3K-0360 O-Ring Seal - Install the hydraulic fittings retained in Step 3 to 143-5605 Brake Control Valve Gp (6) using six 3K-0360 O-Ring Seals (7).
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Illustration 116 g06173818 (6) 143-5605 Brake Control Valve Gp - Install 143-5605 Brake Control Valve Gp (6) using two nuts and the washers.
- Connect hose assembly (2) through hose assembly (5) to 143-5605 Brake Control Valve Gp (6).
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| Illustration 114 | g06173814 |
Lines Group - Service Brake
Note: Where parts are not called out, use existing parts.
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| Illustration 117 | g03795121 |
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Location of the service brake lines group | |
- Assemble Item (1) through Item (15). Refer to Illustration 118 and Illustration 119.
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| Illustration 118 | g03795125 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) | |
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| Illustration 119 | g03795126 |
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(2) (5) (6) (7) (8) (9) (11) (12) (13) (14) (15) | |
- Assemble Item (1) through Item (12). Refer to Illustration 120.
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| Illustration 120 | g03795962 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) | |
Manifold Assemblies - Install
- Install the assembled 211-7068 Manifold (6) using Item (1) through Item (7).
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Illustration 122 g03795975 (8) 398-0346 Manifold - Install the assembled 398-0346 Manifold (8) using existing parts.
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| Illustration 121 | g03795541 |
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(1) (2) (3) (4) (5) (6) (7) | |
Hose Assemblies - Install
- Install Item (1) through Item (25). Refer to Illustration 123 through Illustration 127.
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| Illustration 123 | g03795984 |
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(1) (2) (3) (4) | |
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| Illustration 124 | g03795985 |
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(3) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) | |
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| Illustration 125 | g03796434 |
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(6) (7) (8) (9) (10) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) | |
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| Illustration 126 | g03797652 |
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View A-A (3) (5) (6) (7) (8) (9) (10) (11) (12) (14) (16) (17) (18) (21) (22) (27) | |
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| Illustration 127 | g03796894 |
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(6) (7) (10) (14) (21) (25) | |
Lines Group - Machines Fitted with Axle Cooling
- Install item (1) through Item (4) using existing parts. Refer to Illustration 128 and Illustration 129.
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| Illustration 128 | g03797327 |
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(1) (2) (3) (4) | |
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| Illustration 129 | g03797329 |
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(1) (2) (3) (4) | |
Main Control Valve
- Remove and discard the main control valve. Refer to Disassembly and Assembly, "Main Control Valve - Remove".
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Illustration 130 g03776556 (1) 379-2240 Control Valve Gp
(2)7X-2549 Bolt
(3)8T-7971 Hard Washer
(4)4J-0524 O-Ring Seal
(5)8T-5041 Bolt - Install Item (2) through Item (5) to 379-2240 Control Valve Gp (1). Refer to Illustration 130.
Note: Do not tighten 7X-2549 Bolts (2) at this stage.
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Illustration 131 g03778236 (1) 379-2240 Control Valve Gp
(6)8T-6868 Bolt
(7)8T-4223 Hard Washer
(8)284-9067 Bolt
(9)8T-4835 Bolt
(10)384-0040 Tube As
(11)1P-5767 Half Flange
(12)4J-0522 O-Ring Seal
(13)384-0039 Adapter - Install Item (6) through Item (13) to 379-2240 Control Valve Gp (1). Refer to Illustration 131.
Note: Do not tighten 8T-4835 Bolts (9) at this stage.
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Illustration 132 g03778257 (1) 379-2240 Control Valve Gp
(7)8T-4223 Hard Washer
(12)4J-0522 O-Ring Seal
(14)425-8904 Tube
(15)8T-6868 Bolt
(16)197-3295 Half Flange
(17)8T-4183 Bolt - Install Item (7) through Item (17) to 379-2240 Control Valve Gp (1). Refer to Illustration 132.
Note: Do not tighten 8T-4183 Bolts (17) at this stage.
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Illustration 133 g03778264 (1) 379-2240 Control Valve Gp
(4)4J-0524 O-Ring Seal
(7)8T-4223 Hard Washer
(11)1P-5767 Half Flange
(12)4J-0522 O-Ring Seal
(17)8T-4183 Bolt
(18)1P-3704 Rectangular Seal
(19)8T-4194 Bolt
(20)7X-0338 Bolt
(21)4J-0520 O-Ring Seal
(22)1P-3705 Rectangular Seal
(23)7X-0335 Bolt - Install 379-2240 Control Valve Gp (1) using Item (4) through Item (23). Refer to Disassembly and Assembly, "Main Control Valve - Install" and Illustration 133.
Lines Group - Pilot (Rear)
- Install 383-9973 Hose As (1). Refer to Illustration 134
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| Illustration 134 | g03799700 |
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(1) | |
Operator Station
Note: Where parts are not called out, use existing parts.
Pilot Valve Gp
- Remove the lever from the pilot control valve. Refer to Disassembly and Assembly, "Pilot Control Valve - Remove".
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Illustration 135 g03775285 (1) 450-4597 Handle Control Gp
(2)3J-1907 O-Ring Seal - Install 450-4597 Handle Control Gp (1) to the pilot control valve. Refer to Disassembly and Assembly, "Pilot Control Valve - Install".
- Install the pilot control valve. Refer to Disassembly and Assembly, "Pilot Control Valve - Install".
Note: Use six 3J-1907 O-Ring Seals (2) for the six fittings.
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Illustration 136 g03801537 Machines fitted with standard bucket control
(3)449-1805 Identification Plate
(4)6K-3273 Pop Rivet
(A)25 mm (1.0 inch)
(B)10 mm (0.40 inch) Show/hide table
Illustration 137 g03801538 Machines fitted with 90 degree rotation
(4)6K-3273 Pop Rivet
(5)449-1806 Identification Plate
(B)10 mm (0.40 inch)
(C)40 mm (1.60 inch) - Install 449-1805 Identification Plate (3) or 449-1806 Identification Plate (5).
Note: 449-1805 Identification Plate (3), for standard machines.
Note: 449-1806 Identification Plate (5), for machines with 90 degree rotation.
Steering System
Note: Where parts are not called out, use existing parts.
Lines Group - Steering Oil
- Install Item (1) through Item (7). Refer to Illustration 138.
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| Illustration 138 | g03780186 |
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(1) (2) (3) (4) (5) (6) (7) | |
Lines Group - Machines Fitted with Secondary Steering
- Install 421-3029 Hose As (1) using Item (2) through Item (5), and existing parts. Refer to Illustration 139.
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| Illustration 139 | g03799176 |
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(1) (2) (3) (4) (5) | |
Software
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| Illustration 140 | g03800119 |
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Caterpillar Electronic Technician (ET) service port | |
Power Train ECM
- Flash the Power Train ECM with 459-9172 Power Train Software Gp.
Note: Flash files for the machine can be downloaded from SIS Web, Service Software Files.
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| Illustration 141 | g03800116 |
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Location of the Power Train ECM inside the operator station | |
Engine ECM
- Flash the Engine ECM with the latest software. Refer to the information below in order to determine the correct software.
- Ventilation Reduction (VR) engines - 469-8219 Engine Software
- Tier 3 engines - 468-5199 Engine Software
Note: Flash files for the machine can be downloaded from SIS Web, Service Software Files.
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| Illustration 142 | g03800117 |
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Location of the Engine ECM | |
Machine ECM
- Flash the Machine ECM with 459-9422 Machine Software Gp.
Note: Flash files for the machine can be downloaded from SIS Web, Service Software Files.
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| Illustration 143 | g03800118 |
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Location of the Machine ECM | |
Caterpillar Monitoring System (CMS)
- Flash the Caterpillar Monitoring System (CMS) with 459-9420 Monitor Software Gp.
Note: Flash files for the machine can be downloaded from SIS Web, Service Software Files.
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| Illustration 144 | g03816880 |
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Location of the Caterpillar Monitoring System (CMS) | |
Caterpillar Information System:
Medium L and M Series Wheel Loaders Cat Production Measurement Application on Machines Equipped with Product Link: PLE631 or PLE641 Service Tool Software
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