Rework Procedure to Replace the Lever in the Propel Lever Group on Certain PS-150C and PS-360C Paving Compactors{3065} Caterpillar

Paving Compactor:

PS-150C (S/N: NPK1-UP; FPS1-UP)

PS-360C (S/N: PJF1-UP)

Introduction

This Special Instruction provides the procedure to replace and/or adjust the 197-9461 Lever of 244-4471 Propel Lever Gp or the 457-4568 Lever of 458-2891 Propel Lever Gp

Important Safety Information

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 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 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 Caterpillar. If used, ensure the safety of the operating personnel and others.

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

Operation of the machine and the maintenance of the machine must not occur unless the instructions and warnings in the machines Operation and Maintenance Manual have been read and the instructions and the warnings are understood.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Required Parts

Rework Procedure to Replace and Adjust Propel Control Lever

1. Park the machine on a flat, level surface.

2. Apply the parking brake.

3. Place the key switch in the OFF position.

4. Locate the propel lever on the operator station.

5. Remove bolts from console cover in order to access the tensioner for the control lever.

6. Remove the cover boot from the top of the handle.

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Illustration 1	g03730104
(A) Grip (B) Lever (C) Jam Nut (D) Locknut

7. Remove grip (A) from the lever (B). Discard the part.

8. Cut the heat shrink tubing at the top of the main lever boot where the heat shrink tubing transitions from the boot to the tube. Do not cut the boot.

9. Disconnect the control cable from the lever by removing retaining clip and washer from the swivel.

10. Loosen and remove jam nut (C) and locknut (D). Save the part.

11. Remove the spring washers and thrust bearing and keep clean.

12. Remove lever (B) and discard the part.

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Illustration 2	g03730111
(1) 456-8342 Handle Control Gp (2) 457-4568 Lever (3) 125-7876 Heat Shrink Tube

13. Install new lever (2) .

14. Install the thrust bearing and springs washers.

    Note: Install the first two spring washers with the dished side facing the nut end. Assemble the second two spring washers such that the dished side face away from the nut end. The inner two spring washers will be opposing each other. Refer to Illustration 2.

15. Install locknut (D) and jam nut (C) that was saved in Step 10.

16. Position lever (2) in the NEUTRAL Position.

17. Slide 125-7876 Heat Shrink Tube (3) over the top of the lever (2) and seal the boot to the lever. The boot should be in the neutral state, not pulled up tight nor pushed down.

18. Install new 456-8342 Handle Control Gp (1) to lever (2) .

19. Tighten the grip screws to 1.4 N·m (12 lb in) using a T15 Torx bit.

20. Replace the rubber cap.

21. Check for full FORWARD and REVERSE position of lever (2) .

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Illustration 3	g03730128
(1) 456-8342 Handle Control Gp (2) 457-4568 Lever (C) Jam Nut (D) Locknut

22. Tighten locknut (D) until a force of 24.5 ± 2.2 N (5.5 ± 0.5 lb) applied at the top of hand control group (1) is needed to move lever (2) when lever is out of the neutral detent and while pushing at the top of the grip in the forward and reverse direction.

23. Hold locknut (D) with a wrench and tighten jam nut (C) to a torque of 11 N·m (100 lb in).

24. With lever (2) in the NEUTRAL detent position, it should take 29 ± 2 N (6.5 ± 0.4 lb) applied at the top of hand control group (1) to move the lever out of the detent position. Adjust the screws holding the detent roller as necessary to meet the specification.

25. Reconnect the control cable by reinstalling the swivel, washer, and clip.

26. Install console cover using bolts.

27. Check for proper operation.