Procedure for Installing a New Steering Control Valve on 16M Motor Graders {4307, 4322} Caterpillar

Motor Grader

16M (S/N: B9H1-UP; R9H1-UP)

Introduction

This Special Instruction provides information about the parts and procedures that are required to install a new steering control valve on 16M Motor Graders.

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

The following information includes instructions on registering the updates and retrofits.

1. When performing a retrofit installation, record the vital information in Table 2.

   Note: If the procedure is performed by the customer, ask the customer to record the proper information.

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   Table 2

   Repair Date
   Product Serial Number
   Service Hours or Service Meter Units
   Removed Component Part Number(1)
   Removed Component Serial Number(1)
   Installed Component Part Number(2)
   Installed Component Serial Number(3)

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   (1)	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
   (2)	Record the highest level retrofit kit, arrangement, or group part number.
   (3)	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

2. Update the product configuration by entering the information from Table 2 into SIMSi and AIMS.

   Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit and Submit Service Reporting".

Important Safety Information

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

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. 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.

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Check valves in the hydraulic system may allow pressure to exist in the hydraulic lines after the engine has been stopped. Pressure must be relieved prior to servicing the components of the hydraulic system. Failure to relieve pressure prior to servicing may result in personal injury.

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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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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.

References

Reference: Refer to Disassembly and Assembly, KENR6018, "Steering Control Valve - Remove and Install ".

Reference: Refer to Disassembly and Assembly, KENR6018, " Control Manifold (Steering Backup) - Remove and Install".

Machine Preparation

1. Park on a level surface. If you must park on a grade, chock the machine.

2. Apply the service brake to stop the machine. Move the transmission control switch to the NEUTRAL position.

3. Move the speed control lever to the LOW IDLE position.

4. Connect the steering frame lock. Refer to Operation and Maintenance Manual, SEBU7884, " Steering Frame Lock"

5. Engage the parking brake.

6. Lower all attachments to the ground.

7. Turn the engine start switch to OFF position and remove the key.

8. Release hydraulic pressure. Refer to Operation and Maintenance Manual, SEBU7884, " System Pressure Release"

9. Turn battery disconnect switch to the OFF position. Refer to Operation and Maintenance Manual, SEBU7884, "Battery Disconnect Switch"

10. Drain the hydraulic tank. Refer to Operation and Maintenance Manual, SEBU7884, " Hydraulic System Oil - Change".

    Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug or cap all lines, hoses, and tubes. This helps to prevent fluid loss and helps to keep contaminants from entering the system.

Required Parts

To Install the new steering control valve you will need to order 494-9355 Steering Upgrade Kit. Additionally, you will need to order the electrical parts listed in table 4.

The hose assemblies are not included in the kit and must be assembled prior to delivery to build site.

Removal of Existing Parts

Note: Best practice is to label connections and hardware for reassembly.

Illustration 1	g06048901
View of parts that need removed and discarded from the right-hand side of the machine

Illustration 2	g06048904
View of parts that need removed and discarded from the left-hand side of the machine

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Illustration 3	g06048973
View of right-hand side of the frame (A) Right Cover (B) Top Cover (C) Left Cover (D) Front Cover

1. Remove control valve covers (A), (B), (C), and (D) from the front frame. Discard cover (A). Retain covers (B), (C), (D), and the hardware for later installation.
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   Illustration 4	g06049005
   View of tube assemblies (E) Tube Assembly (F) Tube Assembly (G) Tube Assembly (H) Tube Assembly

2. Disconnect tube assemblies (E), (F), (G), and (H) from the control valve.
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   Illustration 5	g06050622
   View of hose assemblies (J) Hose Assembly (K) Hose Assembly (L) Hose Assembly

3. Disconnect hose assemblies (J), (K), and (L) from the return manifold. Retain hose assemblies (J), (K), and (L) for later installation.
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   Illustration 6	g06050633
   View of tube assemblies (M) Supply Hose Assembly (N) Steering Tube Assembly (P) Steering Tube Assembly (R) Load Sense Hose Assembly

4. Disconnect supply hose assembly (M), steering tube (N), steering tube (P), and load sense hose assembly (R) from the steering control valve. Retain the hardware, supply hose assembly (M), and load sense hose assembly (R) for later installation. Discard steering tube (N) and steering tube (P).
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   Illustration 7	g06050651
   View of tube assemblies and hose assemblies (S) Tube Assembly (T) Hose Assembly (U) Hose Assembly (V) Hose Assembly (W) Hose Assembly (X) Hose Assembly (Y) Hose Assembly (Z) Tube Assembly

5. Disconnect tube assembly (S), tube assembly (Z), hose assembly (T), hose assembly (U), hose assembly (V), hose assembly (W), hose assembly (X), and hose assembly (Y) from the implement control valves. Retain tube assembly (S), hose assembly (T), hose assembly (U), hose assembly (V), hose assembly (W), hose assembly (X), and hose assembly (Y) for later installation. Discard tube (Z) connected to the "B" port on the ripper control valve.
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   Illustration 8	g06051082
   View of hose assembly and tube assembly (AA) Centershift Hose Assembly (AB) Pilot Supply Tube Assembly

6. Disconnect centershift hose assembly (AA) from the pilot supply fittings. Disconnect pilot supply tube assembly (AB) and fittings from the implement control valve. Disconnect the pilot supply hose from the pilot supply tube. Retain the pilot supply hose for later installation. Discard the pilot supply tube.
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   Illustration 9	g06051112
   View of load sense tube assembly (AC) Load Sense Tube Assembly

7. Disconnect load sense tube assembly (AC) from the implement control valve.
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   Illustration 10	g06051149
   View of electrical harness (AD) Electrical Harness

8. Disconnect electrical harness (AD) from the implement control valves, steering control valve, and secondary steering valve. Move harness (AD) out of the way for later installation.
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   Illustration 11	g06051168
   View of the lifting device

9. Attach a suitable lifting device to the implement control valve mounting plate.
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   Illustration 12	g06051245
   View of plates (AE) Bolt (AF) Washer (AG) Bolt (AH) Plate (AJ) Plate (AK) Bolt (AL) Washer

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   Illustration 13	g06051266
   View of bolts and washers (AE) Bolt (AF) Washer (AK) Bolt (AL) Washer

10. Remove six bolts (AE), two bolts (AG), eight washers (AF), plate (AH), plate (AJ), two bolts (AK), and two washers (AL) as shown in Illustration 12 and Illustration 13. Retain the hardware for later installation.
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    Illustration 14	g06051280
    View of the implement control valve and steering control valve

11. Remove the implement control valve and steering control valve as an assembly from the frame.
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    Illustration 15	g06051715
    View of tube assemblies and valves (AM) Implement Control Valve Stack (AN) Implement Drain Tube Assembly (AP) Bolt (AR) Washer (AS) Tee Adapter (AT) Bolt (AU) Washer (AV) Pilot Drain Tube Assembly (AW) Return Manifold

12. Remove implement drain tube assembly (AN), pilot drain tee adapter (AS), and pilot drain tube assembly (AV) from the valves. Retain parts for later installation.

13. Remove two bolts (AP), two washers (AR), and return manifold (AW) from the frame. Retain parts for later installation.

14. Remove four bolts (AT), four washers (AU), and implement control valve stack (AM) from the plate. Retain parts for later installation.

15. Discard the steering control valve, secondary steering valve, pressure reducing valve, mounting plates, and associated tubes and hoses.
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    Illustration 16	g06051888
    View of control manifold (AX) Control Manifold

16. Remove control manifold (AX). Retain the fittings and hardware for later installation. Discard control manifold (AX).

Front Frame Boss Rework

Note: All images in this section refer to Table 5 for corresponding part numbers.

Note: Use an existing boss as a reference for dimension (D) and dimension (E).

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Illustration 17	g06048783
View of right-hand side of the machine (1) Boss (D) 22.5 mm (0.89 inch) (E) 20 mm (0.79 inch) (W3) 3 mm (0.12 inch)

1. Weld boss (1) to the right-hand side of the front frame as shown in Illustration 17.
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   Illustration 18	g06325464
   View of the boss (2) Boss (F) 95 mm (3.74 inch) (G) 40 mm (1.58 inch) (W1) 3 mm (0.12 inch)

2. Weld boss (2) onto the bracket as shown in Illustration 18.

Install the Steering Control Valve

Note: All images in this section refer to Table 6 for corresponding part numbers.

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Illustration 19	g06324052
View of steering valve group (1) Steering Valve Gp (2) Connector (3) O-Ring Seal (4) O-Ring Seal (5) Connector (6) O-Ring Seal (7) O-Ring Seal (8) Tee Adapter (9) O-Ring Seal (10) O-Ring Seal (11) Elbow (12) Elbow (13) Connector (14) O-Ring Seal (18) Elbow (19) Connector (20) O-Ring Seal (90) Adapter As

1. Assemble the following fittings and seals into steering valve group (1) as shown in Illustration 19.

   Install O-ring seal (3), O-ring seal (4), and connector (2) to steering valve group (1).

   Install O-ring seal (6), O-ring seal (7), and connector (5) to steering valve group (1).

   Install O-ring seal (9), O-ring seal (10), and tee adapter (8) to steering valve group (1). Install O-ring seal (9) and elbow (11) to tee adapter (8).

   Install O-ring (3), Elbow (12), and O-ring (7) to steering valve group 1.

   Install adapter assembly (90) to steering valve group (1).

   Install O-ring seal (10), connector (13), and O-ring (14) to steering valve group (1).

   Install O-ring seal (14), O-ring seal (20), and connector (19) to steering valve group (1). Install O-ring seal (14) and elbow (18) to connector (20).

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   Illustration 20	g06016300
   View of plate assembly (1) Steering Valve Group (21) Bolt (22) Washer (23) Plate Assembly

2. Install plate assembly (23) to steering valve group (1) with three washers (22) and three bolts (21). Tighten three bolts (21).
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   Illustration 21	g06016483
   View of plate assembly (24) Plate Assembly (AM) Implement Control Valve Stack (AT) Bolt (AU) Washer

3. Install implement control valve stack (AM) onto plate assembly (24) with washers (AU) and four bolts (AT). Tighten four bolts (AT).
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   Illustration 22	g06016666
   View of plate assembly (24) Plate Assembly (25) Bolt (26) Hard Washer (27) Plate Assembly

4. Install assembled plate assembly (24) onto plate assembly (27) with five hard washers (26) and five bolts (25). Tighten five bolts (25).
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   Illustration 23	g06017126
   View of plate assembly (23) Plate Assembly (25) Bolt (26) Hard Washer (27) Plate Assembly

5. Install plate assembly (23) with the steering valve group onto plate assembly (27) with three hard washers (26) and three bolts (25). Tighten three bolts (25).
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   Illustration 24	g06037987
   View of tube assembly (1) Steering Valve Gp (26) Hard Washer (28) Bolt (29) Split Flange (30) O-Ring Seal (31) Tube Assembly (AM) Implement Control Valve Stack

6. Install one end of tube assembly (31) onto implement control valve stack (AM). Install the other end of tube assembly (31) onto steering valve group (1) with one O-ring (30), two split flanges (29), four hard washers (26), and four bolts (28). Tighten four bolts (28).
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   Illustration 25	g06038016
   View of tube assembly (1) Steering Valve Group (21) Bolt (26) Hard Washer (27) Plate Assembly (33) O-Ring Seal (34) Bolt (35) Grommet (36) Clip (37) Clip

7. Install one end of tube assembly (32) onto steering valve group (1) with O-ring seal (33), four hard washers (26), and four bolts (34). Tighten four bolts (34). Secure the other end of tube assembly (32) to plate assembly (27) with grommet (35), clip (36), clip (37), and bolt (21). Tighten bolt (21).
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   Illustration 26	g06038142
   View of return manifold (3) O-Ring Seal (4) O-Ring Seal (9) O-Ring Seal (38) Tee Adapter (AP) Bolt (AR) Washer (AW) Return Manifold

8. Install return manifold (AW) onto plate assembly (24) with two washers (AR) and two bolts (AP). Tighten two bolts (AP). Install tee adapter (38) to return manifold (AW) with O-ring (3), O-ring (4), and O-ring (9).
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   Illustration 27	g06038194
   View of hose assemblies (1) Steering Valve Group (2) Connector (8) Tee Adapter (38) Tee Adapter (39) Hose Assembly (40) Hose Assembly

9. Connect one end of hose assembly (39) to tee adapter (8) on steering valve group (1) and the other end of hose assembly (39) to the fitting return manifold.

   Connect one end of hose assembly (40) to connector (2) on steering valve group (1) and the other end of hose assembly (40) to tee adapter (38) on the return manifold.

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   Illustration 28	g06041240
   View of tube assembly (AM) Implement Control Valve Stack (AN) Tube Assembly (AW) Return Manifold

10. Install one end of implement drain tube (AN) to return manifold (AW) and install the other end of implement drain tube (AN) to implement control valve stack (AM).
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    Illustration 29	g06041248
    View of tube assembly (AM) Implement Control Valve Stack (AS) Tee Adapter (AV) Tube Assembly (AW) Return Manifold

11. Install tee adapter (AS) and pilot drain tube assembly (AV) to implement control valve stack (AM) and return manifold (AW).
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    Illustration 30	g06324158
    View of connectors and adapters (3) O-Ring Seal (4) O-Ring Seal (5) Connector (6) O-Ring Seal (7) O-Ring Seal (9) O-Ring Seal (12) Elbow (14) O-Ring Seal (20) O-Ring Seal (41) Shutoff Valve Group (45) Elbow (46) Connector (47) Connector (48) Tee Adapter (49) Elbow (50) Elbow

12. Assemble the following fittings and seals onto shutoff valve group (41) as shown in Illustration 30.

    Install elbow (45) with O-ring seal (6) and O-ring seal (7) to shutoff valve group (41).

    Install connector (5) with O-ring seal (6) and O-ring seal (7) to shutoff valve group (41).

    Install elbow (12) with O-ring seal (3) and O-ring seal (7) to shutoff valve group (41). Install elbow (50) with O-ring seal (3) to elbow (12).

    Install tee adapter (48) with O-ring seal (4) and O-ring seal (14) to shutoff valve group (41). Install elbow (49) with O-ring seal (14) to tee adapter (48).

    Install elbow (12) with O-ring seal (3) and O-ring seal (7) to shutoff valve group (41).

    Install connector (46) with O-ring seal (9) and O-ring seal (20) to shutoff valve group (41).

    Install connector (47) with O-ring seal (4) and O-ring seal (9) to shutoff valve group (41).

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    Illustration 31	g06041955
    View of plate assembly (26) Hard Washer (41) Shutoff Valve Group (42) Plate As (43) Bolt (44) Bolt

13. Install shutoff valve group (41) onto plate assembly (42) with two hard washers (26) and two bolts (43). Tighten two bolts (43).

    Install plate assembly (42) onto the right-hand front frame with two hard washers (26) and two bolts (44). Tighten two bolts (44).

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    Illustration 32	g06042653
    View of the left-hand side of the plate assembly (27) Plate Assembly (AE) Bolt (AF) Washer (AG) Bolt (AH) Plate (AJ) Plate (AK) Bolt (AL) Washer

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    Illustration 33	g06042677
    View of the right-hand side of the plate assembly (1) Steering Valve Group (27) Plate Assembly (AE) Bolt (AF) Washer (AK) Bolt (AL) Washer (AM) Implement Control Valve Stack

14. Attach a suitable lifting device to plate assembly (27), implement control valve stack (AM), and steering control group (1).

    Install plate assembly (27), implement control valve stack (AM), and steering control group (1) as an assembly to the front frame with hardware as shown in Illustration 32 and Illustration 33.

    Install plate assembly (27) onto the frame with four washers (AF), four bolts (AE), two washers (AL), and two bolts (AK). Tighten four bolts (AE) and two bolts (AK).

    Install plate (AH) and plate (AJ) onto plate assembly (27) with two washers (AF) and two bolts (AG). Tighten two bolts (AG).

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    Illustration 34	g06042713
    View of tube assembly and hose assembly (26) Hard Washer (28) Bolt (29) Half Flange (30) O-Ring Seal (M) Hose Assembly

15. Connect pump supply hose (M) to the other end of tube assembly (32) with O-ring (30), two half flanges (29), four hard washers (26), and four bolts 28. Tighten four bolts (28).
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    Illustration 35	g06042985
    View of tube assemblies and hose assembly (E) Tube Assembly (F) Tube Assembly (G) Tube Assembly (H) Tube Assembly (AA) Centershift Hose Assembly (AB) Fitting (AC) Load Sense Tube Assembly

16. Connect fittings (AB) into the implement control valve stack.

    Connect tube assemblies (E), (F), (G), and (H) to the implement control valve stack.

    Connect hose assembly (AA) to fitting (AB).

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    Illustration 36	g06043289
    View of hose assemblies (J) Hose Assembly (K) Hose Assembly (L) Hose Assembly

17. Connect centershift drain hose assembly (J), pilot drain hose assembly (K), and main drain hose assembly (L) to the return manifold.
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    Illustration 37	g06043306
    View of hose assemblies and tube assemblies (S) Tube Assembly (T) Hose Assembly (U) Hose Assembly (V) Hose Assembly (W) Hose Assembly (X) Hose Assembly (Y) Hose Assembly

18. Connect tube (S) to implement control valve stack.

    Connect hose assemblies (T), (U), (V), (W), (X), and (Y), to the implement control valve stack.

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    Illustration 38	g06043356
    View of tube assembly (26) Hard Washer (51) Tube Assembly (52) Bolt (53) Clip

19. Connect one end of tube assembly (51) to the implement control valve stack. Connect the other end of tube assembly (51) to the existing ripper hose assembly. Secure tube assembly (51) with clip (53), washer (26), and bolt (52). Adjust hose slack accordingly. Tighten bolt (52).
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    Illustration 39	g06324196
    View of hose assemblies (85) Hose Assembly (86) Hose Assembly (88) Adapter Assembly (FF) Area View of Clips (GG) Area View of Clips

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    Illustration 40	g06324198
    Area view of clips (FF) ( 34) Bolt (85) Hose Assembly (86) Hose Assembly (93) Clip (94) Clip (95) Washer

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    Illustration 41	g06324199
    Area view of clips (GG) ( 26) Hard washer (34) Bolt (62) Nut (85) Hose Assembly (86) Hose Assembly (92) Spacer (93) Clip (94) Clip (95) Washer

20. Connect the following hose assemblies to the steering valve group and to the existing tube assemblies as shown in Illustrations 39,40, and 41.

    Install two adapter assemblies (88) to the existing tube assemblies.

    Connect one end of hose assembly (85) to the steering valve group and connect the other end of hose assembly (85) to an adapter assembly (88).

    Connect one end of hose assembly (86) to the steering valve group and connect the other end of hose assembly (86) to an adapter assembly (88).

    Secure hose assembly (85) and hose assembly (86) to the boss with two clips (93), two clips (94), washer (95), and bolt (34). Tighten bolt (34).

    Secure hose assembly (85) and hose assembly (86) to the bracket with two clips (93), two clips (94), spacer (92), washer (95), washer (26), bolt (34), and nut (62). Tighten bolt (34) and nut (62).

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    Illustration 42	g06324351
    View of right-hand side of the machine (1) Steering Valve Group (14) O-Ring Seal (41) Shutoff Valve Group (49) Elbow (56) Pilot Hose Assembly (57) Steering Load Sense Hose Assembly (58) Drain Hose Assembly (59) Implement Load Sense Hose Assembly (60) Implement Pilot Hose Assembly (61) Pilot Hose Assembly (AM) Implement Control Valve Stack (CC) Area View of Clips (DD) Area View of Clip (EE) Area View of Clip

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    Illustration 43	g06324429
    Area view of (CC) clips (26) Hard Washer (28) Bolt (56) Hose Assembly (62) Nut (63) Spacer (64) Clip (65) Clip

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    Illustration 44	g06324455
    Area view of (DD) clip (26) Hard Washer (44) Bolt (60) Hose Assembly (68) Clip

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    Illustration 45	g06324603
    Area view of (EE) clip (21) Bolt (26) Hard Washer (59) Hose Assembly (63) Spacer (64) Clip

21. Connect the following hoses and elbow to implement control valve stack (AM), shutoff valve group (41), and steering valve group (1) as shown in Illustrations 42,43,44, and 45.

    Connect O-ring (14) and elbow (49) into implement control valve stack (AM).

    Connect one end of pilot hose assembly (56) to steering valve group (1) and connect the other end of pilot hose assembly (56) to shutoff valve group (41). Secure pilot hose assembly (56) to the tube assembly with clip (64), clip (65), spacer (63), two hard washers (26), bolt (28), and nut (62). Tighten bolt (28) and nut (62).

    Connect one end of steering load sense hose assembly (57) to steering valve group (1) and connect the other end of steering load sense hose assembly (57) to shutoff valve group (41).

    Connect one end of drain hose assembly (58) to steering valve group (1) and connect the other end of drain hose assembly (58) to shutoff valve group (41).

    Connect one end of implement load sense hose assembly (59) to implement control valve stack (AM) and connect the other end of implement load sense hose assembly (59) to shutoff valve group (41). Secure implement load sense hose assembly (59) to the bracket with clip (64), spacer (63), hard washer (26), and bolt (21). Tighten bolt (21).

    Connect one of implement pilot hose assembly (60) to elbow (49) and connect the other end of implement pilot hose assembly (60) to shutoff valve group (41). Secure implement pilot hose assembly (60) to the boss with clip (68), hard washer (26), and bolt (44). Tighten bolt (44).

    Connect one end of pilot hose assembly (61) to steering valve group (1) and connect the other end of pilot hose assembly (61) to shutoff valve group (41).

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    Illustration 46	g06043810
    View of hose assembly (41) Shutoff Valve Group (49) Elbow

22. Connect the existing pilot supply hose assembly to elbow (49) on shutoff valve group (41).
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    Illustration 47	g06047479
    View of clips and bolt (26) Washer (28) Bolt (62) Nut (67) Clip (68) Clip

23. Secure the articulation cylinder and ripper cylinder hoses with clip (67), clip (68), two washers (26), bolt (28), and nut (62). Tighten bolt (28) and nut (62).
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    Illustration 48	g06047551
    View of manifold group (70) Manifold Group (71) Pressure Sensor Group (72) O-Ring Seal

24. Install the fittings and the hardware from original control manifold onto manifold group (70).

    Install manifold group (70) to the bracket with the original mounting hardware. Install pressure sensor group (71) and one O-ring (72) into manifold group (70).

Electrical Rework

Chassis Harness Rework

Note: All images in this section refer to Table 7 for corresponding part numbers.

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Illustration 49	g06047747
View of electrical harness (1) Valve Harness Assembly (2) Bolt (3) Washer (4) Ladder Clip (5) Bracket Assembly (6) Bolt (7) Nut (8) Bolt (9) Clip (10) Spacer (11) Cable Strap (13) Heat Shrink Tube (A) Bracket Assembly

1. Install valve harness assembly (1) to the steering control valve mounting plate with two washers (3), bolt (2), bolt (6), and bracket assembly (5). Tighten bolt (2) and bolt (6).

   Secure valve harness assembly (1) with cable strap (11), ladder clip (4), washer (3), and bolt (2). Tighten bolt (2).

   Also, secure valve harness assembly (1) with spacer (10), two washers (3), two clips (9), bolt (8), and nut (7). Tighten bolt (8).

   Install heat shrink tube (13) onto valve harness assembly (1).

   Connect each connector on valve harness assembly (1) to the corresponding solenoid on the steering control valve.

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   Illustration 50	g06325555
   View of solenoid harness (12) Solenoid Harness (A) U-C1 (B) U-C70 (C) Connect to Steering Valve Harness Assembly (D) Connect to Spool Sensor Assembly (E) Connect to Shutoff Valve Group (F) UK-C5

2. Route solenoid harness assembly (12) along side the existing machine harness as shown in Illustration 50. Connect solenoid harness assembly (12), steering valve harness assembly (C), spool sensor assembly (D), and shutoff valve group (E).

   Note: The loose pins and connector (F) will be connected in the following steps.

3. Move existing U747-U9-OR(Orange)from position "9" in connector (A) to position "38" in connector (A).

4. Move existing U748-U10-GY(Grey)from position "10" in connector (A) to position "63" in connector (A).

5. Move existing R800-U83-OR(Orange)from position "28" in connector (A) to position "1" in connector (F).

6. Move existing P967-U84-PU(Purple)from position "29" in connector (A) to position "2" in connector (F).

7. Remove and seal existing wires from position "26" and position "55" in connector (A) with 50 mm (1.97 inch) of heat shrink tube (13) on each wire. Then secure the wires to the main trunk of the harness with cable straps (11).

8. Remove and seal existing wires from position "25", position "60", and position "62" in connector (A) with 50 mm (1.97 inch) of heat shrink tube (13) on each wire. Then secure the wires to the main trunk of the harness with cable straps (11). Insert three plugs (14) into position "25", position "60", and position "62" in connector (A).

9. Remove and seal existing wires from position "3", position "4", and position "5" in connector (B) with 50 mm (1.97 inch) of heat shrink tube (13) on each wire. Then secure the wires to the main trunk of the harness with cable straps (11).

10. Use seal cap (15), two seal caps (16), and heat shrink tube (13) to seal the old steering valve control module and secondary steering connectors. Then secure the connectors to the main trunk of the harness with cable straps (11).

11. Use seal cap (16) and heat shrink (13) to seal the old implement pilot supply solenoid connector near the pilot control manifold at the rear of the machine. Then secure the connector to the main trunk of the harness with cable straps (11).

12. Connect the sockets of solenoid harness assembly (12) to the existing cab harness connectors (A) and (B). Insert the sockets into the appropriate positions listed in Table 8.
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    Table 8

    Wire Positions
    Wire Name	Color - Gauge	Connector	Position
    E804–UK5	BU-18	A	9
    E803–UK4	YL-18	A	10
    H807-UK11	YL-18	A	26
    R800–UK18	OR-18	A	28
    P967–UK20	PU-18	A	29
    P988-UK13	OR-18	A	41
    U736-UK15	YL-18	A	55
    H804-UK8	GN-18	A	61
    G953-UK6	BU-18	A	66
    G965-UK7	PU-18	A	67
    X754-UK16	GN-18	B	3
    X755-UK17	WH-18	B	4
    925-UK1	YL-18	B	5

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    Illustration 51	g06052447
    View of cover assemblies (87) Cover Assembly

13. Reinstall the control valve covers and cover assembly (87) using the saved hardware.

Cab Harness Rework and Configuration

Cab Harness Rework

Note: All images in this section refer to Table 9 for corresponding part numbers.

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Illustration 52	g06053690

1. Remove instrument cluster (A), secondary steering switch (C), parking brake switch (D), key switch (E), and dash panel (B).
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   Illustration 53	g06053717
   View of cab floor

2. Remove storage bins (F) and floormat (G).
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   Illustration 54	g06053727

3. Remove console covers (H), (J), and floor cover (K).
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   Illustration 55	g06053752

4. Remove seat (L). Refer to Disassembly and Assembly, KENR6018, "Seat - Remove and Install ".
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   Illustration 56	g06053756

5. Remove both covers (M) from the back wall of the cab to access the implement ECM's.
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   Illustration 57	g06016597
   View of Implement ECM's (N) Implement 2 ECM (P) Implement 1 ECM (J1) Implement 1 ECM Connector P-C41. Implement 2 ECM Connector P-C45 (J2) Implement 1 ECM Connector P-C39. Implement 2 ECM Connector P-C27

6. Remove and seal existing wire G953-P186-BU(Blue)from position "7" Implement 1 ECM (P) connector (J2) with 50 mm (1.97 inch) of heat shrink tube (1). Then secure the wire to the main trunk of the harness with cable straps (2).

7. Remove and seal existing wire G965-P185-PU(Purple)from position "8" Implement 1 ECM (P) connector (J2) with 50 mm (1.97 inch) of heat shrink tube (1). Then secure the wire to the main trunk of the harness with cable straps (2).
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   Illustration 58	g06053775
   View of cab harness connectors behind gauge cluster (A) ( R1) Connector P-C50 (R2) Connector P-C151

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   Illustration 59	g06053815
   View of cab harness below plate (K)

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   Illustration 60	g06053826
   View of cab harness below plate (H) and (J)

8. Inspect "UC-1" pin "66" for a wire. If the wire exists remove the wire and seal the wire. Proceed with the remainder of Step 8. Assemble one socket (3) and one pin (4) to orange wire (5). Connect the socket end of orange wire (5) to position "7" of connector (J2) on Implement 1 ECM (P). Connect the pin end of orange wire (5) to position "66" of connector (R1).

9. Assemble one socket (3) and one pin (4) to gray wire (6). Connect the socket end of gray wire (6) to position "8" of connector (J2) on Implement 1 ECM (P). Connect the pin end of gray wire (6) to position "67" of connector (R1).

10. Check for wire on Implement 1 ECM position "J1-54 and R1-61". If the wire is there check continuity - if good use the existing wire. If wire is not there or does not pass continuity follow Step 10. Assemble one socket (3) and one pin (4) to blue wire (7). Connect the socket end of blue wire (7) to position "54" of connector (J1) on implement 1 ECM (P). Connect the pin end of blue wire (7) to position "61" of connector (R1).

11. Check for wire on Implement 1 ECM position "J1-5 and R1-41". If the wire is there check continuity - if good use the existing wire. If wire is not there or does not pass continuity follow Step 11. Assemble one socket (3) and one pin (4) to purple wire (8). Connect the socket end of purple wire (8) to position "5" of connector (J2) on implement 1 ECM (P). Connect the pin end of purple wire (8) to position "41" of connector (R1).

12. Check for wire on Implement 2 ECM position "J1-67 and R1-38". If the wire is there check continuity - if good use the existing wire. If wire is not there or does not pass continuity follow Step 12. Assemble one socket (3) and one pin (4) to orange wire (5). Connect the socket end of orange wire (5) to position "67" of connector (J1) on implement 2 ECM (N). Connect the pin end of orange wire (5) to position "38" of connector (R1).

13. Check for wire on Implement 2 ECM position "J1-68 and R1-63". If the wire is there check continuity - if good use the existing wire. If wire is not there or does not pass continuity follow Step 13. Assemble one socket (3) and one pin (4) to gray wire (6). Connect the socket end of gray wire (6) to position "68" of connector (J1) on implement 2 ECM (N). Connect the pin end of gray wire (6) to position "63" of connector (R1).
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    Illustration 61	g06053756

14. Reinstall both covers (M) from the back wall of the cab to access the implement ECM's.
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    Illustration 62	g06053752

15. Reinstall seat (L). Refer to Disassembly and Assembly, KENR6018, "Seat - Remove and Install ".
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    Illustration 63	g06053727

16. Reinstall console covers (H) and (J) and floor cover (K).
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    Illustration 64	g06053717
    View of cab floor

17. Reinstall storage bins (F) and floormat (G).
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    Illustration 65	g06053690

18. Reinstall instrument cluster (A), secondary steering switch (C), parking brake switch (D), key switch (E), and dash panel (B).

Steering Configuration

1. Turn battery disconnect switch to the ON position.

2. Turn the key to the ON position and connect to Cat ET. Do not start the engine at this time.
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   Illustration 66	g03400992

3. Go to the configuration screen in Cat ET by clicking the configuration icon.
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   Illustration 67	g03401029

4. Double-click the value for “Steering System Configuration Code”.
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   Illustration 68	g03401044

5. Enter “New Value” of “2”, then click “OK”.

6. Turn the key to the OFF position.

7. Turn the key to the ON position and reconnect to Cat ET. Do not start the engine at this time.
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   Illustration 69	g03401058

8. Verify that the machine is now programmed to the new steering configuration by going to the “Joystick Steering” status screen.
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   Illustration 70	g03401082

9. “Primary Steering Valve Command Signal Duty Cycle” and “Primary Steering Valve Power Supply Output Status” should both read “Disabled or Not Installed”.

10. Check for any diagnostic codes. If codes are present, you will need to calibrate the steering solenoids. For calibration procedures, refer to the "Calibrate the Steering Solenoids" section within this Special Instruction. If codes are still present, review the electrical installation and verify that the procedure was done correctly.

11. Once the diagnostic check is completed, start the engine. Steer to the right and steer to the left to verify proper functionality. Also, wheel lean left and wheel lean right to verify proper functionality.

Calibrate the Steering Solenoids

The calibration of the steering solenoids should be performed if any of the following items occur:

• The steering cycle time is slow.

• Steering is too sensitive.

• The steering solenoid is remounted.

• The steering solenoid is replaced.

• The machine Electronic Control Module (ECM) is replaced.

Note: The following information is an example of the calibration procedure. The actual calibration screens may vary as new versions of the software are released.

1. Slightly raise the blade off the ground.

2. Activate the implement lock out switch.

3. To start, select the Implement ECM.

4. To get to the calibration procedures for the steering solenoids, click the service menu.
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   Illustration 71	g03419602

5. Select Service - Calibrations

6. Choose the "Arm Steering System/Solenoid Calibrations"

7. Click the "Start" button
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   Illustration 72	g03419603

8. Read the warning and understand all warnings then click the "Accept" button
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   Illustration 73	g03419604

9. Follow the instructions in the calibration window

10. Click "Solenoid Calibrations".

11. Follow the directions on the screen to complete the calibration procedure.

Hydraulic Schematic

Illustration 74	g06043210

Electrical Schematic

Illustration 75	g06334310