Procedure for Installing a Locking Set Screw into the Shift Handle on Certain Off-Highway Trucks {5063, 5705} Caterpillar

Articulated Truck

725C (S/N: LFB1-UP; TFB1-UP)

730C (S/N: LFF1-UP; TFF1-UP)

730C EJECTOR (S/N: TFH1-UP)

735B (S/N: L4D1-UP; T4P1-UP; E4R1-UP)

735C (S/N: LFJ1-UP; TFJ1-UP)

740B (S/N: L4E1-UP; T4R1-UP; E4S1-UP)

740B EJECTOR (S/N: L4F1-UP; T4S1-UP)

740C EJECTOR (S/N: LFN1-UP)

745C (S/N: LFK1-UP; TFK1-UP)

Off-Highway Truck/Tractor

770 (S/N: BZZ1-UP)

770G (S/N: ECM1-UP)

772 (S/N: RLB1-UP)

773F (S/N: EED1-UP)

777F (S/N: JRP1-UP; JXP1-UP)

777G (S/N: TNM1-UP; RDR1-UP; T4Y1-UP)

793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)

793F AC (S/N: EMD1-UP)

795F AC (S/N: ERM1-UP)

795FAC XQ (S/N: SNT1-UP)

797F (S/N: LAJ1-UP; WSP1-UP)

Quarry Truck

773G (S/N: JWS1-UP)

775F (S/N: DLS1-UP)

775G (S/N: RFM1-UP; MJS1-UP)

Wheel Tractor-Scraper

621G (S/N: NEL1-UP; KJW1-UP; MEX1-UP)

621H (S/N: DBK1-UP; HKK1-UP; NYY1-UP; EAZ1-UP)

621K (S/N: WTA1-UP; WTE1-UP; WTL1-UP; WTP1-UP)

623G (S/N: CES1-UP)

623H (S/N: EJD1-UP; DBF1-UP)

623K (S/N: WTB1-UP; WTM1-UP)

627H (S/N: LCT1-UP; DBW1-UP)

627K (S/N: WTC1-UP; WTN1-UP)

631G (S/N: DFA1-UP; DXE1-UP)

631K (S/N: WTW1-UP)

637G (S/N: DFJ1-UP)

637K (S/N: WTS1-UP)

657G (S/N: W1B1-UP; W1C1-UP)

Introduction

This special instruction provides the procedure to install the socket setscrew to prevent the lower screw from backing out of the shift handle assembly.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

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 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. If a tool, a procedure, a work method, or operating technique that is not specifically recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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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.

Required Parts

Table 1 represents the required part list to install the socket setscrew.

Installation Procedure

Illustration 1	g06129865
Location of the screw in the shift lever (A) Set Screw

Perform the following procedure to ensure that the correct screw preparation, installation and tightening procedures are used to fasten the handle on the shaft:

Note: Torque screw driver or a torque wrench with T20 Torx bit is the recommended tool to use for tightening the socket setscrews. A regular T20 Torx driver tool can be used if a torque screw driver is not available.

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Illustration 2	g06129883

1. Remove the Screw (A) with T20 Torx bit driver.
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   Illustration 3	g03796055

2. Apply adequate amount of Loctite 425 on the entire length of thread on the screw.
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   Illustration 4	g03796056

3. With a paper towel, touch the end of the screw to remove excess compound of Loctite. Refer to Illustration 4.
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   Illustration 5	g03796057

4. Using a torque screw driver or a T20 Torx bit driver, tighten the screw back on the shift handle assembly with a torque of 10 ± 1 N·m (89 ± 9 lb in).
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   Illustration 6	g06129899

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   Illustration 7	g06130497
   (1) 010-2591 Socket Setscrew

5. Install 010-2591 Socket Setscrew (1) using the hexagonal socket and ensure that the set screw is square with the plane of the shift handle. Apply firm pressure and thread the set screw into the hole.

6. The set screw will act as a self-taping screw and create its own threads onto the shift handle.
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   Illustration 8	g06129928

7. Tighten until the set screw touches the existing screw. This will be noticed by a very slight increase in resistance.

8. Remove the set screw. Apply adequate amount of Loctite 425 on the threads of the set screw.

9. Reinstall the set screw and tighten until the set screw touches the existing screw. Wipe off any excess compound of Loctite.