Procedure to Replace the Steering Pin on Certain AP500F, AP600F, and AP1000F Asphalt Pavers {4300, 4304, 4309, 4310, 4338} Caterpillar

Asphalt Paver

AP1000F (S/N: AC41-399)

AP500F (S/N: 5031-109; 4491-148)

AP600F (S/N: AP61-184; LR61-121)

Introduction

The following instructions provide the steps necessary to upgrade the steering pin on certain AP500F, AP600F, and AP1000F Asphalt Pavers.

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

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Required Parts

The following table includes the parts required to upgrade one machine (two consoles).

Machine Preparation

1. Park the machine in a smooth surface and extend both the extenders and screed drop off on the ground.

2. Switch off the machine.

Installation Procedure

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Illustration 1	g06311272
(A) Covers (B) Console

1. Remove and retain all covers (A) and hardware from console (B).
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   Illustration 2	g06316581
   (C) Connector plugs (D) Harness retainer (E) Harness

2. Disconnect connector plugs (C), remove and retain one bolt at (D), and position harness (E) aside.
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   Illustration 3	g06316630
   (F) Socket head bolts (G) Steering column (H) Console plate

3. Remove and retain three socket head bolts (F) that secure steering column (G) to the console plate (H).

4. Remove and retain steering column (G).
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   Illustration 4	g06316649
   (H) Console plate (J) Square key (K) Socket head bolts (L) Friction steering unit connector (M) Steering mechanism

5. Remove and retain square key (J).

6. Disconnect friction steering unit connector (L) from the harness in console (B).

7. Remove and retain two socket head bolts (K) that secure the steering mechanism (M) to the console plate (H).

8. Remove steering mechanism (M) from console (B).

9. Place steering mechanism (M) on a suitable working surface.
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   Illustration 5	g06316892
   (N) Steering shaft (P) Spring pin

10. Using a suitable punch, drive spring pin (P) out of steering shaft (N). Discard pin (P). 

    Note: A new dowel (4) will replace the spring pin (P) upon reassembly.

    Note: The steering shaft (N) has another spring pin at the upper (steering column) end. It is not necessary to remove this pin. The new steering shaft (1) has a larger hole at the same location and will have a larger spring pin (3) installed.

11. Remove the old steering shaft (N) from the steering mechanism (M) and discard.
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    Illustration 6	g06316930
    (1) 557-8263 Steering Shaft (2) 1L-8497 Snap Ring (3) 2H-2525 Spring Pin

12. Assemble the new steering shaft (1). Insert new spring pin (3) into the hole in the upper (steering column) end. Temporarily install the new snap ring (2) between the grooves on the lower end of the steering shaft (1).
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    Illustration 7	g06316979
    (1) 557-8263 Steering Shaft (2) 1L-8497 Snap Ring (4) 5S-6458 Dowel

13. Install the steering shaft (1) into the steering mechanism (M). Insert new dowel (4) into the steering shaft (1) to secure the shaft to the friction steering unit.

14. Reposition the snap ring (2) into the lower groove of the steering shaft (1), overlapping the hole with the dowel (4). Make sure the opening of the snap ring (2) is oriented 90 degrees from the dowel (4).

15. Install steering mechanism assembly (M) into console in the reverse order of removal. Use hardware retained during disassembly. Make sure the square key (J) remains in place when reinstalling the steering column. Refer to Steps 1 through 7.

16. Repeat Steps 1 through 15 for the opposite operator console.