5031810 JOHNSON BOLT (10X50)

Introduction
This Special Instruction contains procedures on reworking the engine wiring harness and the wiring harness for the torque converter. This rework will replace the interface connector between the engine wiring harness and the wiring harness for the torque converter with two new DT connectors. This rework will also relocate this interface connector to the frame of the machine. This will reduce vibration of the wiring harnesses and this will improve the service life of the wiring harnesses.These changes are effective with the following machines.
854G (S/N: A4W239-UP)
992G (S/N: AZX638-UP)This rework is adaptable to first production of the machines that are listed.Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication.This Special Instruction is available through the normal literature distribution system.This publication can be found on the Caterpillar Service Information System (SIS).Required Parts
Table 1
Qty     Part Number     Description    
1     090-8247     Block    
1     300-1292     Bracket As    
2     6K-8178     Clips    
7     8T-4137     Bolts    
7     8T-4121     Hard Washers    
1     192-5624     Bracket As    
1     9M-8406     Clip    
2     6D-4246     Clips    
2     174-4613     Angle As    
4     4S-1962     Clips    
4     5P-8939     Grommets    
1     124-3019     Bracket As    
1     4P-8134     Clip    
1     299-1033     Bracket As    
2     130-5300     Clips    
1     155-2255     Connecting Plug Kit (12-PIN)    
8     186-3736     Connector Sockets    
1     102-8801     Receptacle Kit (12-PIN)    
12     186-3735     Connector Pins    
5     8T-8737     Seal Plugs    
1     298-6772 (1)     Harness As    
1     266-8577 (2)     Speed Sensor Gp (TORQUE CONVERTER OUTPUT)    
1     3K-0360 (2)     O-Ring Seal    
( 1 ) If the engine wiring harness is REWORKED and the machine is equipped with the Oil Renewal System, this harness is required.
( 2 ) This part is required if one of the following harnesses is replaced: 115-5603 Transmission Harness As (TORQUE CONVERTER), 205-0334 Transmission Harness As (TORQUE CONVERTER), 226-7162 Transmission Harness As (TORQUE CONVERTER) or 248-2769 Transmission Harness As (TORQUE CONVERTER)
Table 2
Qty     New Part Number     Description     Former Part Number    
1     302-4020     Transmission Harness As (TORQUE CONVERTER)     115-5603    
205-0334
226-7162
298-3556 Transmission Harness As (TORQUE CONVERTER)     248-2769    
284-7468
1     304-4415     Engine Harness As (3)     161-1546    
300-6785 217-7048
( 3 ) Only replace the engine wiring harness, if necessary.Machine Preparation
Move the machine to a surface that is smooth, hard, and level. Move the machine to an area that is away from operating machines and away from personnel.
Install blocks on the front and the rear of the front tires.
Install the steering frame lock.Preparing the Area for Welding
Personal injury can result from working with cleaning solvent.Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions.Always wear protective clothing and eye protection when working with cleaning solvents.
Clean the area in order to be welded. Clean the area of the substances that follow:
Oil
Grease
Paint
DirtIf the temperature of the base metal is below 0 °C (32 °F), heat the base metal to a temperature of at least 21 °C (70 °F). Maintain the temperature of the base metal at 21 °C (70 °F) during the welding procedure.Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.Attach the welding ground cable directly to the base metal. Protect machined surfaces from the sparks. Protect machined surfaces from the weld splatter.Weld Specifications and Qualifications
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.
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.Ke