COVER 2428770 - Caterpillar

Illustration 4
Place new gate as. into housing.
Insert hex shaft through the gate, leaving enoughroom to install spacer on hex shaft. Use needle nose pliers to place spaceronto the shaft.
Using fingers, push hex shaft in fully, installnew "C" clip.
Make sure that hex shaft pointer isin alignment with the words "OPEN" or "CLOSED".
With gate pivoted out, align spring shaft withspring shaft opening and allow gate to hang freely.
Apply thread locker onto the spring retainingbolt, install spring, washer and hex head bolt into housing, holding gatein closed position, turn bolt by hand until bolt threads engage with springshaft.
Tighten spring shaft bolt (with gate in fullyclosed position) until spring washer is flush with O-ring groove, thentighten one additional turn or until gold colored washer is about .010"below the housing surface. See Illustration 5.
Illustration 5
Reinstall spring cover applying thread lockerto the hardware and tighten.
Clean the mating surfaces of both housings.
Use a medium size round file (a grinder may alsobe used) to file a groove approximately 5/16" (8mm) wide by 1/8" (3mm)deep. This groove is needed for accessing the anti-turn screw. Please referto illustration 6 for visual reference. NOTE groove can be filed on eitherside of the housing.
Illustration 6
Apply a thin coating of high temperature RTV (Permatex26B or equivalent) to one housing.
Reinstall housing applying thread locker to thehardware and tighten.
Install adapter plate from new electrical solenoidassembly, apply thread locker to the new hardware and tighten.
Apply thread locker to threads on the new solenoid,screw new solenoid onto adapter and tighten (use band wrench or large adjustablepliers) then tighten "anti turn" allen screw that is located on the frontof the solenoid. See Illustration 7.
Install the diodes that were removed in step 1to the new solenoids and reattach the engine harness to the solenoids.
These diodes are not polarity specific. Illustration 7
SWITCH INSTALLATION ? Remove existing plug orswitch and any existing washer/shims from air shutoff valve. Apply antiseize to threaded portion of the 2277483 switch and install into air shutoffvalve torquing switch to 10 ft lb.
No washers or shims are needed withthis switch. Refer to Illustration 8 for visual differences in the switches. Illustration 8
After switches are installed connect 2110194 harnessto the switches and then wire in series into the emergency stop circuit.
For GROUP 3: Switch harness is builtinto the engine harness and is equipped with jumper plugs. Remove jumperplugs and connect harness to air shutoff switches. Refer to Illustrations9 and 10. Illustration 9 Illustration 10
Utilize the following procedures when wiring 2110194air shutoff switch harness into the emergency stop circuit.
Find the 40 pin "Customer connector" on the enginebeing serviced
Remove the two jumper wires from pins 33, 34,20 and 21.
From the 211-0194 switch harness, insert wirelabeled "Shutdown C IN" into the 40-pin connector at location #33.
From the 211-0194 switch harness, insert wirelabeled "Shutdown D IN" into the 40-pin connector at location #34.
From the 211-0194 switch harness, insert wirelabeled "Shutdown C OUT" into the 40-pin connector at location #20.
From the 211-0194 switch harness, insert wirelabeled "Shutdown D OUT" into the 40-pin connector at location #21.
If a remote emergency stop is