Replacing the shift cable on a Komatsu CD60R-1 Crawler Carrier involves several steps and requires specific tools and components. View and download the manual with one click here……
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Below is a detailed description of the process, including the necessary components and tools.
### Components Involved
1. **Shift Cable**: The component that connects the transmission shifter to the transmission itself, allowing for gear changes.
2. **Cable Clamps**: Used to secure the cable in place.
3. **Cable Grommets**: Protect the cable where it passes through any metal or sharp edges.
4. **Nuts and Bolts**: Various sizes used to secure the shift cable in place.
5. **Transmission**: The component that the shift cable connects to, responsible for gear selection.
### Tools Required
1. **Socket Set**: For removing bolts and nuts.
2. **Wrench Set**: To assist with any nuts that may be difficult to access.
3. **Screwdriver**: For any clips or screws that may hold the cable in place.
4. **Pliers**: Useful for removing clips or securing the cable.
5. **Cable Lubricant**: To ensure smooth operation of the new cable.
6. **Safety Equipment**: Gloves and safety glasses.
### Step-by-Step Replacement Process
#### 1. Preparation
– **Safety First**: Ensure the engine is off, and the keys are removed. Engage the parking brake.
– **Raise the Vehicle**: If necessary, use a jack to lift the crawler carrier and secure it with jack stands for safety.
#### 2. Remove the Old Shift Cable
– **Locate the Shift Cable**: find the shift cable running from the gear selector inside the operator’s compartment to the transmission.
– **Disconnect the Cable from the Selector**:
– Use a screwdriver or pliers to remove any clips or fasteners securing the cable to the gear selector.
– Carefully pull the cable out of the selector mechanism.
– **Disconnect the Cable from the Transmission**:
– Locate the point where the cable connects to the transmission. This may require some maneuvering or removal of other components for better access.
– Remove any securing fasteners (nuts or bolts) with the socket or wrench.
– Once the fasteners are removed, carefully pull the cable from its connection point.
– **Remove Cable Clamps and Grommets**:
– Detach any clamps that may be holding the cable in place along its routing.
– If there are grommets, carefully remove them to free the cable completely.
#### 3. Install the New Shift Cable
– **Prepare the New Cable**:
– Compare the new cable with the old one to ensure it’s the correct part.
– Apply cable lubricant to the new cable to ensure smooth operation.
– **Route the New Cable**:
– Begin at the transmission end and route the new shift cable through any grommets and along the same path as the old cable. This may require some gentle bending of the cable.
– **Secure the Cable**:
– Use cable clamps to secure the cable in place along its route. Ensure it is not pinched or kinked, which may affect operation.
#### 4. Connect the Shift Cable
– **Attach to the Transmission**:
– Align the cable end with the transmission connection point.
– Install and tighten any bolts or nuts that hold the cable in place. Be sure not to overtighten, as this could damage the cable or transmission.
– **Connect to the Gear Selector**:
– Route the other end of the cable to the gear selector inside the operator’s compartment.
– Secure it with the appropriate clips or fasteners.
#### 5. Testing
and Final Adjustments
– **Test the Operation**:
– With everything secured, sit in the operator’s seat and test the gear selector. Ensure that shifting through the gears is smooth and responsive.
– **Check for Obstructions**:
– Inspect the cable routing to ensure there are no kinks or pinch points that could interfere with operation.
– **Reassemble Any Removed Components**:
– If any panels or guards were removed during the process, reinstall them.
#### 6. Final Inspection
– **Inspect**:
– Double-check all connections, bolts, and ensure everything is secure.
– **Lower the Vehicle**:
– If the vehicle was raised, carefully lower it back to the ground.
### Conclusion
Replacing the shift cable on a Komatsu CD60R-1 Crawler Carrier requires careful attention to detail and methodical execution. By following these steps and using the correct tools and components, you can ensure a successful installation of the new shift cable, restoring functionality to the vehicle’s transmission system. Always refer to the manufacturer’s service manual for specific details and torque specifications.
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