Installation of the Power Shift Solenoid{5264, 5479} Caterpillar

Track Feller Buncher:

TK711 (S/N: 101185-213,245-276)

TK721 (S/N: 102185-213,345-367)

TK722 (S/N: 103185-221,445-467)

TK732 (S/N: 104185-203,545-549)

Introduction

This special instruction provides information on the installation of the power shift solenoid. The power shift solenoid allows more power to be distributed throughout the machine.

Safety

1. Clean the machine. Cleaning the machine will help to prevent dirt from entering the hydraulic system when hydraulic components are being installed.

2. Start the engine. Fully extend the stick. Lower the attachment to the ground.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids. Dispose of all fluids according to local regulations and mandates.

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Personal injury can result from contact with hot hydraulic oil and from contact with hydraulic oil that is under high pressure. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. The hydraulic oil pressure must be released before any service on the hydraulic system is performed or serious personal injury could occur. Verify that all of the work tools have been completely lowered to the ground. Release the hydraulic oil pressure at the hydraulic tank through the breaker relief valve when the breaker relief valve is cool enough to touch with your bare hand. Verify that the hydraulic oil is cool before you begin to remove any hydraulic components or hydraulic lines.

3. Release the oil pressure in all of the implement circuits (the boom, the stick and the attachment) before any of the hydraulic lines or any of the components are disconnected or removed. Procedure to release the pressure

   1. Shut off the engine and turn the switch to the ON position. Put the hydraulic lockout control in the UNLOCK position.

   2. Cycle all control levers through the full range of motion. This will release any pressure that might be present in the hydraulic system.

      Note: If the hydraulic circuit requires the activation of a switch for operation, activate the necessary switches for the hydraulic circuit.

   3. Turn the start switch to the OFF position.

   4. Move the hydraulic lockout control to the LOCKED position.

      Note: When the hydraulic lockout control is in the LOCKED position no implements will function.

   5. Push down on the hydraulic tank breaker relief valve until all pressure is released.

   6. When the pressure in the hydraulic system has been released then the hydraulic oil lines and the components can be removed.

4. Drain the oil from the hydraulic oil tank in a suitable container for storage or disposal.

Part Numbers

Assemble O-ring Seals to Fittings

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Illustration 1	g01407847
(2) 3J-1907 O-Ring Seal (6) 6V-8397 O-Ring Seal (8) 6V-8636 Connector

1. Assemble O-ring seals to six 6V-8636 Connectors (8). Refer to Illustration 1.

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Illustration 2	g01407848
(2) 3J-1907 O-Ring Seal (6) 6V-8397 O-Ring Seal (11) 6V-8774 Tee

2. Assemble O-ring seals to 6V-8774 Tee (11). Refer to Illustration 2.

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Illustration 3	g01407849
(2) 3J-1907 O-Ring Seal (6) 6V-8397 O-Ring Seal (10) 6V-8724 Elbow

3. Assemble O-ring seals to two 6V-8724 Elbows (10). Refer to Illustration 3.

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Illustration 4	g01407850
(3) 3J-7354 O-Ring Seal (6) 6V-8397 O-Ring Seal (13) 6V-9872 Connector

4. Assemble O-ring seals to 6V-9872 Connector (13). Refer to Illustration 4.

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Illustration 5	g01407851
(2) 3J-1907 O-Ring Seal (7) 6V-8398 O-Ring Seal (24) 8T-6876 Elbow

5. Assemble O-ring seals to 8T-6876 Elbow (24). Refer to Illustration 5.

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Illustration 6	g01407852
(6) 6V-8397 O-Ring Seal (14) 8C-8988 Elbow

6. Assemble O-ring seals to 8C-8988 Elbow (14). Refer to Illustration 6.

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Illustration 7	g01407853
(1) 2M-9780 O-Ring Seal (7) 6V-8398 O-Ring Seal (9) 6V-8721 Elbow

7. Assemble O-ring seals to 6V-8721 Elbow (9). Refer to Illustration 7.

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Illustration 8	g01407854
(6) 6V-8397 O-Ring Seal (12) 6V-9836 Swivel Tee

8. Assemble O-ring seals to 6V-9836 Swivel Tee (12). Refer to Illustration 8.

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Illustration 9	g01407855
(3) 3J-7354 O-Ring Seal (31) 164-7900 Adapter

9. Assemble O-ring seals to 164-7900 Adapter (31). Refer to Illustration 9.

Procedure to Install the Power Shift Solenoid

1. Drain the hydraulic fluid.

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Illustration 10	g01407857

2. Remove the eight bolts (44) and remove plate (45). Remove the four bolts (46) and loosen the two clamps (48). Remove tube (47) .

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Illustration 11	g01407859
Inside of hydraulic tank

3. Remove the four bolts (49). Remove plate (50) .

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Illustration 12	g01407860
Inside of hydraulic tank

4. Loosen the two clamps (51) .

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Illustration 13	g01407861

5. Remove the eight bolts (52) that hold the hydraulic oil filter housing in place. Remove hydraulic oil filter housing (53) .

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Illustration 14	g01407975

6. Place 279-5059 Tube Assembly (39) on filter housing (54). Place two 8T-4223 Hard Washers (23) and two 5P-2566 Bolts (5) onto 279-5059 Tube Assembly (39) and tighten 5P-2566 Bolts (5) .

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Illustration 15	g01407976

7. Place filter housing (53) in the original location and tighten the eight bolts (52) .

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Illustration 16	g01407987
Inside of hydraulic tank

8. Tighten the two clamps (51) .

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Illustration 17	g01407989
Inside of hydraulic tank

9. Place plate (50) in the original location on the machine. Tighten the four bolts (49) .

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Illustration 18	g01415695

10. Place plate (45) in place and tighten the eight bolts (44). Place tube (47) in place and tighten four bolts (46) and two clamps (48) .

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Illustration 19	g01408008

11. Remove hose assembly (55), hose assembly (56), and hose assembly (58). Also remove the two bolts (57) .

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Illustration 20	g01408010
Hydraulic tank (59)

12. Remove hose assembly (60) .

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Illustration 21	g01408012
Main hydraulic pump (62)

13. Remove hose assembly (61) .

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Illustration 22	g01408014

14. Remove bolts (64) and control housing (63) .

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Illustration 23	g01408017

15. Remove valves (65) and valves (66) .

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Illustration 24	g01408018

16. Remove spring retainers (67) .

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Illustration 25	g01408019

17. Remove springs (68) .

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Illustration 26	g01408022

18. Install two 204-2704 Springs (34) .

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Illustration 27	g01408025

19. Install spring retainers (67) .

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Illustration 28	g01408027

20. Install valves (66) and valves (65) .

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Illustration 29	g01408030

21. Install control housing (63) and bolts (64) .

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Illustration 30	g01408033

22. Install 227-1082 Hose Assembly (36), 6V-9872 Connector (13), and 164-7900 Adapter (31) on the manifold block. Also install 217-3077 Hose Assembly (35) and 8T-6876 Elbow (24) onto the main hydraulic pump.

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Illustration 31	g01408034

23. First place the old bracket (71) onto the machine. Then place 307-2975 Bracket (40) onto the machine. Install 8T-4172 Bolt (21) and old bolt (69) with two old washers (70) onto the machine in order to secure the brackets to the machine.

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Illustration 32	g01408036

24. Install 195-3739 Solenoid Valve Group (32) onto the 121-5927 Manifold (29). Tighten nut (72) to a torque of 13 ± 1.5 N·m (10 ± 1 lb ft). Tighten nut (73) to a torque of 50 ± 5 N·m (37 ± 4 lb ft).

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Illustration 33	g01408037

25. Place 121-5927 Manifold (29) onto the machine. Install two 8T-4121 Hard Washers (17) and two 8T-4182 Bolts (22) onto the machine in order to secure 121-5927 Manifold (29) .

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Illustration 34	g01408038

26. Install 310-7657 Hose Assembly (42) and 6V-8721 Elbow (9) onto the machine.

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Illustration 35	g01408040

27. Install 276-9072 Shuttle Valve (37) onto 121-5927 Manifold (29). Then install 217-3077 Hose Assembly (35) onto 276-9072 Shuttle Valve (37) .

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Illustration 36	g01408042

28. Install 6V-8636 Connector (8) onto 121-5927 Manifold (29). Install 8C-8988 Elbow (14) onto 6V-8636 Connector (8). Install 113-7145 Hose Assembly (28) onto 8C-8988 Elbow (14) .

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Illustration 37	g01408043

29. Install 6V-8724 Elbow (10) and 6V-8774 Tee (11) onto the machine. Install 279-5042 Tube Assembly (38) onto 6V-8724 Elbow (10) and 6V-8774 Tee (11) .

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Illustration 38	g01408046

30. Install 203-9196 Hose Assembly (33) onto the machine.

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Illustration 39	g01408049

31. Install 308-0464 Hose Assembly (41) onto the machine.

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Illustration 40	g01408068

32. Install 6V-8724 Elbow (10) onto the hydraulic tank. Install 6V-9836 Swivel Tee (12) onto 6V-8724 Elbow (10). Install 9U-2966 Hose Assembly (25) and 113-7145 Hose Assembly (28) onto the machine.

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Illustration 41	g01408054
(25) 9U-2966 Hose Assembly (28) 113-7145 Hose Assembly

33. Install 5K-5338 Clip (4), 8T-4121 Hard Washer (17), and 8T-4136 Bolt (19) onto the machine.

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Illustration 42	g01409194

34. Install 203-9196 Hose Assembly (33), 9U-2966 Hose Assembly (25), 308-0464 Hose Assembly (41), and 310-7657 Hose Assembly (42) onto solenoid valve block (74) .

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Illustration 43	g01408058

35. Remove bolt (75) and clip (76) .

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Illustration 44	g01408061

36. Place 8R-9137 Angle (16) and the old clamp (76) on the machine. Bolt 8R-9137 Angle (16) and the old clamp (76) onto the machine. Place 8M-2773 Clip (15) onto 217-3077 Hose Assembly (35). Secure 8M-2773 Clip (15) to 8R-9137 Angle (16) with 8T-4121 Hard Washer (17), 8T-4133 Nut (18), and 8T-4137 Bolt (20) .

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Illustration 45	g01408063

37. Install 311-4954 Control Harness Assembly (43) onto the machine.

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Illustration 46	g01408577

38. Install 311-4954 Control Harness Assembly (43) onto engine ECM (77). Place the green wire in position 43 on the ECM connector. Place the white wire in position 51 on the ECM connector.

Machine Settings

Displacement of the Piston Pump

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Illustration 47	g01411747
Main Hydraulic Pumps

1. Remove two setscrews (78) .

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Illustration 48	g01411748
Main Hydraulic Pumps

2. Install two 9X-2403 Hex Socket Setscrews (26) .

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Illustration 49	g01411750
Area A

3. [In order to find the length of dimension (A), refer to Table 2.

   Note: Measure dimension (A) from the locknut to the end of the setscrew.

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   Table 2

   Sales Model	Implement	Travel
   TK711	13.00 mm (0.512 inch)	13.00 mm (0.512 inch)
   TK721	16.00 mm (0.630 inch)	19.00 mm (0.748 inch)
   TK722	16.00 mm (0.630 inch)	19.00 mm (0.748 inch)
   TK732	16.00 mm (0.630 inch)	19.00 mm (0.748 inch)

Torque Setting for the Piston Pump

Illustration 50	g01411752
Main Hydraulic Pumps

Refer to Table 3 for the length of setscrew (79). Measure from the locknut to the end of the setscrew

Displacement Settings for the Travel Motor

Note: This procedure will be performed on the right travel motor and the left travel motor.

Illustration 51	g01417364
Location of the travel motor

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Illustration 52	g01417365

1. Remove bolt (80) and remove bolt (81) from the travel motor.

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Illustration 53	g01417368

2. Place 9X-8482 Socket Setscrew (27) and place 125-1379 Socket Setscrew (30) onto the machine.

3. Adjust the setscrews to the proper length. Refer to Table 4 for the length of bolt (27) and bolt (30).
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   Table 4

   Sales Model	Bolt Length for Minimum Displacement	Bolt Length for Maximum Displacement
   TK711	17.30 mm (0.681 inch)	20.70 mm (0.815 inch)
   TK721	16.80 mm (0.661 inch)	17.20 mm (0.677 inch)
   TK722 (1)	20.70 mm (0.815 inch)	14.50 mm (0.571 inch)
   TK722 (2)	19.1 mm (0.752 inch)	13.80 mm (0.543 inch)
   TK732	18.20 mm (0.717 inch)	18.20 mm (0.717 inch)

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   ( 1 )	This set of lengths are used with the 279-9872 Travel Motor .
   ( 2 )	This set of lengths are used with the 236-1237 Travel Motor .

4. Flash the IQAN software. Refer to Table 5 for the correct software.
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   Table 5

   Part Number	Language	Machine Configuration	Sales Model	Serial Number Breaks
   306-1845	English	Feller Buncher	TK711 TK721 TK722 TK732	S/N:1011-210 S/N:1021-210 S/N:1031-206 S/N:1041-194
   307-1306	English/Spanish	Feller Buncher	TK711 TK721 TK722 TK732	S/N:101211-UP S/N:102211-UP S/N:103207-UP S/N:104195-UP
   307-1307	English/French	Feller Buncher	TK711 TK721 TK722 TK732	S/N:101211-UP S/N:102211-UP S/N:103207-UP S/N:104195-UP
   307-1310 (1)	English/French	Feller Buncher	TK711 TK721 TK722 TK732	S/N:101211-UP S/N:102211-UP S/N:103207-UP S/N:104195-UP
   307-1311	English/Spanish	Intermittent Saw	TK711 TK721 TK722 TK732	S/N:101211-UP S/N:102211-UP S/N:103207-UP S/N:104195-UP
   307-1312	English/French	Intermittent Saw	TK711 TK721 TK722 TK732	S/N:101211-UP S/N:102211-UP S/N:103207-UP S/N:104195-UP
   307-1315	English	Harvester	TK711 TK721 TK722 TK732	S/N:1011-210 S/N:1021-210 S/N:1031-206 S/N:1041-194
   307-1317	English/Spanish	Harvester	TK711 TK721 TK722 TK732	S/N:101211-UP S/N:102211-UP S/N:103207-UP S/N:104195-UP
   307-1318	English/French	Harvester	TK711 TK721 TK722 TK732	S/N:101211-UP S/N:102211-UP S/N:103207-UP S/N:104195-UP
   307-1321 (1)	English/French	Feller Buncher	TK711 TK721 TK722 TK732	S/N:1011-210 S/N:1021-210 S/N:1031-206 S/N:1041-194

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   ( 1 )

   This part number is for machines with additional patterns for the joystick.

5. Flash the engine software. Refer to Table 6 for the correct software.
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   Table 6

   Sales Model	Part Number
   TK711	319-3254
   TK721	319-3255
   TK722	319-3255
   TK732	319-3257