Rework Procedure For the 192-0086 Ride Control Valve Gp {5004, 5054} Caterpillar

Integrated Toolcarrier:

IT28G (S/N: WAC1-622; DBT1-1676)

Wheel Loader:

928G (S/N: DJD1-2449; WLG1-992)

Introduction

This Special Instruction describes the rework procedure for the 192-0086 Ride Control Valve Gp that is used on the 928G and IT28G Wheel Loader. The procedures in this instruction are performed on machines that have exhibited problems with the functionality of the ride control system.

Do not begin reworking the ride control system until you have read the information that is contained in this instruction.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

ReferenceDisassembly and Assembly, "Steering Frame Lock - Separate and Connect"

ReferenceDisassembly and Assembly, RENR6433-02, "System Pressure - Release"

ReferenceOperation and maintenance Manual, SEBU7645-04, "Welding on Machines and Engines with Elecrtonic Controls"

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

Required Parts

In order to rework the 192-0086 Ride Control Valve Gp , the following parts are required:

Required Tooling

The following tooling needs to be used with the hydraulic tank in order to prevent loss of hydraulic fluid:

Illustration 1	g01415589
Vacuum Gauge Gp Installation (AA) 311-1362 Vacuum Gauge Gp

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Illustration 2	g01415594
(A1) Plug Assembly

1. Remove the existing plug assembly (A1) from the 311-1362 Vacuum Gauge Gp (AA) .

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Illustration 3	g01415603
(AA) 311-1362 Vacuum Gauge Gp (A2) 5P-3415 Adapter (A3) 6V-5050 O-Ring Seal

2. Install the 6V-5050 O-Ring Seal (A3) onto the 5P-3415 Adapter (A2). Connect the 5P-3415 Adapter (A3) onto the 311-1362 Vacuum Gauge Gp (AA) .

3. Remove the hydraulic tank breather from the hydraulic tank.

4. Install the 311-1362 Vacuum Gauge Gp (AA) into the hydraulic tank.

5. Attach an air supply hose onto the 311-1362 Vacuum Gauge Gp (AA) .

   Apply 138 kPa (20 psi) in order to prevent damage to the hydraulic tank. This procedure will pull a vacuum on the hydraulic system.

Welding Procedure

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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.

All grease, water, paint, rust, dirt and scale must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Remove paint, rust, dirt, and scale with a wire brush or by buffing or grinding.

Remove any oil or grease that is on the machine with a Caterpillar approved solvent.

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Illustration 4	g01409057
The 141-1481 Shuttle Valve is removed in order to show the location of the bosses. (3) 141-1481 Shuttle Valve (BB) Upper hitch plate (CC) Frame support (A) 170 ± 2 mm (7 ± 0.08 inch) (B) 110 ± 2 mm (4 ± 0.08 inch) (C) 50.8 ± .5 mm (2 ± 0.02 inch) (10) Two 4E-3956 Bosses (W1) 3 mm (0.19 inch) fillet weld (2 Places)

1. Lay out dimension (A) 170 ± 2 mm (7 ± 0.08 inch) from the end of frame support (CC). Lay out dimension (B) 110 ± 2 mm (4 ± 0.08 inch) from the inside edge of the frame support (CC). Lay out dimension (C) 50.8 ± .5 mm (2 ± 0.02 inch) from the center of dimension (B). Center punch the intersection of each dimension in order to locate each boss. See illustration 4.

   Use a transfer punch with the same diameter as the internal diameter of the threaded hole in the 4E-3956 Boss (10) in order to center the bosses on the marked locations. The transfer punch helps to hold the boss in place for tack welding.

2. Locate a 4E-3956 Boss (10) to the frame. Insert the transfer punch into one of the 4E-3956 Bosses (10). Insert the tip of the transfer punch into the punch mark. Slide the 4E-3956 Boss (10) to the frame. Tack weld the boss in place. Ensure that the boss is square with the frame before any final welding is performed. Repeat this procedure for the second 4E-3956 Boss (10) .

3. Ensure that the threaded holes of the 4E-3956 Bosses (10) align with the 141-1481 Shuttle Valve (3) mounting holes.

4. Weld around the perimeter of each 4E-3956 Boss (10) with a 3 mm (0.12 inch) fillet weld.

5. Clean the area around the welds and paint the area in order to inhibit rust.

141-1481 Shuttle Valve and Hydraulic Hose Installation

Note: Put identification marks on all hydraulic lines for installation purposes. Plug all hydraulic lines in order to help prevent hydraulic fluid loss.

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Illustration 5	g01409714
(3) 141-1481 Shuttle Valve (9) 6V-8625 Elbow (8) 3J-1907 O-Ring Seal (11) 6V-9002 Elbow (13) 6V-8397 O-Ring Seal (14) 6V-8398 O-Ring Seal (17) 6V-8782 Tee (19) 7X-2534 Bolt (21) 3K-0360 O-Ring Seal (22) 9T-1013 Check Valve As (23) 9X-8256 Washer (27) 6V-8636 Connector (P1) Signal Port for Accumulator (P2) Pressure Port (P3) Tank Port (P4) Port for Lift Head End (P5) Signal Port for Accumulator

1. Install 9T-1013 Check Valve As (22) into port (P2) of the 141-1481 Shuttle Valve (3) .

   Torque the 9T-1013 Check Valve As (22) to 82 ± 2 N·m (61 ± 2 lb ft).

2. Install one 3K-0360 O-Ring Seal (21) and two 6V-8398 O-Ring Seal (14) onto the 6V-8782 Tee (17). Install the 6V-8782 Tee (17) into port (P5) of the 141-1481 Shuttle Valve (3) .

   See illustration 5 for the correct orientation of the 6V-8782 Tee (17) .

   Torque the 6V-8782 Tee (17) to 82 ± 8 N·m (60 ± 6 lb ft).

3. Install one 3J-1907 O-Ring Seal (8) and one 6V-8397 O-Ring Seal (13) on the 6V-8636 Connector (27). Install 6V-8636 Connector (27) into port (P1) .

   Torque the 6V-8636 Connector (27) to 48 ± 5 N·m (35 ± 4 lb ft).

4. Install one 3K-0360 O-Ring Seal (21) and one 6V-8398 O-Ring Seal (14) onto the 6V-8625 Elbow (9). Install the 6V-8625 Elbow (9) into port (P3) of the 141-1481 Shuttle Valve (3) .

   See illustration 5 for the correct orientation of the 6V-8625 Elbow (9) .

   Torque the 6V-8625 Elbow (9) to 82 ± 8 N·m (60 ± 6 lb ft).

5. Install one 3K-0360 O-Ring Seal (21) and one 6V-8398 O-Ring Seal (14) on the 6V-9002 Elbow (11). Install 6V-9002 Elbow (11) into port (P4) .

   See illustration 5 for the correct orientation of the 6V-9002 Elbow (11). Torque the 6V-9002 Elbow (11) to 82 ± 8 N·m (60 ± 6 lb ft).

6. Mount the 141-1481 Shuttle Valve (3) on the welded 4E-3956 Bosses (10) with two 7X-2534 Bolts (19) and two 9X-8256 Washers (23) .

   Torque the 7X-2534 Bolts (19) to 12 ± 3 N·m (106 ± 27 lb in).

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Illustration 6	g01409819
(2) 6V-8939 Reducer (14) 6V-8398 O-Ring Seal (16) 2M-9780 O-Ring Seal (18) 6V-9851 Elbow (20) 6V-8555 Face Seal Nut (24) 7J-9108 O-Ring Seal (26) 6V-8776 Face Seal Tee (C) 192-0086 Ride Control Valve Gp (P6) Accumulator Port

7. Disconnect all of the hoses from 192-0086 Ride Control Valve Gp (C) .

   Note: Mark the hoses and the hose locations for installation reference.

8. Remove 192-0086 Ride Control Valve Gp (C) from the machine.

   Note: Save the removed bolts for reinstallation.

9. Remove the existing 6V-8626 Elbow from port (P6) .

10. Install two 7J-9108 O-Ring Seals (24) and one 2M-9780 O-Ring Seal (16) on the 6V-8776 Face Seal Tee (26). Install 6V-8776 Face Seal Tee (26) into port (P6). See illustration 6 for the correct orientation of the 6V-8776 Face Seal Tee (26) .

    Torque 6V-8776 Face Seal Tee (26) to 140 ± 14 N·m (103 ± 10 lb ft).

11. Install one 6V-8398 O-Ring Seal (14) on the 6V-8939 Reducer (2). Install 6V-8555 Face Seal Nut (20) onto 6V-8939 Reducer (2) .

    Attach the 6V-8939 Reducer (2) to the 6V-8776 Face Seal Tee (26) with the 6V-8555 Face Seal Nut (20) .

    Torque 6V-8555 Face Seal Nut (20) to 40 ± 4 N·m (30 ± 3 lb ft).

12. Install one 6V-8398 O-Ring Seal (14) onto the 6V-9851 Elbow (18). Install 6V-9851 Elbow (18) onto 6V-8939 Reducer (2) .

    See illustration 6 for the correct orientation of the 6V-9851 Elbow (18) .

    Torque 6V-9851 Elbow (18) to 55 ± 5 N·m (41 ± 4 lb ft).

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Illustration 7	g01410310
Location of "LSP " Port (P7) "LSP " Port (C) 192-0086 Ride Control Valve Gp (D) Resolver Ball (E) Seat (8) 3J-1907 O-Ring Seal (28) 9S-8004 O-Ring Plug

13. Remove 6V-8636 Connector from the "LSP " Port (P7) on the 192-0086 Ride Control Valve Gp (C) .

14. Remove the Seat (E) and Resolver Ball (D) from the "LSP " Port (P7) .

    Install one 3J-1907 O-Ring Seal (8) on the 9S-8004 O-Ring Plug (28). Connect the 9S-8004 O-Ring Plug (28) to the "LSP " Port (P7) .

    Torque the 9S-8004 O-Ring Plug (28) to 48 ± 5 N·m (35 ± 4 lb ft).

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Illustration 8	g01410326
View looking to the rear of the machine. (C) 192-0086 Ride Control Valve Gp (4) 277-8241 Hose As (18) 6V-9851 Elbow (P6) Accumulator Port (H1) 204-6743 Hose As (H2) 226-0347 Tube As (H3) 213-6219 Hose As (H4) 213-6219 Hose As

15. Reinstall the 192-0086 Ride Control Valve Gp (C) onto the machine. Use the original mounting bolts for installation.

    Torque the bolts to 55 ± 10 N·m (41 ± 7 lb ft).

16. Reconnect the 204-6743 Hose As (H1) to the original location. Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. See illustration 8 for the correct hydraulic hose connections.

    Torque the 204-6743 Hose As (H1) to 40 ± 4 N·m (30 ± 3 lb ft) .

17. Reconnect the 226-0347 Tube As (H2) to the original location. Ensure that the O-ring face seal is in the O-ring seat before connecting the hydraulic tube. See illustration 8 for the correct hydraulic tube connections.

    Torque the 226-0347 Tube As (H2) to 86 ± 8 N·m (63 ± 6 lb ft).

18. Reconnect the 213-6219 Hose As (H3) for the lift head end to the original location. Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. See illustration 8 for the correct hydraulic hose connection.

    Torque the 213-6219 Hose As (H3) to 125 ± 15 N·m (92 ± 11 lb ft).

19. Reconnect the 213-6219 Hose As (H4) for the hydraulic hose for the rod end to the original location. Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. See illustration 8 for the correct hydraulic hose connections.

    Torque the 213-6219 Hose As (H4) to 125 ± 15 N·m (92 ± 11 lb ft).

20. Connect the 90° end of the 277-8241 Hose As (4) to the 6V-9851 Elbow (18) at port (P6). Ensure that the O-ring face seal is in the O-ring seat before connecting the hose.

    Torque the 277-8241 Hose As (4) to 55 ± 5 N·m (41 ± 4 lb ft).

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Illustration 9	g01410686
(1) 297-1861 Hose As (4) 277-8241 Hose As (5) 255-0639 Hose As (6) 254-4461 Hose As (7) 254-3349 Hose As (9) 6V-8625 Elbow (11) 6V-9002 Elbow (12) 6V-9837 Swivel Tee (14) 6V-8398 O-Ring Seal (17) 6V-8782 Tee (22) 9T-1013 Check Valve As (27) 6V-8636 Connector (30) 200-6345 Mount (31) 204-2281 Tie Strap (H6) 124-4844 Hose As (P1) Signal Port for Accumulator (P2) Pressure Port (P3) Tank Port (P4) Port for Lift Head End (P5) Signal Port for Accumulator (P8) Tank Port

21. Connect the straight end of the 277-8241 Hose As (4) to the 6V-8782 Tee (17) at port (P5). Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. Torque the straight end of the 277-8241 Hose As (4) to55 ± 5 N·m (41 ± 4 lb ft).

22. Connect the straight end of the 254-4461 Hose As (6) to the 6V-9002 Elbow (11) at port (P4). Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. Install the straight end of the 254-4461 Hose As (6) hand tight. See illustration 9 for the correct orientation.

    Note: The straight end of the 254-4461 Hose As (6) will be torqued after the 45° end of the hose is torqued.

23. Connect one end of the 254-3349 Hose As (7) to the 6V-8636 Connector (27) at port (P1). Install the opposite end of the 254-3349 Hose As (7) to the 6V-8782 Tee (17) at port (P5). Ensure that the O-ring face seals are in the O-ring seat before connecting the hose ends. See illustration 9 for the correct orientation.

    Torque the 254-3349 Hose As (7) at the 6V-8636 Connector (27) to 40 ± 4 N·m (30 ± 3 lb ft).

    Torque the 254-3349 Hose As (7) at the 6V-8782 Tee (17) to 55 ± 5 N·m (41 ± 4 lb ft).

24. Connect the 90° end of the 297-1861 Hose As (1) to the 9T-1013 Check Valve As (22) at port (P2). Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. See illustration 9 for the correct orientation of the 90° end of the 297-1861 Hose As (1) .

    Torque the 297-1861 Hose As (1) at the 9T-1013 Check Valve As (22) to 55 ± 5 N·m (41 ± 4 lb ft).

25. Install two 6V-8398 O-Ring Seals (14) on the 6V-9837 Swivel Tee (12). Install 6V-9837 Swivel Tee (12) on the connector at port (P8). See illustration 9 for the correct orientation of the 6V-9837 Swivel Tee (12) .

    Torque the 6V-9837 Swivel Tee (12) at port (P8) to 55 ± 5 N·m (41 ± 4 lb ft).

26. Connect the 90° end of the 124-4844 Hose As (H6) to the end of the 6V-9837 Swivel Tee (12) at port (P8). Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. See illustration 9 for the correct orientation of the 124-4844 Hose As (H6) .

    Torque the 90° end of the 124-4844 Hose As (H6) to 55 ± 5 N·m (41 ± 4 lb ft).

27. Connect the straight end of the 255-0639 Hose As (5) to the 6V-8625 Elbow (9) at port (P3). Connect the 90° end of the 255-0639 Hose As (5) to the 6V-9837 Swivel Tee (12). Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. See illustration 9 for the correct orientation of the hydraulic hose.

    Torque both ends of the 255-0639 Hose As (5) to 55 ± 5 N·m (41 ± 4 lb ft).

28. Secure the 255-0639 Hose As (5) and 297-1861 Hose As (1) together. Use two 204-2281 Tie Straps (31) and the 200-6345 Mount (30) in order to secure the hydraulic hoses. See illustration 9 for the correct location of the tie straps.

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Illustration 10	g01411036
(8) 3J-1907 O-Ring Seal (6) 254-4461 Hose As (13) 6V-8397 O-Ring Seal (15) 6V-8774 Tee (F) 112-1817 Manual Valve Gp (H7) 221-9774 Hose As

29. Locate the existing 112-1817 Manual Valve Gp (F). Remove the existing 221-9774 Hose As (H7) from the 112-1817 Manual Valve Gp (F) .

30. Remove existing 6V-8724 Elbow (Not Shown) from 112-1817 Manual Valve Gp (F) .

31. Install two 6V-8397 O-Ring Seals (13) and one 3J-1907 O-Ring Seal (8) on the 6V-8774 Tee (15). Connect the 6V-8774 Tee (15) to the existing 112-1817 Manual Valve Gp (F). See illustration 10 for the correct orientation of the 6V-8774 Tee (15) .

    Torque the 6V-8774 Tee (15) at the existing 112-1817 Manual Valve Gp (F) to 25 ± 3 N·m (18 ± 2 lb ft).

    Connect the existing 221-9774 Hose As (H7) to the end of 6V-8774 Tee (15). Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. See illustration 10 for the correct orientation of the hydraulic hose.

    Torque the 221-9774 Hose As (H7) at the 6V-8774 Tee (15) to 40 ± 4 N·m (30 ± 3 lb ft).

32. Connect the 45° end of the 254-4461 Hose As (6) (Not Shown) to the opposite side of the 6V-8774 Tee (15). Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. See illustration 10.

    Torque the 45° end of the 254-4461 Hose As (6) (Not Shown) at the 6V-8774 Tee (15) to 40 ± 4 N·m (30 ± 3 lb ft).

    Torque the straight end of the 254-4461 Hose As (6) (Not Shown) that was previously connected to the 141-1481 Shuttle Valve (3) in step 22 to 40 ± 4 N·m (30 ± 3 lb ft).

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Illustration 11	g01411170
View of existing connections and new connections for the return manifold (1) 297-1861 Hose As (8) 3J-1907 O-Ring Seal (14) 6V-8398 O-Ring Seal (18) 6V-9851 Elbow (25) 6V-9873 Connector (29) 081-5645 Tee (G) 209-0787 Manifold (H) 164-5567 Fitting As (Male Quick Disconnect)

33. Remove the existing 164-5567 Fitting As (Male Quick Disconnect) (H) from the 209-0787 Manifold (G) .

    Note: The 164-5567 Fitting As (Male Quick Disconnect) (H) will be reused.

34. Install one 3J-1907 O-Ring Seal (8) and one 6V-8398 O-Ring Seal (14) on the 6V-9873 Connector (25). Connect the 6V-9873 Connector (25) to the 209-0787 Manifold (G) .

    Torque the 6V-9873 Connector (25) to 55 ± 5 N·m (41 ± 4 lb ft).

35. Install one 6V-8398 O-Ring Seals (14) to the 081-5645 Tee (29). Connect the 081-5645 Tee (29) to the 6V-9873 Connector (25). See illustration 11 for the correct orientation of the 081-5645 Tee (29).

    Torque the 081-5645 Tee (29) to 55 ± 5 N·m (41 ± 4 lb ft).

36. Connect the 164-5567 Fitting As (Male Quick Disconnect) (H) that was removed in step 33 to the opposite end of the 081-5645 Tee (29). See illustration 11 for the correct orientation of the 164-5567 Fitting As (Male Quick Disconnect) (H) .

    Torque the 164-5567 Fitting As (Male Quick Disconnect) (H) to 48 ± 5 N·m (35 ± 4 lb ft).

37. Install one 6V-8398 O-Ring Seal (14) to 6V-9851 Elbow (18). Connect 6V-9851 Elbow (18) to the side of the 081-5645 Tee (29). See illustration 11 for the correct orientation of the 6V-9851 Elbow (18) .

    Torque the 6V-9851 Elbow (18) to 55 ± 5 N·m (41 ± 4 lb ft).

38. Connect the straight end of 297-1861 Hose As (1) to the 6V-9851 Elbow (18). Ensure that the O-ring face seal is in the O-ring seat before connecting the hose. See illustration 11 for the correct orientation of the hydraulic hose.

    Torque the straight end of the 297-1861 Hose As (1) at the 6V-9851 Elbow (18) to 55 ± 5 N·m (41 ± 4 lb ft).

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Illustration 12	g01411504
Top View Location of hydraulic hose clips (J) Front Hose Support (K) Rear Hose Support (L) Hydraulic Hose (1) 297-1861 Hose As (6) 254-4461 Hose As (33) 5I-3978 Clip (34) 6D-4246 Clip (35) 6V-9829 Cap As

39. Remove the bolt and the washer from front hose support (J). Route 297-1861 Hose As (1) through the 6D-4246 Clip (34). Place the 6D-4246 Clip (34) on the front hose support (J). Secure the 6D-4246 Clip (34) and front hose support (J) with the removed bolt.

    Torque the bolt to 55 ± 5 N·m (41 ± 4 lb ft).

40. Remove the bolt and the washer from rear hose support (K) .

    Note: Perform the following steps if the machine is equipped with a coupler lines group.

    1. Remove the hose clip that supports the coupler lines group at the rear hose support. Reinstall the clip on the hose so that the loop is facing downward.

    2. Install 7X-7729 Washer (36) under the existing clip.

41. Route the 254-4461 Hose As (6) with the 297-1861 Hose As (1) through the 5I-3978 Clip (33).

    Install the 5I-3978 Clip (33) to the rear hose support (K) with the removed bolt.

    Note: Install the 5I-3978 Clip on top of the hose clip for the coupler lines group, if the machine is equipped with a coupler lines group.

    Torque the bolt to 55 ± 5 N·m (41 ± 4 lb ft).

42. Disconnect hydraulic hose (L) from the Tee. Discard hydraulic hose (L).

    Hydraulic hose (L) was previously connected to the 6V-8636 Connector at the "LSP " Port (P7) on the 192-0086 Ride Control Valve Gp (C) .

43. Connect the 6V-9829 Cap As (35) in place of hydraulic hose (L) .

    Torque the 6V-9829 Cap As (35) to 40 ± 4 N·m (30 ± 3 lb ft).

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Illustration 13	g01411524
Use the illustration as a reference for the placement of the cable straps. (6) 254-4461 Hose As (32) 4K-8302 Clip (37) 7X-2543 Bolt (38) 8T-4133 Nut

44. Remove the existing bolt. Replace the existing bolt with 7X-2543 Bolt (37) .

45. Route the 254-4461 Hose As (6) through the 4K-8302 Clip (32) .

    Attach the 4K-8302 Clip (32) to the 7X-2543 Bolt (37) with the 8T-4133 Nut (38) .

    Torque the 8T-4133 Nut (38) to 55 ± 5 N·m (41 ± 4 lb ft).

46. Remove the 311-1362 Vacuum Gauge Gp (AA) from the hydraulic tank.

47. Install the hydraulic tank breather.

Checking the Functionality of the Ride Control

ReferenceDisassembly and Assembly, "Steering Frame Lock - Separate and Connect"

1. Disconnect the steering frame lock.

2. Start the machine in order to warm the hydraulic system.

3. Turn the ride control system On. Power down the loader bucket in order to raise the front of the machine off the ground.

   The front tires should drift back to the ground when the ride control is on.

4. Power down the loader bucket. Raise the front of the machine off the ground. Turn the ride control system Off.

   The front tires of the machine should stay elevated.