Installation of the 522-3935 SATCO Standby Kit on the 538 GF Forest Machine {5069, 5117} Caterpillar

Forest Machine

538 (S/N: GMY1-UP)

Harvester Head

SAT318 (S/N: HH31-UP)

SAT323 (S/N: SHE1-UP)

Introduction

This Special Instruction is for the installation of the 522-3935 SATCO Standby Kit. Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. If you need more information about the installation of the Standby Kit on your machine, consult your Caterpillar dealer.

Safety Section

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from sudden work tool movement. Sudden movement of the work tool can cause injury to persons near the work tool. To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool.

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Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

Illustration 1	g00104545

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillardealer.

Required Parts

Illustration 2	g06146372
Overall Kit (4) Cable Straps (11) Hose Assembly (12) Hose Assembly (13) Hose Assembly (14) Hose Assembly (19) O-Ring Seal (22) O-Ring Seal (26) Tee (29) Adapter

Illustration 3	g06146426
Close-up of Area "A" (1) Fitting (2) Union (5) Check Valve Group (6) Needle Valve (7) Fitting Assembly (8) Adapter (17) Rectangular Seal (19) O-Ring Seal (21) Coupling (22) O-Ring Seal (24) Connector (25) Tee (30) Bolt

Illustration 4	g06146448
Close-up of Area "B" (3) Elbow (9) Test Manifold Block (10) Plate (15) Valve Group, 50 ± 5 N·m (37 ± 3.7 lb ft) (16) Tee (18) Nut (19) O-Ring Seal (20) Rectangular Seal (22) O-Ring Seal (23) Connector (27) Bolt (28) Connector (31) Tee (32) Washer

Installation Procedure

Note: Plug all hose assemblies. This action helps prevent fluid loss, and helps keep contaminants from entering the system.

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Illustration 5	g06146426
Close-up of Area "A" (1) Fitting (2) Union (5) Check Valve Group (6) Needle Valve (7) Fitting Assembly (8) Adapter (17) Rectangular Seal (19) O-Ring Seal (21) Coupling (22) O-Ring Seal (24) Connector (25) Tee (30) Bolt

1. Assemble the group of components in Area"A"as illustrated above.
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   Illustration 6	g06146448
   Close-up of Area "B" (3) Elbow (9) Body (10) Plate (15) Relief Valve (16) Tee (18) Nut (19) O-Ring Seal (20) O-Ring Seal (22) O-Ring Seal (23) O-Ring Seal (27) Bolt (28) O-Ring Seal (31) Tee (32) Washer

2. Assemble the group of components in Area"B" as illustrated above. Tighten valve group (15) to a torque of 50 ± 5 N·m (37 ± 3.7 lb ft).
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   Illustration 7	g06146797
   Top of machine (A) Rubber Sheet (B) Enclosure Arrangement

3. Remove rubber sheet (A) for access.

4. Remove enclosure arrangement (B) for access.
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   Illustration 8	g06146802
   Inside swing compartment (C) Bolt (D) Washer (E) Spacer (F) Clip (G) Cable strap (H) Harness Assembly

5. Remove bolts (C) and washers (D) from the right support. Place these parts aside for future use.

   Note: A spacer (E) for each bolt (C) is on the outboard side of the right support, between the support and the machine frame. The clamping force of the other mounting hardware for the right support may not retain the spacers when bolts (C) are removed. Make sure to catch the spacers when the bolts are removed, if necessary.

6. Cut cable strap (G), and place clip (F) aside for future use. Move harness assembly (H) out of the way.
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   Illustration 9	g06146807
   Inside swing compartment (C) Bolt (D) Washer (E) Spacer (F) Clip (G) Cable Strap (H) Harness Assembly (10) Plate

7. Position plate (10). Install bolt (C), washer (D), and spacer (E), if necessary, in the top hole.

8. Position clip (F). Install bolt (C), washer (D), and spacer (E), if necessary, in the bottom hole.

9. Secure harness assembly (H) to clip (F) with a cable strap.
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   Illustration 10	g06146748
   Inside swing compartment (J) Bolts (K) Washers (L) Split Flange (M) Hose Assembly

10. Remove four bolts (J) and washers (K). Remove both halves of split flange (L). Save the washers and the split flange for future use.

11. Move hose assembly (M) out of the way. Inspect the rectangular seal in the flange coupling of the hose assembly. Replace the rectangular seal if the seal is damaged.
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    Illustration 11	g06146812
    Inside swing compartment (K) Washer (L) Split flange (M) Hose Assembly (8) Adapter (30) Bolt

12. Position adapter (8) and the bottom half of split flange (L).

13. Position hose assembly (M) and the top half of split flange (L).

14. Install four bolts (30) and washers (K).
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    Illustration 12	g06146820
    Inside swing compartment (13) Hose Assembly (16) Tee (24) Connector

15. Connect the 90-degree coupling of hose assembly (13) to connector (24) as illustrated above.

16. Connect the straight coupling of hose assembly (13) to Tee (16) as illustrated above.
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    Illustration 13	g06146824
    Inside swing compartment (3) Elbow (5) Check Valve Group (11) Hose Assembly

17. Connect the 45-degree coupling of hose assembly (11) to check valve group (5) as illustrated above.

18. Connect the straight coupling of hose assembly (11) to elbow (3) as illustrated above.
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    Illustration 14	g06146829
    General hose routing from Area "C" through Area"G" (C) Area "C" (D) Area "D" (E) Area "E" (F) Area "F" (G) Area "G" (12) Hose Assembly (14) Hose Assembly

19. The above illustration shows the general routing for hose assembly (12) and hose assembly (14). Hose assembly (12) is routed between the swing compartment (Area"C") and the pilot valve (Area"G"). Hose assembly (14) is routed between the swing compartment (Area"C") and the pump compartment (Area"F").
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    Illustration 15	g06146883
    Area "D", inside swing compartment (4) Cable Straps (12) Hose Assembly (14) Hose Assembly

20. Route hose assembly (12) and hose assembly (14) as illustrated above. The 45-degree fitting on hose assembly (12) must be toward the front of the machine.

21. Install three cable straps (4) as illustrated above. Leave the cable straps loose to allow movement of the hoses.
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    Illustration 16	g06146891
    Area "C", inside swing compartment (12) Hose Assembly (14) Hose Assembly (16) Tee (31) Tee

22. Connect the 45-degree fitting on hose assembly (12) to Tee (31) as illustrated above.

23. Connect hose assembly (14) to Tee (16) as illustrated above.

24. Remove the slack from the hose routing, and tighten three cable straps (4).

    Note: Refer to Step 21 for location of the cable straps.

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    Illustration 17	g06146895
    Under rear of machine (N) Cover plate

25. Remove bottom cover plate (N).
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    Illustration 18	g06146897
    Area "E", under rear of machine (4) Cable Straps (12) Hose Assembly (14) Hose Assembly

26. Route hose assembly (12) and hose assembly (14) as illustrated above.

27. Install two cable straps (4) as illustrated above.
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    Illustration 19	g06146898
    Area "G", under rear of machine (12) Hose Assembly (P) Pilot Valve Assembly

28. Route hose assembly (12) to port "PSA2" of pilot valve assembly (P) as illustrated above.
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    Illustration 20	g06146786
    Under rear of machine (R) Connector (S) Hose Assembly

29. Disconnect hose assembly (S) from connector (R). Remove the connector from the pilot manifold.
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    Illustration 21	g06146900
    Under rear of machine (12) Hose Assembly (19) O-Ring Seal (22) O-Ring Seals (26) Tee (S) Hose Assembly

30. Install O-ring seal (19) and two O-ring seals (22) on Tee (26), and install the Tee as illustrated above.

31. Connect hose assembly (12) to Tee (26) as illustrated above.

32. Connect hose assembly (S) to Tee (26) as illustrated above.
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    Illustration 22	g06146901
    Under rear of machine (14) Hose Assembly

33. Route hose assembly (14) into the pump compartment as illustrated above.
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    Illustration 23	g06146903
    Right side of machine (T) Pump Compartment Door

34. Open pump compartment door (T). Install the door prop.
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    Illustration 24	g06146904
    Area "F", front of pump compartment (14) Hose Assembly (U) Hose Assembly

35. Route hose assembly (14) as illustrated above.

36. Disconnect hose assembly (U).
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    Illustration 25	g06146906
    Front of pump compartment (14) Hose Assembly (19) O-Ring Seal (22) O-Ring Seal (26) Tee (29) Adapter (U) Hose Assembly

37. Install O-ring seal (19) on adapter (29), and install the adapter as illustrated above.

38. Install O-ring seal (19) and two O-ring seals (22) on Tee (26), and connect the Tee to adapter (29) as illustrated above.

39. Connect hose assembly (14) to Tee (26) as illustrated above.

40. Connect hose assembly (U) to Tee (26) as illustrated above.
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    Illustration 26	g00687600

41. Check for leaks.

42. Close pump compartment door (T).

43. Replace bottom cover (N).

44. Replace rubber sheet (A).

45. Replace enclosure arrangement (B).