Installation of the Two-Way Pilot Valve (Control Pattern Change) {5059, 5496} Caterpillar

Excavator:

330B L (PIN: 6DR; 8TR)

Introduction

This Special Instruction outlines the basic steps and parts in order to install a two-way pilot valve. Installation of a two-way pilot valve allows the operator to change the machine control pattern. The operator has a choice of two patterns: Caterpillar SAE and the standard backhoe loader hydraulic system (BHL).

The adaptability of the two-way pilot valve will enable the operator to be more productive with the 330B L Excavators.

Do not carry out any of the installation procedures until you have read the information in this publication.

Also refer to the appropriate Parts Manual, Operation and Maintenance Manual, and Service Manual for your machine.

Required Parts

For parts identification and ordering parts, refer to Table 1.

Note: See Tables 5 and 6 for more parts information.

Release of Pressure in the Hydraulic System

1. Park the excavator on level ground in order to place the machine in the servicing position.

Show/hide table



Illustration 1	g00100836
Before servicing, put the machine in the servicing position.

Show/hide table

Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted. When possible, the bucket must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and bucket have correct support. The swing lock (if equipped) must be engaged before service is started. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

2. The servicing position is attained by lowering the boom until the bucket is flat on the ground. The stick should be in the vertical position when the bucket is flat on the ground. Refer to Illustration 1.

3. Shut off the engine.

4. Move the control levers for the boom, the stick, the bucket, swing operation, and the left and right travel to the full stroke positions. This movement will release any actuator pressure in the hydraulic lines.

5. Move the hydraulic activation control lever to the UNLOCK position. This will release any pressure in the pilot system.

6. Slowly loosen the fill/vent plug on the hydraulic tank in order to release the pressure in the tank.

Installing the Two-Way Pilot Valve

Show/hide table



Illustration 2	g00363995
(A) Main control valve (B) Upper frame assembly (C) Flow control valve (bR3) Port on main control valve (1) Support assembly (4) Two-way pilot valve (6) Hose (7) Hose (8) Hose (11) Hose (17) Band (18) Band (19) Band (20) Band

1. Locate the main control valve (A). Find the plate (D) which supports the hydraulic pilot lines under the cab. Refer to Illustrations 2 and 3 and Table 1 for parts identification.

Show/hide table



Illustration 3	g00363996
This is the hydraulic lines group for the two-way pilot valve. For identification of numbered parts, refer to Table 1. (A) Main control valve. (B) The left side of the upper frame assembly. (C) Flow control valve. (D) Support under the cab.

2. Install the support assembly (1) by fastening two bolts (2) and two washers (3) through the support assembly and into the left upper frame assembly (B). Refer to Illustration 3 for installation information.

3. Install the two-way pilot valve (4) to the support assembly (1). Fasten four bolts (5) and four washers (3) through the support assembly and into the back of the two-way pilot valve. Refer to Illustration 3.

Show/hide table



Illustration 4	g00360394
This is the main control valve. Ports on the main control valve are numbered: (E) bL4, (F) bL3, (G) bR2, (H) bR3, (J) aR4, (K) aL3, (L) aR2 and (M) aR3.

Show/hide table



Illustration 5	g00360395
This is the top view of the two-way pilot valve. The bolt (N) secures the lever (P) after a selection has been made. The operator has a choice of two separate machine control patterns: Caterpillar SAE and the standard backhoe loader hydraulic system (BHL).

Show/hide table



Illustration 6	g00349953
Port locations on the two-way pilot valve.

4. Loosen the bolt (N) on top of the two-way pilot valve. Turn the bolt counterclockwise in order to loosen. Refer to Illustration 5.

5. Move the lever (P) in Illustration 5 to the SAE position.

6. In order to secure the lever in the SAE position, tighten the bolt in Illustration 5 by turning the bolt clockwise.

Show/hide table

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

7. Remove the three existing hoses which connect the flow control valve (C) to the support under the cab (D) .

8. Disconnect the hose with the blue colored band from port bR3 on the main control valve. Disconnect this hose from the support under the cab. Refer to Illustration 4 for the port location.

9. Install three new hoses from the flow control valve to the two-way pilot valve. Refer to Table 2 and Illustrations 3 and 6 for routing information.

10. Install a new hose (6) from port bR3 on the main control valve to the two-way pilot valve. Refer to Table 2 and Illustrations 3 and 6 for routing information.
    Show/hide table

    Table 2

    Hose Routing from the Main Control Valve via the Flow Control Valve to the Two-Way Pilot Valve
    Main Control Valve	Function	Band			Flow Control Valve		Item Number of the Hose	Port on Two-Way Pilot Valve
    Port		Number	Color	Item Number	Port
    aR4	boom raise	R1	orange	19	3	C	11	A
    bL4	boom down	R3	green	20	2	B	8	B
    aR3	stick out	L1	red	17	1	A	7	D
    bR3	stick in	L3	blue	18			6	C

    Note: Hose fittings should be tightened to a torque of 40 ± 5 N·m (29.5 ± 3.7 lb ft).

11. Install four new hoses from the two-way pilot valve to the support under the cab. Refer to Table 3 and Illustrations 3 and 6 for routing information.
    Show/hide table

    Table 3

    Hose Routing from the Two-Way Pilot Valve to the Support under the Cab
    Port on Two-Way Pilot Valve	Band			Item Number of the Hose	Color of Hose under the Cab
    	Number	Color	Item Number
    1	R1	orange	19	9	orange
    2	R3	green	20	9	green
    4	L1	red	17	9	red
    3	L3	blue	18	10	blue

    Note: Hose fittings should be tightened to a torque of 40 ± 5 N·m (29.5 ± 3.7 lb ft).

12. Check the hoses from the support under the cab to the control levers. The hoses must match with the hoses from the two-way pilot valve and the main control valve. Refer to Table 4 for correct hose connections.
    Show/hide table

    Table 4

    Hose Routing to the Control Levers from the Support under the Cab
    Hoses from the Two-Way Valve		Band		Control Lever
    Item Number of Hose	Color of Band	Number	Color
    9	orange	R1	orange	JR1
    9	green	R3	green	JR3
    9	red	L1	red	JL1
    10	blue	L3	blue	JL3

13. Strap the hoses together with the six straps (21). Avoid damage to the hoses by positioning the straps so that no sharp edges come in contact with the hoses. Make sure that the hose assemblies are not twisted or strained.

14. Fill the hydraulic oil tank with hydraulic oil according to the Operation and Maintenance Manual for your machine.

15. Tighten the fill/vent plug on the hydraulic tank.

16. Start the engine at low idle. Purge the hydraulic lines during each movement of the control levers. The checking procedure confirms correct machine movements for the SAE pattern.

17. Place the machine in the servicing position. Shut off the engine.

Show/hide table

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.

18. Check the hydraulic lines and fittings for leaks and torque. Hose fittings should be tightened to a torque of 40 ± 5 N·m (29.5 ± 3.7 lb ft).

19. Restart the engine. Raise engine speed up to normal speed. There should be no delay of response time when the control levers are operated.

20. Put the excavator in the servicing position. Shut off the engine.

21. Maintain the hydraulic oil level between the marks on the sight gauge in the appropriate temperature range. Refer to the section on the hydraulic oil tank in your Operation and Maintenance Manual.

22. The following procedures must be repeated when you select the BHL machine control pattern: ""Release of Pressure in the Hydraulic System" ", and Steps 4, 5, 6, 19 and 23.

Show/hide table



Illustration 7	g00355796
This is the correct placement for the instruction plates and the warning films. Refer to Tables 5 and 6 for part numbers before ordering.

Show/hide table

CHECK MACHINE CONTROL PATTERN FOR CONFORMANCE TO PATTERN ON CARD IN CAB. IF NOT, CHANGE CARD TO MATCH PATTERN BEFORE OPERATING MACHINE. FAILURE TO DO SO COULD RESULT IN INJURY.

23. Select the instruction film that matches the machine control pattern which is chosen. The instruction film must be installed on the outside of the cab. The correct instruction plate must also be installed in the cab. Refer to Illustration 7 for correct placement of the instruction plate and warning and instruction films.

24. See Table 5 for ordering the required warning and instruction films and the instruction plate.
    Show/hide table

    Table 5

    Required Parts
    Item Number	Quantity	Part Number	Description
    22	1	4I-2885	Case
    23	1	7I-0455	Warning Film
    24	1	7I-0456	Instruction Film
    25	1	7I-0719	Instruction Plate
    26	1	7I-1549	Warning Film

    Note: The case (22) in Table 5 uses adhesive backing to adhere to the cab window. The instruction plate is stored in this case. Display the surface of the instruction plate which matches the machine control pattern.

25. Match warning and instruction films with the operator's language. The films are printed in other languages. Refer to Table 6 for related part numbers.
    Show/hide table

    Table 6

    Warning and Instruction Film in Other Languages
    Language	Related Part Numbers
    	Warning Film		Instruction Film
    English	7I-0455	7I-1549	7I-0456
    French	7I-0459	7I-1550	7I-0460
    Spanish	7I-0461	7I-1551	7I-0462
    German	7I-0463	7I-1552	7I-0464
    Italian	7I-0465	7I-1553	7I-0466
    Portuguese	7I-0467	7I-1554	7I-0468
    Dutch	7I-0471	7I-1555	7I-0472
    Greek	7I-0473	7I-1556	7I-0474
    Danish	7I-0475	7I-1557	7I-0476

Machine Control Patterns

A machine control pattern is selected by repositioning the lever on top of the two-way pilot valve. See Illustration 5 and Step 22 in ""Installing the Two-Way Pilot Valve" " for correct changing procedures.

Use the following icons to learn the corresponding machine movements in Illustration 8. Each machine control pattern has specific movements.

Stick Out (1) - Move the control lever to this position in order to move the stick outward.

Swing Right (2) - Move the control lever to this position in order to turn the upper structure to the right.

Stick In (3) - Move the control lever to this position in order to move the stick inward.

Swing Left (4) - Move the control lever to this position in order to turn the upper structure to the left.

Boom Lower (5) - Move the control lever to this position in order to lower the boom.

Bucket Dump (6) - Move the control lever to this position in order to dump the bucket.

Boom Raise (7) - Move the control lever to this position in order to raise the boom.

Bucket Close (8) - Move the control lever to this position in order to close the bucket.

HOLD (9) will stop the movements of the stick, the boom, the bucket, and the upper structure.

Two incorporated functions may be performed at the same time by moving the appropriate control lever diagonally.

If the machine is equipped with a hydraulic hammer, the functions of positions (6) and (8) are distinct.

Hydraulic Hammer Raise (6) allows you to raise the hydraulic hammer.

Hydraulic Hammer Lower (8) allows you to lower the hydraulic hammer.

The two machine control patterns are shown in Illustration 8.

Illustration 8	g00101291
The machine control patterns in the left and right columns correspond to the left and right control levers: (A) SAE machine control pattern and (B) standard backhoe (BHL).