Installation Instructions for the 2Q-8564 Ride Control Gp (KIT){5004, 5004} Caterpillar

Wheel Loader:

980G Series II (S/N: AWH1-UP)

980H (S/N: A8J1-UP; KZL1-UP; JMS1-UP)

Introduction

This service publication contains the information that is needed in order to Charge the Accumulator. This service publication also contains the information that is needed in order to Configure the Software.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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NOTICE
Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

This supplemental product support literature should be used with the appropriate Service Manual that is available for the standard machine.

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.

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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 machine. Be prepared to collect the fluid with suitable containers before you open any compartment or disassemble 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.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Conversion of the Main Control Valve and Mounting Gp

Removal of the Standard Parts from the Valve and Mounting Gp of the Main Control Valve

Illustration 1	g01430769
Right side view of the Valve and Mounting Gp of the Main Control Valve

Illustration 2	g01430770
Section "C-C" from Illustration 1 (A) Tube Assembly (B) O-Ring Seal

1. Remove Tube Assembly (A) and O-Ring Seal (B) .

Illustration 3	g01430771
Section "A-A" from Illustration 1 (C) O-Ring Seal (D) Plug (E) Check Valve (F) Swivel Tee (G) Tube Assembly

1. Remove the following parts:
   • One O-Ring Seal (C)

   • One Plug (D)

   • Two Check Valves (E)

   • One Swivel Tee (F)

   • One Tube Assembly (G)

Installation of Conversion Kit onto the Valve and Mounting Gp

Illustration 4	g01430800
View of Valve and Mounting Gp

1. Use two 3J-1907 O-Ring Seals (1) in order to install two 162-0177 Plugs (2) .

2. Reuse the old O-Ring Seal and install the 201-8986 Tube As (4) .

3. Use the following parts and secure the 201-8986 Tube As (4) :
   • One 9X-2027 Washer (3)

   • One 1F-7567 Clip (5)

   • One 8T-4137 Bolt (6)

4. Remove the Quick Disconnect fitting (H). Retain the Quick Disconnect fitting (H) for later use.

5. Use a 3J-1907 O-Ring Seal (1) and install the 164-5546 Tee As (7) in place of the Quick Disconnect fitting (H) .

6. Use the original O-Ring Seal and install the Quick Disconnect fitting (H) into the 3E-7410 O-Ring Tee (7) .

7. Use a 3J-1907 O-Ring Seal (1) and install the 357-4372 Connector As (9) into the 3E-7410 O-Ring Tee (7) .

Installation of the 144-5728 Ride Control Lines Gp

Installation of the 115-9328 Diverter Valve (RIDE CONTROL)

Illustration 5	g03165877
Right side view and Top View of Diverter Valve

1. Use the following parts and mount the 115-9328 Diverter Valve (RIDE CONTROL) (12) onto the 124-4812 Bracket (18) :
   • One 128-2841 Cover (20)

   • One 4J-0520 O-Ring Seal (34)

   • Four 7X-0507 Hard Washers (59)

   • Four 8T-6466 Bolts (74)

2. Use the hardware and install the 115-9328 Diverter Valve (RIDE CONTROL) (12) and the 124-4812 Bracket (18) onto the front frame:
   • Two 8T-4133 Nuts (65)

   • Two 7X-7729 Washers (61)

   • One 8T-5005 Bolt (73)

   • One 8T-4121 Hard Washers (64)

Installation of the 141-1481 Shuttle Valve

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Illustration 6	g03170841
Rear view of Shuttle Valve

1. Use the following hardware and mount the 141-1481 Shuttle Valve (22) onto the 143-9100 Plate As (23) :
   • Two 9X-8256 Washers (14)

   • Two 7X-2535 Bolts (60)

   • Two 8T-4224 Hard Washers (72)

   • Two 198-4775 Hard Washers (79)

2. Use a 3K-0360 O-Ring Seal (33) and install a 8T-5879 Adapter (6) into the 141-1481 Shuttle Valve (22) .

3. The parts for this step are from the 357-4427 Elbow As . Use the 3J-1907 O-Ring Seal (31) and install the 6V-8627 Elbow (43) into the 8T-5879 Adapter (6). Save the 4J-5477 O-Ring Seal for later use.

4. The parts for this step are from the 357-4371 Connector As . Use the 3K-0360 O-Ring Seal (33) and install the 6V-8639 Connector (46) into the 141-1481 Shuttle Valve (22). Save the 6V-8398 O-Ring Seal for later use.

5. The parts for this step are from the 357-4540 Swivel Tee . Use the 6V-8398 O-Ring Seal (40) and install a 6V-9837 Swivel Tee (54) into the 6V-8639 Connector (46). Save the other 6V-8398 O-Ring Seal for later use.

6. The parts for this step are from the 357-4437 Elbow As . Use the 3K-0360 O-Ring Seal (33) and install the 6V-8625 Elbow (42) into the 141-1481 Shuttle Valve (22). Save the 6V-8398 O-Ring Seal for later use.

7. The parts for this step are from the 357-4460 Elbow As . Use the 6V-8398 O-Ring Seal (40) and install the 6V-9851 Elbow (56) into the 6V-8625 Connector (42) .

8. Use a 6V-8398 O-Ring Seal (40) and install the 207-1810 Check Valve Group (RIDE CONTROL) (10) into the 6V-8625 Connector (42).

9. The parts for this step are from the 357-4362 Connector As . Use the 3J-1907 O-Ring Seal (31) and install a 6V-8641 Connector (47) into the 141-1481 Shuttle Valve (22). Save the 4J-5477 O-Ring Seal for later use.

10. The parts for this step are from the 148-8436 Tee As . Use the 3K-0360 O-Ring Seal (33) and install the 6V-8775 Face Seal Tee (48) into the 141-1481 Shuttle Valve (22). Save the 6V-8398 O-Ring Seal for later use.

11. The parts for this step are from the 357-4460 Elbow As . Use the 6V-8398 O-Ring Seal (40) and install the 6V-9851 Elbow (56) into the 141-1481 Shuttle Valve (22) .

12. Install the 152-8340 Solenoid Valve Gp (RIDE CONTROL) (11) into the 7T-9745 Valve Manifold (4). Tighten the 152-8340 Solenoid Valve Gp (RIDE CONTROL) (11) to 108 ± 7 N·m (80 ± 5 lb ft). Secure with one 7K-1181 Cable Strap (80) .

13. The parts for this step are from the 357-4439 Elbow As . Use the 3J-1907 O-Ring Seal (31) and install the 8T-6876 Elbow (76) into the 7T-9745 Valve Manifold (4) .

14. The parts for this step are from the 357-4362 Connector As . Use the 3J-1907 O-Ring Seal (31) and install the 6V-8641 Connector (47) into the 7T-9745 Valve Manifold (4). Save the 4J-5477 O-Ring Seal for later use.

15. The parts for this step are from the 357-4439 Elbow As . Use the 3J-1907 O-Ring Seal (31) and install the 8T-6876 Elbow (76) into the 7T-9745 Valve Manifold (4). Save the 6V-8398 O-Ring Seal for later use.

16. Use the following hardware and loosely mount the 7T-9745 Valve Manifold (4) onto the 143-9100 Plate As (23) :
    • Four 8T-4224 Hard Washers (72)

    • Two 8T-6869 Bolts (75)

17. Use two 6V-8398 O-Ring Seals (40) and install the 143-9103 Tube As (25) .

18. Use a 4J-5477 O-Ring Seal (35) and install the 143-9107 Tube As (29). Use a 8M-2772 Clip (63) and secure the 143-9107 Tube As (29) .

19. Tighten the mounting hardware for the 7T-9745 Valve Manifold (4) .

20. Use two 4J-5477 O-Ring Seals (35) and install the 143-9105 Tube As (27) .

21. Use two 6V-8398 O-Ring Seals (40) and install the 143-9104 Tube As (26) .

22. Use the following hardware and install the 143-9100 Plate As (23) onto the front frame.
    • Two 8T-4121 Hard Washers (64)

    • Two 8T-4137 Bolts (67)

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Illustration 7	g03171540
Top view of front frame

23. Use a 3J-1907 O-Ring Seal (31) and install the 6V-8627 Elbow (43) into the 9J-3866 Adapter (7) .

24. Remove the four bolts (D) that hold the right-hand hose for the lift cylinder to the bulkhead. Use the following hardware and install the 9J-3866 Adapter (7) .
    • Four 8T-5005 Bolts (73)

    • One 4J-0520 O-Ring Seal (34)

25. Use a 4J-5477 O-Ring Seal (35) and connect the 143-9107 Tube As (29) that was previously installed onto the 6V-8627 Elbow (43) .

Installation of the Accumulator Gp

Illustration 8	g03171677
Right side view and Top View of Diverter Valve

1. Install a 153-6265 Connector (5) into the 325-7154 Ride Control Accumulator Gp (CHARGED) (21) .

2. The parts for this step are from the 357-4464 Elbow As . Use a 5K-9090 O-Ring Seal (36) and install a 6V-9854 Elbow (57) into the 8C-3323 Connector (5) .

3. Use the following hardware and install the 325-7154 Ride Control Accumulator Gp (CHARGED) (21) :
   • One 124-4814 Bracket As (19)

   • One 9U-3890 Plate (9)

   • Two 7X-7729 Washers (61)

   • Two 8T-4121 Hard Washers (64)

   • Two 8T-4133 Nuts (65)

   • Two 8T-4136 Bolts (66)

   • Two 8T-4192 Bolts (70)

   • Two 8T-4223 Hard Washers (71)

4. Install the 224-0672 Warning Plate (3) onto the front frame.

Installation of the Hydraulic Hoses

Illustration 9	g03171705
Right side view and top view of diverter valve

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Illustration 10	g03173016

1. The parts for this step are from the 357-4539 Tee As . Use the 6V-8397 O-Ring Seal (39) and install the 6V-9836 Swivel Tee (53) into the implement valve. Save the other 6V-8397 O-Ring Seal for later use.

2. The parts for this step are from the 357-4434 Elbow As . Use the 3J-7354 O-Ring Seal (32) and install the 6V-9200 Elbow (52) into the diverter valve. Save the 6V-8397 O-Ring Seal for later use.

3. Use a 6V-8397 O-Ring Seal (39) and connect the end of the 124-4144 Hose As (17) that has the straight fitting onto the 6V-9200 Elbow (52) .

4. Use a 6V-8397 O-Ring Seal (39) and connect the other end of the 124-4144 Hose As (17) onto the 6V-9836 Swivel Tee (53) .

5. The parts for this step are from the 357-4447 Elbow As . Use the 7M-8485 O-Ring Seal (58) and install the 6V-9005 Elbow (51) into the diverter valve. Save the 5K-9090 O-Ring Seal for later use.

6. Use a 4J-0520 O-Ring Seal (34) and connect the flange end of the 244-5924 Hose As (78) onto the implement valve.

7. Use a 5K-9090 O-Ring Seal (36) and connect the other end of the 244-5924 Hose As (78) onto the 6V-9005 Elbow (51) .

8. The parts for this step are from the 148-8369 Elbow As . Use the 3J-7354 O-Ring Seal (32) and install the 6V-8628 Elbow (44) into the diverter valve. Save the 4J-5477 O-Ring Seal for later use.

9. The parts for this step are from the 164-5598 Plug As . Use the 7M-8485 O-Ring Seal (58) and install the 8J-0426 Plug (62) into the diverter valve.

10. The parts for this step are from the 357-4427 Elbow As . Use the 3J-1907 O-Ring Seal (31) and install the 6V-8627 Elbow (43) into the 8J-0426 Plug (62). Save the 4J-5477 O-Ring Seal for later use.

11. Use two 4J-5477 O-Ring Seals (35) and install a 4E-3083 Tube As (2) .

12. The parts for this step are from the 357-4497 Elbow As . Use the 7M-8485 O-Ring Seal (58) and install the 6V-9005 Elbow (50) into the implement valve. Save the 5K-9090 O-Ring Seal for later use.

13. The parts for this step are from two 357-4381 Connector Assemblies . Use two 7M-8485 O-Ring Seals (58) and install two 6V-8635 Connectors (45) into the diverter valve. Save the two 5K-9090 O-Ring Seals for later use.

14. The parts for this step are from the 357-4543 Tee As . Use two 5K-9090 O-Ring Seals (36) and install two 6V-9840 Swivel Tees (55) into the 6V-8635 Connectors (45). Save the other two 5K-9090 O-Ring Seals for later use.

15. The parts for this step are from the 148-8412 Reducer As and from the 357-4543 Tee As . Use two 5K-9090 O-Ring Seals (36) and install two 6V-8944 Reducers (49) and two 9X-6579 Face Seal Nuts (41) onto the two 6V-9840 Swivel Tees (55). Save the 6V-8398 O-Ring Seals for later use.

16. Use two 5K-9090 O-Ring Seals (36) and connect the 164-7440 Hose As (30) between the 6V-9840 Swivel Tee (55) and the 6V-9005 Elbow (50) .

17. The parts for this step are from the 148-8407 Plug As . Use the 3J-1907 O-Ring Seal (31) and install the 9S-4191 Plug (77) into the diverter valve.

18. The parts for this step are from the 357-4447 Elbow As . Use the 7M-8485 O-Ring Seal (58) and install the 6V-9008 Elbow (51) into the diverter valve. Save the 5K-9090 O-Ring Seal for later use.

19. Use a 4J-0520 O-Ring Seal (34) and connect the flange end of the 244-5925 Hose As (15) onto the implement valve.

20. Use a 5K-9090 O-Ring Seal (36) and connect the other end of the 244-5925 Hose As (15) onto the 6V-9005 Elbow (51) .

21. Refer to View "H-H" in Illustration 10 for the flow direction of the valve. Use the 3J-1907 O-Ring Seal that is included in the 164-7474 Check Valve Group (8) and install the 164-7474 Check Valve Group (8) into the diverter valve.

22. The parts for this step are from the 357-4459 Elbow As . Use the 6V-8397 O-Ring Seal and install the 6V-9850 Elbow (69) into the top of the 164-7474 Check Valve Group (8) .

23. Use a 6V-8397 O-Ring Seal (39) and connect one end of the 144-8155 Hose As (16) onto the 6V-9850 Elbow (69) .

24. Use a 6V-8397 O-Ring Seal (39) and connect the other end of the 144-8155 Hose As (16) onto the tube on the implement valve.

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Illustration 11	g03173416
Left rear view of Diverter Valve

25. Use a 5K-9090 O-Ring Seal (36) and connect the 327-1069 Hose As (13) to the elbow on the bottom of the accumulator.

26. Use a 5K-9090 O-Ring Seal (36) and connect the 177-1061 Elbow As (38) to 327-1069 Hose As (13). Connect 177-1061 Elbow As (38) onto the 6V-9840 Swivel Tee (55) that is on the rear of the diverter valve.

27. Use a 6V-8398 O-Ring Seal (40) and connect the end of the 353-5449 Hose As (1) that has the straight fitting onto the 207-1810 Check Valve Group (10). Secure 353-5449 Hose As (1) with the following hardware:
    • One 8T-4121 Hard Washer

    • One 8T-4172 Bolt

    • One 6D-4244 Clip

    • One 4I-7889 Spacer

28. Use a 6V-8398 O-Ring Seal (40) and connect the other end of the 353-5449 Hose As (1) onto the 3E-7410 O-Ring Tee . Refer to item number "7" in Illustration 4.

29. Use a 6V-8398 O-Ring Seal (40) and connect the end of the 228-9003 Hose As (28) that has the straight fitting onto the 6V-9851 Elbow (56) .

30. Use a 6V-8398 O-Ring Seal (40) and connect the other end of the 228-9003 Hose As (28) onto the 6V-8775 Tee (48) that is on the rear of the diverter valve.

31. Use a 6V-8398 O-Ring Seal (40) and connect the end of the 164-7005 Hose As (24) that has the straight fitting onto the 6V-9837 Swivel Tee (54) .

32. Use a 6V-8398 O-Ring Seal (40) and connect the other end of the 164-7005 Hose As (24) onto the 6V-8944 O-Ring Reducer (49) that is on the rear of the diverter valve.

Installation of the 123-8944 Ride Control Wiring Gp

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Illustration 12	g03155657
View of Ride Control Wiring Gp

1. Use the following hardware and install the 228-5071 Ride Control Harness As (2) :
   • One 7K-1181 Cable Straps (1)

   • Two 130-5301 Clip (4)

   • One 5P-9085 Clip (5)

2. Use the following hardware and install the 231-5130 Ride Control Harness As (3) :
   • Four 7K-1181 Cable Straps (1)

Installation of the 197-4147 Ride Control Switch

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Illustration 13	g01114548
View of Overhead Console

1. Remove the 3E-0109 Plug (ROCKER SWITCH) (1) .

2. Connect the 219-9531 Rocker Switch (1) to the Cab Harness and mount the switch into the Overhead Console.

Accumulator Charging

1. Refer to Testing and Adjusting, RENR6018, "Ride Control Accumulator - Test and Charge" and charge the Ride Control Accumulator .

Software Configuration

Note: This group is a configurable feature that must be activated with PSPS or a service tool.

1. Use a Caterpillar Electronic Technician and select the proper Electronic Control Module.

2. Select "SERVICE" from the menu.

3. Select "CONFIGURATION" from the menu.

4. Double click on the desired feature on the Configuration screen.

5. Select the desired status of the feature and click "OK".

Note: The feature will be activated on the next power cycle.