Installation Procedure for the 422-3309 Valve Kit (High Flow) {5070} Caterpillar

Compact Track Loader

259D (S/N: LW51-UP; FTK1-UP; GTK1-UP; FTL1-UP)

Multi Terrain Loader

257D (S/N: EML1-UP; FMR1-UP; D5T1-UP; EZW1-UP)

Skid Steer Loader

236D (S/N: K2D1-UP; SEN1-UP; MPW1-UP; BGZ1-UP)

242D (S/N: HFB1-UP; DML1-UP; DZT1-UP; A9W1-UP)

Introduction

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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 Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

The following Special Instruction details the installation procedure for the 422-3309 Valve Kit (High Flow).

Note: If machine is currently equipped with a two-button only Right-Hand Joystick, the customer would need to purchase the two-button and thumb roller 379-1613 Joystick Control Gp (Right-Hand) separately as a serviceable part. This 379-1613 Joystick Control Gp (Right-Hand) will allow the customer to control the flow of operation of the machine with the thumb roller proportional feature.

Reference: Refer to Special Instruction, REHS8704 for instructions on installing the Right-Hand Joystick.

Removal Procedure of the Standard Flow Pump

1. Raise the cab. Lock the cab into the upright position.

   Reference: Refer to the Operations and Maintenance Manual for further instruction.

   Note: The Machine must remain off during this entire procedure.

2. Drain the fluid tank in order to avoid spills or injuries.

3. Remove the 373-8426 Gear Pump Gp (Standard Flow).
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   Illustration 1	g03425436

   1. Remove the 345-5726 Hose As and the 148-8347 Elbow As from the right-hand side of the pump. Discard removed components.
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   Illustration 2	g03425472

4. Disconnect the 388-8050 Hose As and the 148-8390 Elbow Gp in front of the Pump. Retain these components for reinstallation later in this procedure.

   Note: If the machine is equipped with ride control, remove the 345-5786 Hose As and the 148-8390 Elbow Gp in front of the pump. Retain these components for reinstallation later in this procedure.

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   Illustration 3	g03425477

5. Remove the 343-6821 Clamps from both sides of the 435-8881 Hose.

6. Remove the 435-8881 Hose and discard all of these components.
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   Illustration 4	g03466817

7. Remove the 423-0437 Adapter As by removing the 8T-4121 Hard Washers and 8T-4195 Bolts. Retain the 423-0437 Adapter As for reinstallation.
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   Illustration 5	g03467002

8. Remove the 8T-4956 Bolts and the 8T-4223 Hard Washers that attach the 373-8426 Gear Pump Gp (Standard Flow) to the 258-2405 Piston Pump Gp (HYDROSTATIC).

9. Remove the 373-8426 Gear Pump Gp (Standard Flow) and discard.

Installation of the New High Flow Pump Group

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Illustration 6	g03426020

1. Install the 8T-5049 O-Ring Seal onto the face of the implement pump that connects to the hydrostatic pump.

2. Install the 5P-3863 O-Ring Seal onto the face of the Implement Pump that connects to the Charge Pump.

   Note: Steps 1 and 2 must be completed before further installation.

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   Illustration 7	g03425942

3. Mount the 358-5002 Piston Pump Gp onto the 258-2405 Piston Pump Gp (HYDROSTATIC). Use the 8T-4956 Bolts and the 8T-4223 Hard Washers to mount the pumps together.

4. Verify that Pressure Port B and the Case Drain Port L2 on the Implement Pump face the right-hand side of the Machine. Verify that the Deutsch Connector faces the bottom of the Machine.
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   Illustration 8	g03426041

5. Mount the 258-2555 Gear Pump Gp (HIGH FLOW) onto the implement pump. Use the two 101-7404 Bolts and two 8T-4121 Hard Washers. Verify that the Pressure Port B on the Pump faces the right-hand side of the Machine.
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   Illustration 9	g03426047

6. Reinstall the 423-0437 Adapter As onto the Left-Hand side of the High Flow Pump using the provided 8T-4195 Bolts and 8T-4121 Hard Washers.
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   Illustration 10	g03426091

7. Install the 435-8880 Hose with the widest end of the hose installed on the strainer port on the hydraulic tank and the other end installed on the adapter.
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   Illustration 11	g03426118

8. Secure the hose to the strainer port on the hydraulic tank using the 343-6821 Band Clamp. Secure the hose to the adapter using a 347-4163 Band Clamp. Tighten both clamps to 7.5 ± 1 N·m (66 ± 9 lb in). Cap both clamps with a 323-3308 Cap after tightening.
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   Illustration 12	g03426136

9. Reinstall the 388-8050 Hose As and the 148-8390 Elbow Gp onto Port B on the Charge Pump.

   Note: If the Machine is equipped with ride control, reinstall the 345-5786 Hose As and the 148-8390 Elbow Gp onto "Port B" on the pump.

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   Illustration 13	g03426156

10. Install the 385-5779 Flange onto Port B of the implement pump. Use four 8T-6466 Bolts and four 8T-4121 Hard Washers to attach the flange to the pump.
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    Illustration 14	g03426164

11. Connect the 345-4835 Hose As containing the 6V-9972 Permanent Coupling As onto the flange installed in Step 10.

12. Connect the 6V-9969 Permanent Coupling As from the hose to the 148-8347 Elbow As located on the lower port of the implement valve. This location is nearest to the left-hand side of the machine.

High Flow Harness Connection Procedure

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Illustration 15	g03426218

1. Remove the 378-1029 Front Harness As connected to the implement valve. Discard the harness.
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   Illustration 16	g03615060

2. Install the 378-1030 Solenoid Harness As onto the implement valve.
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   Illustration 17	g03426261

3. Route the harness down towards the tubes from the tilt lines group in front of the firewall.
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   Illustration 18	g03426320

4. Continue routing the harness along the 345-4835 Hose As so the harness reaches towards the bottom of the high flow pump.
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   Illustration 19	g03426326

5. Plug the PV-C2 connector onto the deutsch connector Port on the pump.

   Note: Verify that the connections correspond to the ones shown on Table 2 below.

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   Table 2

   High Flow Wire Harness
   Connectors On Harness As.	Wire Number	Wire Color and Gauge	Position	Connects To
   PV-C3	P978-PV5	GREEN-18	1	AUX A (3A)
   	H802-PV23	GRAY-18	2
   PV-C4	P979-PV6	YELLOW-18	1	AUX B (3B)
   	H802-PV39	GRAY-18	2
   PV-C5	P831-PV3	BROWN-18	1	LIFT HE-WORK PORT (RAISE) (2A)
   	H803-PV18	BLUE-18	2
   PV-C6	P832-PV4	WHITE-18	1	LIFT RE-WORK PORT (LOWER) (2B)
   	H803-PV20	BLUE-18	2
   PV-C7	P845-PV9	WHITE-18	1	TILT RE-WORK PORT (RACK) (1A)
   	H803-PV19	BLUE-18	2
   PV-C8	P846-PV10	PINK-18	1	TILT HE-WORK PORT (DUMP) (1B)
   	H803-PV32	BLUE-18	2
   PV-C2	A588-PV1	BLUE-18	1	PORT ON HIGH FLOW PUMP
   	200-PV2	BLACK-18	2

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   Illustration 20	g03426328

6. Mount the 4P-8134 Clip onto the existing bracket on the firewall. Attach the ladder clip to the bracket by using the existing bolt that is used to support the Bracket.
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   Illustration 21	g03426583

7. Plug the 344-1678 Connector Plug As from the harness assembly onto the 344-1653 Receptacle As from the rear cab harness assembly. Secure this connection with one 7K-1181 Cable Strap.

   Note: Verify that the connections match the connections shown in Table 3.

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   Table 3

   Control Valve to Cab Harness
   IMPLEMENT VALVE HARNESS (PV-C1)		Position	CAB HARNESS (C-C3)
   Wire Number	Wire Color and Gauge		Wire Number	Wire Color and Gauge
   A588-PV1	BLUE-18	1	A588-C110	GREEN-18
   200-PV2	BLACK-18	2	200-C33	BLACK-18
   P831-PV3	BROWN-18	3	P831-C14	BROWN-18
   P832-PV4	WHITE-18	4	P832-C15	WHITE-18
   P978-PV5	GREEN-18	5	P978-C22	GREEN-18
   P979-PV6	YELLOW-18	6	P979-C23	YELLOW-18
   H802-PV7	GRAY-16	7	H802-C137	GRAY-18
   H803-PV8	BLUE-14	8	H803-C17	BLUE-16
   H845-PV9	WHITE-18	9	H845-C12	WHITE-18
   H846-PV10	PINK-18	10	H846-C13	PINK-18

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   Illustration 22	g03426588

8. Continue strapping the pump harness onto the rear cab harness using one 7K-1181 Cable Strap. Strap the harness to the added ladder clip using 3S-2093 Cable Strap.
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   Illustration 23	g03426633

9. Use one 3S-2093 Cable Strap to attach the harness to the lower tube assembly from the tilt lines group.
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   Illustration 24	g03426642

10. Continue strapping the harness onto the top portion of the previously installed 345-4835 Hose As with one 7K-1181 Cable Strap. Also strap the harness onto the end of the hose with one 3S-2093 Cable Strap.
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    Illustration 25	g03426688

11. Finish by attaching the harness to the fitting on the 345-4835 Hose As that is connected to the implement pump.

Installation of Relay

1. Remove the 345-6144 Cover As from the rear liner on the right-hand side of the cab in order to expose the fuse boxes.
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   Illustration 26	g03426183

2. Insert the 146-9439 Relay As in the R5 position in the lower fuse box.

3. Reinstall the fuse box cover.

Installation of Machine Film

1. Ensure that the surface is clean and dry before placing the film.

2. Install one 388-8112 Film right underneath the existing Film that contains the machine number on the right-hand side of the machine.
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   Illustration 27	g03426169

3. Verify that the upper left corner of the film intersects the lower end of the diagonal line from the red stripe on the machine number film. Repeat this procedure on the left-hand side of the machine.

4. Refill the hydraulic tank when installation is completed.

Machine Configuration

Note: Ensure that the 379-1613 Joystick Control Gp (Right Hand Joystick) , which contains the roller wheel for proportional flow control, is already installed on the machine. If changing the control group is necessary, refer to Special Instruction, REHS8704 for installation instructions.

The 422-3309 Valve Kit (High Flow) must be configured using Cat^® Electronic Technician (Cat ET).

1. With the key ON and engine off, using Cat ET, select the machine ECM.
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   Illustration 28	g03618997

2. From the menu, select "Service", then "Configuration", and then "Implement Configuration".
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   Illustration 29	g03619020

3. In the configuration screen, doubleclickon the "Auxiliary Hydraulic High Flow System Installation Status" link.
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   Illustration 30	g03619037

4. In the pop-up window, change the New Value field to Installed. Click "OK".

5. Turn the start key to the OFF position and wait at least 15 seconds. Turn the start key back to the ON position.

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

6. From the Cat ET menu, select "Service", then "Configuration", and then "Implement Configuration".
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   Illustration 31	g03620727

7. In the configuration screen, doubleclickon the "Auxiliary Hydraulic High Flow System Installation Status" link. Ensure that the feature is set to Installed.