Procedure For Updating A 3 Bank Implement Hydraulic System To A 4 Bank Implement Hydraulic System {5051, 5057, 5161, 5170, 5357} Caterpillar

Track-Type Tractor

D3K2 (S/N: KF21-UP; KL21-UP; FT31-UP; LT31-UP; JPJ1-UP)

D4K2 (S/N: KM21-UP; KR21-UP; MT31-UP; RT31-UP)

D5K2 (S/N: KW21-UP; KY21-UP; WT31-UP; YT31-UP; RRE1-UP)

Introduction

This special instruction provides the procedure for updating a 3 Bank implement hydraulic system on the D3K2, D4K2, and D5K2 Track-Type Tractor to a 4 Bank valve implement hydraulic system.

Safety

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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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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, and the 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.

Procedure For Standard Tractors and Tractors That Are Winch Compatible

Required Parts

Machine Preparation

1. Move the machine to a smooth horizontal location. Move away from other machines and personnel.

2. Lower all work tools to the ground.

3. Permit only one operator on the machine. Keep all other personnel away from the machine.

4. Engage the parking brake.

5. Stop the engine.

6. Release the pressure in the hydraulic system.

Procedure for Non-Winch Ready Machines

Necessary Parts

Procedure

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Illustration 1	g03739931

1. If your machine is equipped with a 3-Bank implement valve, remove panel from the right-hand console.
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   Illustration 2	g03739994

2. Install control group (10) onto bracket (11) with four screws (14). Tighten to 3.4 ± .6 N·m (2.5 ± 0.4 lb ft).

3. Install four plugs (8).

4. Install film (9) on bracket (11) in the location that is shown.
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   Illustration 3	g03740003

5. Connect 4-pin connector from control group (10) to connector from control harness (7). Install grommet (19).
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   Illustration 4	g03740009

6. Install bracket (11) onto the right-hand console with six screws (20) and tighten to 3.4 ± .6 N·m (2.5 ± 0.4 lb ft).
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   Illustration 5	g02768999

7. Locate bosses (B) on the right-hand side of the cab frame. Install plate (5) with two washers (15) and two bolts (13).
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   Illustration 6	g03740013

8. Install ECM (6) onto plate (5). Use four nuts (1), four spacers (2), four washers (3), and four isolation mounts (4). Attach the connector of harness (7) onto ECM (6). Torque bolt (C) on the connector of harness (5) to 6 ± 1.5 N·m (53.10 ± 13.27 lb in). Install cable strap (12).
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   Illustration 7	g03740018

9. Route harness (7) in the location that is shown and attach with three straps (12). Install grommet (19).

   Note: Do not tighten straps (12) until harness (7) is routed completely.

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   Illustration 8	g03740040

10. Connect the connectors from harness (16) to the valve bank. When connecting to front solenoid, connect the purple wire. When connecting to rear solenoid, connect the pink wire.

Procedure for Winch Ready Machines

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Illustration 9	g03740264

1. Remove screws (6), and remove bracket (4).

2. Remove plug (2) from the location that is shown to install switch (1).
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   Illustration 10	g03740128

3. Install switch assembly (1) in the location that is shown.

4. Connect 10-pin connector (H) with "BK-18 202-C189" of console harness to switch (1).
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   Illustration 11	g03740121

5. Install the control group (3) with four bolts (5) and tighten to 3.4 ± .6 N·m (2.5 ± 0.4 lb ft).

Valve Group Installation for Non-Winch and Winch Ready Machines

Necessary Parts

Procedure

1. The following steps pertain to all machines.
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   Illustration 12	g03738940

2. Remove two hex nuts (12) and nut (11) from the valve group.

3. Remove mounting bolt (5) and washer (3).

4. Remove housing (15) from the end of the valve.

5. Replace existing three rods one at a time with two rods (9) and rod (10).

   Note: Make sure that three O-rings, spring, and valve remain in the valve group.

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   Illustration 13	g03739085

6. Install control valve group (16) with two o-rings (17), o-rings (18), spring (19), and valve (20).
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   Illustration 14	g03739041

7. Install housing (15) onto rods (9) using nut (12). Install rod (10) using hex nuts (11). Hand tighten hex nut (11) and (12).

8. Install mounting bolt (5), and washer (3). Hand tighten bolt (5) to ensure that the valve is seated correctly on the mounting plate.

9. Tighten three hex nuts (11) and (12) to a torque of 41 ± 2 N·m (30.24 ± 1.48 lb ft).

10. Tighten mounting bolt (5) to a torque of 60 ± 12 N·m (44.25 ± 8.85 lb ft).

    Note: Make sure to torque valve mounting bolts AFTER installing and torquing the valve section rods and nuts.

Installing Rear Hydraulic Lines

Reference Parts List

Procedure

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Illustration 15	g03739142

1. Preassemble valve (2) with the following components:

   • Connector As (7)

   • Elbow As (8)

2. Install valve (2) onto existing plate with two bolts (17) and two washers (23).
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   Illustration 16	g03739194

3. Secure union assembly (10) and elbow (9) to rear guard with nuts (15) and cap assembly (16).
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   Illustration 17	g03739268

4. Install connector assembly (7) onto control valve group (1).
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   Illustration 18	g03739388

5. Install hose assembly (6) to valve group (2) and connector assembly (7).

6. Install hose assembly (4) to tube assembly (3).

7. Install hose assembly (5) to connector assembly (7).

8. Install tube assembly to existing elbow (A).

Mirror Installation for Non-Winch Ready Machines

Required Parts

Procedure

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Illustration 19	g03740220

1. As required, install mirror (2) in the location that is shown with screw (1).

   Note: Add 4C-4030 Thread Lock Compound, or the equivalent to screw (1).

2. Install the battery and the cab floorplate. Refer to Disassembly and Assembly, KENR6043-00, "Battery-Remove and Install" for the proper procedure for battery installation.

3. Fill the hydraulic tank to the proper capacity.

Electronic Control Module (ECM) Flash Program

Perform the following procedure to flash program the ECM. The ECM is flashed to upgrade the software. Flash programming of the ECM must also be done if the ECM has been replaced. The Caterpillar Electronic Technician (ET) contains the program WinFlash. WinFlash is used to load software into the ECM. The following procedure is used to flash software into the ECM.

1. Procedure

   1. Connect the data link cable between the communication adapter and the electronic technician.

   2. Connect the data link cable between the communication adapter and the diagnostic connector of the machine.

   3. Turn the disconnect switch and the key start switch to the ON position.

   4. Set the implement lockout to the LOCKED position.

   5. Ensure that the transmission direction switch is in the NEUTRAL position.

   6. Ensure that the engine is not running.

   7. Use WinFlash to load the software.

      Note: WinFlash may appear different due to later versions of the software.

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   Illustration 20	g01631335

2. WinFlash is equipped with a "Quick Help to use WinFlash" help screen that can be used for assistance to flash the software. The following steps can also be used to flash the software.
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   Illustration 21	g01526689

3. Select the "Blank" ECM.

4. Click the "Select ECM" button to choose the correct ECM that needs flashed.

5. Select the "Browse" button to search for the file that contains the 367-0566 Machine Software Gp or the latest flash file.
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   Illustration 22	g01526711

6. From the "Flash File Selection" screen, select "3670566V00.fls" that is seen in Illustration 22, and click the "Open" button. The next window will show that the software is being flashed.

   Note: The auxiliary hydraulic ECM only communicates on the CAN J1939 data link. If the electronic technician does not find the ECM in "WinFlash", confirm that J1939 communication has not been disabled on your laptop computer.

Configure Caterpillar Electronic Technician (ET) to 4 bank valve.

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Illustration 23	g01526733

1. From the "Configuration" screen, select "Machine Control".
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   Illustration 24	g01526737

2. From the "Description" field, select "Rear Attachment Installation Status.".

3. From the "Change Parameter Value" screen, select one of the following:

   • If your machine is not winch ready, select "Single Axis Ripper".

   • If your machine is winch ready with a winch that had been installed, select "Winch with 4th Function".

   If, your machine is winch ready and if your machine does not have a winch select one of the following:

   • Selecting "Winch Pump with 4th Function" will allow you to control the winch pump with the lever and the fourth function with the switch.

   • Selecting "Single Axis Ripper with Winch Pump" will allow you to control the fourth function with the lever. This selection will not allow control of the winch pump.

4. Calibrate the new control valve group. Refer to Testing and Adjusting, UENR1357, "Calibration" for the proper procedure for the implement valve solenoid calibrations.
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   Illustration 25	g01523701

5. Install right side enclosure (47) with seven bolts (46).

6. Install the floor mat in the cab.