Field Installation of Ride Control Kits{5004} Caterpillar

Wheel Loader:

938G (PIN: 6WS1-UP)

Integrated Toolcarrier:

IT38G (PIN: 1CW1-UP)

Introduction

This service publication contains the installation information that is needed to install ride control on a field machine.

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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.

Reference: Service Manual, SENR6780

Do not perform any procedure and do not order parts that are outlined in this publication until you understand the information that is contained in this document.

Removal of the 133-4238 Control Valve

938G (PIN: 6WS1-UP)

Note: Perform this step only for the 938G. Proceed to the installation of Ride Control Accumulator for the IT38G.

Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This procedure prevents fluid loss.

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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.

Illustration 1	g00285109

Note: The main control valve is located inside the front loader frame.

1. Apply the parking brake.

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Illustration 2	g00277573

2. Raise the lift arms off the ground by approximately 1.5 m (5 ft). Place Tooling (A) under the lift arms, as shown.

3. Release the pressure in the hydraulic system. Refer to Disassembly and Assembly, "Hydraulic System Pressure - Release".

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Illustration 3	g00277575

4. Remove four nuts (1) and cover (2) .

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Illustration 4	g00282132

5. Disconnect the tube assemblies (4) and the hose assemblies (3) from the main control valve.

6. Remove three bolts (5). Remove main 133-4238 Control Valve (6). The weight of the main control valve is 34 kg (75 lb).

Installation of 133-4239 Control Valve

938G (PIN: 6WS1-UP)

Note: Perform this step only for the 938G. Proceed to the installation of Ride Control Accumulator for the IT38G.

1. Before installation of the main control valve, install new O-ring seals on all tube assemblies and on all hose assemblies.

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Illustration 5	g00282132

2. Install main control valve (6) and three bolts (5). The weight of the main control valve is 34 kg (75 lb).

3. Reconnect the tube assemblies and the hose assemblies to the main control valve.

Installation of Ride Control Accumulator and Solenoid Valve (Head End)

(PIN: 1CW1-UP)

(PIN: 6WS1-UP)

Reference: For information about charging the ride control accumulator, refer to Testing and Adjusting, SENR6796, "Ride Control Accumulator - Test and Charge".

1. Stamp the 7J-5311 Warning Plate with the following information.
   • Precharge pressure 3000 kPa (435 psi)

   • Service pressure 24821 kPa (3600 psi)

   • Burst pressure 99284 kPa (14400 psi)

   Fasten the plate near the accumulator on the left side of the machine.

2. Install 124-9439 Ride Control Accumulator (53) .

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Illustration 6	g00546007

3. Use the following parts to secure the accumulator to the frame in two places. Do not tighten the bolts completely.
   • Two 122-1162 Clamps (54)

   • One 8T-6466 Bolt (55) for the (PIN: 6WS)

   • Two 8T-6466 Bolts (55) for the (PIN: 1CW)

   • Two 8T-4121 Washers (56)

   • One 9G-9150 Clip (57)

   • One 8T-4185 Bolt (58) for the (PIN: 6WS)

4. Attach the 103-5406 Film (7) to the side of the accumulator.

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Illustration 7	g00552973

5. Use the following parts to install the 124-6025 Manifold (8) for the (PIN: 6WS) or the 101-2704 Housing (16) for the (PIN: 1CW) to the accumulator.
   • Two 3D-2824 O-Ring Seals (9)

   • One 5P-9560 Union (15)

6. (PIN: 1CW) Connect the 4T-2764 Relief Valve to the top of the 101-2704 Housing (16).

7. Install the 149-2658 Solenoid Valve (10) to the housing. The torque for the valve is 25 ± 5 N·m (18 ± 4 lb ft).

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Illustration 8	g00546202
Typical top view

8. Connect the 105-1520 Harness (12) from the 149-2658 Solenoid Valve (11) to the main harness. Loosen the bolt (6) from the 9G-9150 Clip (5) that is located on the accumulator clamp. Place the 9G-9150 Clip (5) around the harness. Tighten the bolt.

9. Use one 3S-2093 Cable Strap (59) to secure the harness.

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Illustration 9	g00546293
View A-A

10. Use the following parts to secure the 105-1520 Harness (12) to the frame.
    • One 8T-4137 Bolt (13)

    • One 8T-4121 Washer (14)

    • One 9G-9150 Clip (57)

Installation Of Ride Control Solenoid Valve (Rod End)

(PIN: 1CW1-UP)

(PIN: 6WS1-UP)

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Illustration 10	g00546412
Typical example of mounting block

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Illustration 11	g00546651
Typical Example

1. Use the following parts in order to secure the 8C-6162 Manifold (17) to the block.
   • Two 8T-6466 Bolts (3)

   • Two 8T-4121 Washers (4)

2. Install the 149-2658 Solenoid Valve (11) onto the 8C-6162 Manifold (17). The torque for the valve is 25 ± 5 N·m (18 ± 4 lb ft).

Installation Of Ride Control Valves (Rod End) For 6WS Machines

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Illustration 12	g00550780
Right Side Section View of Loader Frame

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Illustration 13	g00553089

1. Use the following parts to secure the 124-8206 Ride Control Valve (20) to the block.
   • Three 8T-3647 Bolts (18)

   • Three 8T-4224 Hard Washers (19)

Installation of Hydraulic Lines for the Ride Control Valves for 1CW Machines

(PIN: 1CW1-UP)

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Illustration 14	g00549313

1. Use the following parts to connect the 6V-8777 Tee (21) to the bottom port of the 8C-6162 Manifold (17) .
   • One 3D-2824 O-Ring Seal (9)

   • One 6V-9746 O-Ring Seal (23)

2. Connect the 105-1522 Tube (33) to the left side of the 8C-6162 Manifold (17) .
   • One 3D-2824 O-Ring Seal (9)

   • One 6V-9746 O-Ring Seal (23)

   • One 6V-8637 Seal Connector (60)

3. Connect the opposite end of the 105-1522 Tube (33) to an existing main control valve port.

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Illustration 15	g00515429
Right side view

4. Use the following parts to connect the 110-9672 Hose Assembly (26) to the right port of the 6V-8777 Tee (21) .
   • One 6V-8943 Reducer Assembly (27)

   • One 7J-9108 O-Ring Seal (28)

5. Use the following parts to connect the 110-9672 Hose Assembly (26) to the main control valve.
   • One 7J-9108 O-Ring Seal (28)

   • One 6V-8642 Connector (29)

   • One 2M-9780 O-Ring Seal (30)

6. Use the following parts to connect the 113-5784 Hose Assembly (31) to the left port of the 6V-8777 Tee (32) .
   • One 3D-2824 O-Ring Seal (9)

   • One 6V-9746 O-Ring Seal (23)

   • One 6V-8637 Seal Connector (24)

7. Use the following parts to connect the 113-5784 Hose Assembly (31) to the side of the 101-2704 Housing (16) .
   • One 3D-2824 O-Ring Seal (9)

   • One 6V-9746 O-Ring Seal (23)

   • One 6V-9007 Elbow (32)

8. Use the following parts to connect the 115-0726 Tube (25) to the bottom port of the 101-2704 Housing (16) .
   • One 3D-2824 O-Ring Seal (9)

   • One 6V-9746 O-Ring Seal (23)

   • One 6V-8637 Seal Connector (24)

9. Connect the opposite end of the 115-0726 Tube (25) to an existing connector.

Installation of Hydraulic Lines for the Ride Control Valves for 6WS Machines

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Illustration 16	g00553235

1. Use the following parts to connect the 105-1522 Tube (33) to the left side of the 8C-6162 Manifold (17) .
   • One 3D-2824 O-Ring Seal (9)

   • One 6V-8637 Seal Connector (60)

   • One 6V-9746 O-Ring Seal (23)

2. Connect the opposite end of the 105-1522 Tube (33) to an existing main control valve port.

3. Use the following parts to connect the 6V-9175 Tee (35) to the bottom port of the 8C-6162 Manifold (17) .
   • One 3D-2824 O-Ring Seal (9)

   • One 7J-9108 O-Ring Seal (34)

4. Connect the straight end of the 110-9672 Hose Assembly (36) to the 6V-9175 Tee (35) .

5. Use one 6V-9746 O-Ring Seal (23) to connect the 3W-6958 Hose Assembly (37) to the bottom of the 6V-9175 Tee (35) .

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Illustration 17	g00552909
Right Side View

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Illustration 18	g00553619
Top View

6. Use the following parts to connect the 110-9672 Hose Assembly (36) to the front of the main control valve.
   • One 7J-9108 O-Ring Seal (34)

   • One 2M-9780 O-Ring Seal (30)

   • One 6V-8642 Connector (29)

7. Use the following parts to connect the opposite end of 3W-6958 Hose Assembly (37) to the 124-8206 Ride Control Valve (20) .
   • One 7M-8485 O-Ring Seal (38)

   • One 8T-4149 Elbow (39)

   • One 6V-9746 O-Ring Seal (23)

8. Use the following parts to attach one end of the 125-2290 Hose Assembly (40) to the bottom port of the 124-6025 Manifold (8) .
   • One 3D-2824 O-Ring Seal (9)

   • One 6V-9007 Elbow (32)

   • One 6V-9746 O-Ring Seal (23)

9. Use the following parts to attach the opposite end of the 125-2290 Hose Assembly (40) to the 124-8206 Ride Control Valve (20) .
   • One 7M-8485 O-Ring Seal (38)

   • One 6V-9182 Elbow (41)

   • One 6V-9746 O-Ring Seal (23)

10. Use the following parts to attach one end of the 9C-2413 Hose Assembly (42) to the top port of the 124-6025 Manifold (8) .
    • One 6V-9746 O-Ring Seal (23)

    • One 3D-2824 O-Ring Seal (9)

    • One 6V-9007 Elbow (32)

11. Use the following parts to attach the opposite end of the 9C-2413 Hose Assembly (42) to the existing tee on the main control valve.
    • One 6V-9746 O-Ring Seal (23)

    • One 6V-9853 Swivel Elbow (43)

12. Use the following parts to attach one end of the 9W-4201 Hose Assembly (51) to the end port of 124-8206 Ride Control Valve (20) .
    • Two 6V-8397 O-Ring Seal (44)

    • One 6V-8636 Connector (45)

    • One 3J-1907 O-Ring Seal (46)

13. Use the following parts to attach the opposite end of the 9W-4201 Hose Assembly (51) to an existing port on the main control valve.
    • One 3J-1907 O-Ring Seal (46)

    • One 6V-8724 Elbow (47)

14. Use the following parts to attach the 90 degree end of the 8W-2332 Hose Assembly (52) to the bottom port of the 124-6025 Manifold .
    • One 3K-0360 O-Ring Seal (48)

    • One 6V-8634 Seal Connector (49)

    • One 6V-8397 O-Ring Seal (44)

15. Use the following parts to attach the opposite end of the 8W-2332 Hose Assembly (52) to the 124-8206 Ride Control Valve (20) .
    • One 3J-7354 O-Ring Seal (50)

    • One 8T-7546 Elbow (59)

    • One 6V-9746 O-Ring Seal (23)

    • One 6V-8397 O-Ring Seal (44)

16. Connect one end of 124-8900 Tube to the existing connector. Connect the opposite end to a top port of the main control valve.

Installation of Ride Control Switch

(PIN: 6WS)

(PIN: 1CW)

Illustration 19	g00111691

Install the 107-6030 Switch in the right hand switch panel. Connect the switch to the existing wiring harness. For more information, refer to the Operation and Maintenance Manual, SEBU7037, "Ride Control".

Illustration 20	g00553972
Typical section view of the console

Install the 130-3033 Relay in the side of the right hand console.

For installation information for the 142-0037 Service Code Plug , refer to the Electrical Schematic, SENR6679.