Field Installation of 209-7561 Access Platform Conversion Ar {6461} Caterpillar

Telehandler:

TH63 (S/N: 5WM6021-6393)

TH83 (S/N: 3RN4015-4202)

Introduction

This Special Instruction provides the necessary information that is required for installing the 209-7561 Access Platform Conversion Ar . This Access Platform Conversion Arrangement enables an access platform (work tool) to operate on TH63 and TH83 machines. The machines must have the type B control arrangement (fork controls).

This Special Instruction also provides the necessary information that is required to validate the installation of the 209-7561 Access Platform Conversion Ar . TH63 and TH83 machines must be equipped with an access platform (work tool) in order to validate the installation of the Access Platform Conversion Arrangement. An access platform (work tool) is not included in the Access Platform Conversion Arrangement.

Note: The 209-7561 Access Platform Conversion Ar must only be installed on machines that are equipped with stabilizers.

Note: Do not perform any procedure until you understand the information that is contained in this Special Instruction.

Reference: Operation and Maintenance Manual, SEBU7370, "TH62, TH63, TH82 and TH83 Telehandler".

Reference: Parts Manual, SEBP3131, "TH63 Telehandler".

Reference: Parts Manual, SEBP3133, "TH83 Telehandler".

Reference: Disassembly and Assembly, RENR3437, "TH62. TH63, TH82, TH83 and TH103 Telehandlers Machine Systems".

209-7561 Access Platform Conversion Arrangement

The following tables contain all of the parts that are required for field installation.

Table 1

Parts that are Required for the Field Installation of the 209-7561 Access Platform Conversion Ar
Item	Part Number	Description	Quantity
1	166-8680	Plate	1
2	8T-4171	Bolt	8
3	8T-4205	Hard Washer	8
4	8I-3719	Eye	1
5	8I-3718	Cable Guide	1
6	165-6852	Plate	1
7	165-6854	Plate	1
8	165-6853	Plate	1
9	187-3462	Switch Gp	1
10	187-3461	Switch Gp	1
11	183-3052	Harness	1
12	165-7929	Plug	1
13	3S-2093	Cable Strap	44
14	138-8368	Contact Block	2
15	8I-3716	Key Switch As	1
16	138-8367	Contact Block	2
17	167-1507	Harness	1
18	140-9378	Relay As	1
19	148-8575	Film	1
20	148-8316 (1)	Connector	10
21	193-7304	Solenoid Valve Gp	1
22	148-8326 (1)	Connector	3
23	148-8325 (1)	Connector	1
24	148-8336 (1)	Connector	4
25	166-4057 (1)	Connector	4
26	204-9047	Valve	1
27	166-4244	Bracket	1
28	7I-8935	Bolt	2
29	8T-4224	Hard Washer	2
30	8T-6912	Bolt	2
31	8T-4121	Hard Washer	11
32	8T-4196	Bolt	2
33	8I-3637	Sleeve (Yellow)	4
34	8I-3641	Sleeve (Blue)	4
35	8I-3636	Sleeve (Orange)	4
36	8I-3638	Sleeve (Pink)	4
37	8I-3640	Sleeve (Brown)	2
38	8I-3639	Sleeve (Red)	2
39	8I-3806	Sleeve (Green)	2
40	192-2553	Hose Assembly	1
41	165-6834	Hose Assembly	1
42	165-6835	Hose Assembly	1
43	168-5302	Film	3
44	171-7024	Hose Assembly	2
45	193-7833	Hose Assembly	2
46	192-3214	Hose Assembly	1
47	191-9223	Hose Assembly	1
48	192-3215	Hose Assembly	1
49	191-9224	Hose Assembly	1
110	202-5297	Valve	1
111	195-9537	Harness	1
112	214-6814	Hose As	1
-	213-6826	Stabilizer Control Valve Gp	2

( 1 )

Refer to Table 3 for serviced parts.

Table 2

213-6826 Stabilizer Control Valve Gp
Item	Part Number	Description	Quantity
113	3J-1907	O-Ring Seal	1
114	8T-4224	Hard Washer	3
115	8T-6869	Bolt	3
116	131-9203	Pressure Switch	1
117	148-8318 (1)	Connector Gp	2
118	205-7555	Plate	1
119	205-7999	Stabilizer Valve As	1

( 1 )

Refer to Table 3 for service parts.

Table 3

Serviced Parts
Item	Part Number	Description	Qty
148-8316 Connector Gp
20	3J-1907	O-Ring Seal	1
	4J-5477	O-Ring Seal	1
	6V-8647	Connector	1
148-8326 Connector Gp
22	3J-7354	O-Ring Seal	1
	6V-8397	O-Ring Seal	1
	6V-9872	Connector	1
148-8325 Connector Gp
23	3J-1907	O-Ring Seal	1
	4J-5477	O-Ring Seal	1
	6V-8641	Connector	1
148-8336 Connector Gp
24	3J-1907	O-Ring Seal	1
	6V-8397	O-Ring Seal	1
	6V-8636	Connector	1
166-4057 Connector
25	3J-7354	O-Ring Seal	1
	4J-5477	O-Ring Seal	1
	9X-2067	Connector	1
148-8318 Connector Gp
117	3K-0360	O-Ring Seal	1
	6V-8397	O-Ring Seal	1
	6V-8634	Connector	1

Installation Procedure

If equipped, remove the existing work tool from the quick coupler. Park the machine on level ground. Fully retract and fully lower the boom. Lower the stabilizers to the ground. Move the transmission control to the NEUTRAL position and ensure that the parking brake is engaged. Shut off the engine. Attach a "Do Not Operate" warning tag to the engine start switch key.

Installing the Connections for the 183-3052 Harness

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Illustration 1	g00780814

1. Install 166-8680 Plate (1) onto the right side of the first section of the boom. Use two 8T-4171 Bolts (2) and two 8T-4205 Hard Washers (3) .

2. Install one locknut and one washer onto the threaded part 8I-3719 Eye (4) .

   Install the eye onto the right side of the first section of the boom and ensure that the gap in the eye is in the position that is shown in Illustration 1. Tighten the locknut.

3. Install one locknut and one washer onto the threaded part of 8I-3718 Cable Guide (5). Install the cable guide onto the right side of the second section of the boom and ensure that the cable guide is in the position that is shown in Illustration 1. Tighten the locknut.

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Illustration 2	g00642385

4. Install 165-6852 Plate (6) onto the left side of the first section of the boom. Use two 8T-4171 Bolts (2) and two 8T-4205 Hard Washers (3) .

5. Install 165-6854 Plate (7) onto the left side of the second section of the boom. Use two 8T-4171 Bolts (2) and two 8T-4205 Hard Washers (3) .

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Illustration 3	g00642390

6. Install 165-6853 Plate (8) on top of the frame at the rear, left side of the machine. Use two 8T-4171 Bolts (2) and two 8T-4205 Hard Washers (3) .

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Illustration 4	g00642669

7. Install 187-3462 Switch Gp (9) onto 165-6853 Plate (8) which is located on top of the frame at the rear, left side of the machine. From the side of the boom, set distance (A) to 15 ± 2 mm (.6 ± .08 inch).

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Illustration 5	g00642671

8. Install 187-3461 Switch Gp (13) onto 165-6852 Plate (6) which is located at the front, left side of the boom. Set distance (B) to 3 ± 1 mm (0.12 ± 0.04 inch).

Installing the 183-3052 Harness

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Illustration 6	g00782169

1. Install Receptacle (50) which is located at the end of 183-3052 Harness (11) to 166-8680 Plate (1). Tighten Locknut (51) to 41 ± 7 N·m (30 ± 5 lb ft).

2. Install 165-7929 Plug (12). Align the ribs on Connector Plug (52) with the grooves in Receptacle (50). Push the connector plug into the receptacle. Rotate the lockring that is on the connector plug until one of the locking pins on the receptacle is locked in the hole of the lockring. Ensure that End Bell (53) is hand tightened.

   Note: When you perform the following instructions, install the 3S-2093 Cable Straps to the existing chain links that are located on the boom and the chassis. Trim the end of the cable straps after you have completed the appropriate step. If your machine is equipped with a work light, route the 183-3052 Harness alongside the harness for the work light.

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Illustration 7	g00780816

3. Route the longer section of 183-3052 Harness (11) along the lower chain links as far as the first chain link. Secure the harness with 3S-2093 Cable Straps (13) .

4. Route the shorter section of the 183-3052 Harness over the top of the boom. Connect the plug of the harness to Receptacle (54) for the 187-3461 Switch Gp . Secure the harness and the cable for the position sensor with 3S-2093 Cable Straps (13) .

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There is no working clearance between the boom and frame when the boom is lowered. Working in this area could result in personal injury or death. Do not approach or work in this area until the boom is properly supported.

5. Start the engine. Raise the boom to a height that will allow you to continue the installation of the 183-3052 Harness . Shut off the engine. Install a suitable stand under the first section of the boom.

6. Continue to route the longer section of the 183-3052 Harness as far as possible toward the rear of the boom. Secure the harness with the 3S-2093 Cable Straps .

   Note: Toward the rear of the boom, the existing chain links are located on the bottom of the boom.

7. Start the engine. Fully raise the boom in order to continue the installation of the 183-3052 Harness . Support the boom with a suitable crane. The weight of the boom should be no heavier than 2500 kg (5500 lb). Shut off the engine and remove the stand.

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Illustration 8	g00815881

8. Continue to route the longer section of the 183-3052 Harness to the rearmost chain link (55) on the boom. Secure the harness with the 3S-2093 Cable Straps (13) to the existing chain links.

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Illustration 9	g00815882

9. From the rearmost chain link (55) on the boom, measure 865 mm (34 inch) along 183-3052 Harness . Mark the position. At the position that is marked on the harness, install 3S-2093 Cable Strap (13) to the rearmost chain link (56) on the chassis.

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Illustration 10	g00780823

10. Remove the existing cable strap (13) in order to release the receptacles that are located at the rear of the chassis.

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Illustration 11	g00780929

11. Identify the plug (57) that is attached to a blue wire and a yellow wire. The plug is connected to a receptacle that is not used. Remove the 160-5797 Wire (Link) from the Receptacle. Replace this wire with the receptacle which is attached to the shortest section of the 183-3052 Harness . Discard the wire.

12. Route the longer section of 183-3052 Harness alongside the existing harness assembly until you reach the underside of the chassis. Do not route the longer section of the harness to the underside of the chassis at this stage.

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Illustration 12	g00780935

13. Route the shorter section of 183-3052 Harness (11) to the frame at the left side of the machine. Connect the plug of the harness to Receptacle (58) for the 187-3462 Switch Gp . Secure the harness and the cable for the position sensor with 3S-2093 Cable Straps (13) .

14. Install 3S-2093 Cable Strap (13) in order to secure Receptacle (58) to the harnesses.

15. Remove the equipment that is supporting the boom head. Start the engine and fully lower the boom. Shut off the engine.

16. Continue to route the longer section of 183-3052 Harness alongside the existing harness assembly. Route the harness along the underside of the chassis at the right side until you reach the subframe. Secure the harness with 3S-2093 Cable Straps .

17. Open the engine enclosure in order to provide extra light beneath the subframe. Remove the bolts, the washers, and the guard plate from the bottom of the subframe. Retain the parts.

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Illustration 13	g00780956

18. Continue to route the longer section of 183-3052 Harness (11) alongside the existing harness in the subframe. The existing receptacle (12 way) (59) that is not used is located on the rear of the subframe on the left side of the subframe. Remove the cap plug from the receptacle. Replace the cap plug with the receptacle that is attached to harness (11). Discard the cap plug. Secure the harness with 3S-2093 Cable Straps (13) .

Installing the Lockout System

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Illustration 14	g00782188

1. Two 138-8368 Contact Blocks (14) are required for the lockout system. Remove yellow Plug (60), two Clips (61), and two Screws (62) from the first contact block. Discard the yellow plug, two clips and two screws. On the second contact block, only remove the yellow plug. Discard the yellow plug.

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Illustration 15	g00643013

2. Connect the two 138-8368 Contact Blocks together.

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Illustration 16	g00782199

Note: A white label is attached to 8I-3716 Key Switch As (15). This side of the key switch is referred to as the "White Side". The opposite side of the key switch is referred to as the "Black Side".

3. Assemble 138-8368 Contact Blocks (14) to the bottom of 8I-3716 key Switch As (15). Tighten two Screws (62) that are between the contact blocks. Remove the terminal screws.

4. Connect the terminals on the 167-1507 Harness to the bottom of the terminals on 138-8368 Contact Blocks (14). Install the terminal screws to the bottom of the terminals. Refer to Illustration 15 and Table 4 for the installation of the terminals.
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   Table 4

   Installation of the 167-1507 Harness to the 138-8368 Contact Blocks
   Item	Wire Code	Side of Switch
   63	No Code-Black and White	White Side
   64	P978-Green	White Side
   65	308-Yellow	Black Side
   66	329C-Yellow	Black Side
   67	332-Blue	Black Side
   68	329D-Yellow	Black Side

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Illustration 17	g00782204

5. Two 138-8367 Contact Blocks (16) are required for the lockout system. Install yellow Plug (69) and two Screws (70) onto the first contact block. Discard the two screws for the second contact block.

6. Refer to Illustration 15. Connect the two 138-8367 Contact Blocks together.

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Illustration 18	g00782215

7. Assemble 138-8367 Contact Blocks (16) to the bottom of 138-8368 Contact Blocks (14). Tighten two Screws (70) that are between the contact blocks. Remove the terminal screws.

8. Connect the terminals on the 167-1507 Harness to the bottom of the terminals on 138-8367 Contact Blocks (16). Install the terminal screws to the bottom of the terminals. Refer to Illustration 18 and Table 5 for the installation of the terminals.
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   Table 5

   Installation of the 167-1507 Harness to the 138-8367 Contact Blocks
   Item	Wire Code	Side of Switch
   71	200-Black	White Side
   72	G969-Yellow	White Side
   73	103-Yellow	White Side
   74	327-Pink	White Side
   75	162-Yellow	Black Side
   76	585-Yellow	Black Side

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Illustration 19	g00782225

9. Remove five screws (77), strip (78), two clips (79), and floormat (80). Retain the parts.

10. Remove the five screws that secure the trim on the right side of the operator station in order to install 8I-3716 Key Switch As (15). Retain the parts.

11. Turn the key in the 8I-3716 Key Switch As as far as possible in a clockwise direction in order to remove the key. Remove the locknut. Retain the parts. Leave the three rubber washers in place.

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Illustration 20	g00780980

12. Install 8I-3716 Key Switch As (15) into the hole in the cover plate from the underside. Ensure that the arrow on the top of the key switch is pointing between the front of the machine and the right side of the machine.

13. A plastic ring and a lockwasher are supplied with the 8I-3716 Key Switch As . Install the plastic ring and then install the lockwasher. Ensure that the plastic ring and the lockwasher are properly seated on the cover plate. The tab of the lockwasher should be inside the slot in the cover plate. If necessary, assemble the plastic ring and the lockwasher before you install the plastic ring and the lockwasher. Install the locknut and tighten. Install the key and turn the key as far as possible in a counterclockwise direction.

14. Identify the receptacle (12 way) (81) that is not used. Replace the cap plug in the receptacle with receptacle (82) that is attached to 167-1507 Harness (17). Discard the cap plug that is not used.

15. Identify the receptacle (2 way) (83) which is connected to a white wire and a green wire. The receptacle is not used. Remove the cap plug in this receptacle. Replace the cap plug with Receptacle (84) that is attached to 167-1507 Harness (17). Discard the cap plug that is not used.

16. Install four of the 3S-2093 Cable Straps in order to secure the 167-1507 Harness beneath the cover plate. Trim the end of the cable straps.

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Illustration 21	g00782243

17. Remove the cover plate for the fuse panel which is located at the left side of the seat support. There are two link wires in the fuse panel. Remove the lower right side link wire from the fuse panel. Replace the link wire in the fuse panel with 140-9378 Relay As (18). Discard the link wire. Reinstall the cover plate.

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Illustration 22	g00782250

18. Install 148-8575 Film (19) to the cover plate in the position that is shown in Illustration 22.

Assembling the 193-7304 Solenoid Valve Gp

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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.

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Illustration 23	g00781235

1. Install a 148-8316 Connector Gp (20) to each of the following ports that are marked on 193-7304 Solenoid Valve Gp (21) : "A1", "A2", "B1", "B2", "P1" and "P2".

2. Install 148-8336 Connector (24) to the port that is marked "X1" on the 193-7304 Solenoid Valve Gp (21) .

3. Install 148-8325 Connector (23) to the port that is marked "Y" on the 193-7304 Solenoid Valve Gp (21) .

4. Install 148-8336 Connector (24) to the ports that are marked "X2" and "T" on the 193-7304 Solenoid Valve Gp (21) .

Assembling the 204-9047 Valve

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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.

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Illustration 24	g00781238

1. Install 166-4057 Connector Gp (25) to each of the following ports that are marked on 204-9047 Valve (26) : "BL", "BR", "TL" and "TR".

2. Install 148-8316 Connector (20) to each of the following ports that are marked on the 204-9047 Valve : "JBL", "JBR", "JTL" and "JTR".

3. Install 148-8326 Connectors (22) to each of the following ports that are marked on the 204-9047 Valve : "JS", "PT" and "T"

4. Install 166-4244 Bracket (27) to the 204-9047 Valve . Use two 7I-8935 Bolts (28) in order to secure the bracket.

Installing the 193-7304 Solenoid Valve Gp

1. Remove the guard from the underside of the subframe in order to gain access to the valves. Retain the guard and retain the attaching hardware.

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Illustration 25	g00781244

2. Remove the existing cable strap from the harness for the subframe in order to release three receptacles (85) from the rear of the subframe. Remove the cap plugs from the plugs. Retain two cap plugs. Discard one of the cap plugs.

3. Disconnect four Plugs (86) from the receptacles that are attached to the cables for the existing solenoid valve.

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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 product. 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 on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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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.

4. Label Hose Assemblies (87) according to the connections. The following connections are marked on existing Solenoid Valve (88) : "T1", "Y", "X1" and "X2".

Note: Remove any existing cable straps from the hose assemblies and the nylon tubing before the hose assemblies and the nylon tubing are disconnected.

5. Disconnect Hose Assembly (87) that is labelled as "T1". Ensure that the end of the hose assembly is properly plugged.

6. Disconnect Hose Assemblies (87) that are labelled as "Y", "X1", and "X2".

7. Disconnect all hose assemblies (89) from the existing solenoid valve. Retain the Hose Assembly with the brown sleeve and the hose assembly with the red sleeve. Discard the hose assembly with the blue sleeve and the hose assembly with the yellow sleeve.

8. Remove the two bolts and the two washers from the existing solenoid valve and remove the solenoid valve. Discard the parts.

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Illustration 26	g00782296

9. Install 193-7304 Solenoid Valve Gp (21). Use two 8T-4224 Hard Washers (29) and two 8T-6912 Bolts (30) .

10. Connect the receptacle for Solenoid (90) to the plug that is attached to a white wire.

11. Connect the receptacle for solenoid (91) to the plug that is attached to a pink wire.

12. Connect the receptacle for Solenoid (92) to the plug that is attached to a pink wire.

13. Connect the receptacle for Solenoid (93) to the plug that is attached to a white wire.

14. Connect the receptacle for Solenoid (94) to the plug that is attached to a blue wire.

15. Connect the two cap plugs that were retained in Step 2 to two unconnected Plugs (95) that remain. Install 3S-2093 Cable Straps (13) .

16. Connect Hose Assemblies (87) that were labelled in Step 9 to the connectors in the ports that are marked "Y", "X1", and "X2" on 193-7304 Solenoid Valve Gp (21). Do not connect the hose assembly that is labelled as "T1" at this stage.

Installing the 204-9047 Valve

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Illustration 27	g00643469

1. Remove the existing cable straps from the harness for the subframe in order to release six plugs from the right side of the subframe. Disconnect the receptacles from the plugs and discard the receptacles.

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Illustration 28	g00782518

2. Secure the hoses that pass behind the mounting position of the 204-9047 Valve . Use existing clips (96) .

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Illustration 29	g00781254

3. Install 204-9047 Valve (26). Install two 8T-4121 Hard Washers (31) and two 8T-4196 Bolts (32) in order to hold the valve loosely in place.

4. Connect the existing plug with a gray sleeve to the receptacle for Solenoid (97).

5. Connect the existing plug with a green sleeve to the receptacle for Solenoid (98).

6. Connect the existing plug with a pink sleeve to the receptacle for Solenoid (99).

7. Connect the existing plug with a brown sleeve to the receptacle for Solenoid (100).

8. Connect the existing plug with an orange sleeve to the receptacle for Solenoid (101) .

9. Connect the existing plug that is without a sleeve to the receptacle for Solenoid (102) .

10. Tighten 8T-4196 Bolts (32). Push the receptacles and the wires behind the valve.

Installing the Pilot Lines

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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.

1. Before you install the pilot lines it will be necessary to install sleeves onto the hoses in order to identify the hoses.
   • Install one 8I-3636 Sleeve on each end of 171-7024 Hose As .

   • Install one 8I-3636 Sleeve on each end of 192-3214 Hose As .

   • Install one 8I-3637 Sleeve on each end of 193-7833 Hose As .

   • Install one 8I-3637 Sleeve on each end of 193-3215 Hose As .

   • Install one 8I-3638 Sleeve on each end of 192-9223 Hose As .

   • Install one 8I-3638 Sleeve on each end of 171-7024 Hose As .

   • Install one 8I-3641 Sleeve on each end of 193-7833 Hose As .

   • Install one 8I-3641 Sleeve on each end of 191-9224 Hose As .

   • Install one 8I-3806 Sleeve on each end of 171-7024 Hose As .

   Note: If the sleeve will not pass over the coupling it may be necessary to install the sleeves onto the hose before you install the coupling onto the hose.

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Illustration 30	g00781277

2. Connect the existing 171-7024 Hose As (103) with the green sleeve to the connector in port "P2" on the 193-7304 Solenoid Valve Gp (21) .

3. Connect the existing 171-7024 Hose As (103) to the connector in port "P1" on the 193-7304 Solenoid Valve Gp (21) .

4. Connect 193-7833 Hose As (45) with the yellow sleeve (33) to the connector in port "B2" on the 193-7304 Solenoid Valve Gp (21) .

5. Connect existing 171-7025 Hose As (104) with the brown sleeve to the connector in port "A1" on the 193-7304 Solenoid Valve Gp (21) .

6. Connect existing 171-7025 Hose As (104) with the red sleeve (38) to the connector in port "A2" on the 193-7304 Solenoid Valve Gp (21) .

7. Connect 193-7833 Hose As (45) with the blue sleeve (34) to the connector in port "B1" on the 193-7304 Solenoid Valve Gp (21) .

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Illustration 31	g00781337

8. Connect 193-7833 Hose As (45) with the blue sleeve (34) to the connector in port "JTR" on the 204-9047 Valve (26) .

9. Connect 193-7833 Hose As (45) with the yellow sleeve (33) to the connector in port "JTL" on the 204-9047 Valve (26) .

10. Connect the new 171-7024 Hose As (44) with the pink sleeve (36) to the connector in port "JBR" on the 204-9047 Valve .

11. Connect the new 171-7024 Hose As (44) with the orange sleeve (35) to the connector in port "JBL" on the 204-9047 Valve .

12. Connect the 90 degree coupling that is on one end of 191-3214 Hose As (46) to the connector in port "BL" on the 204-9047 Valve (26). The hose assembly has an orange sleeve (35) .

13. Connect the 90 degree coupling that is on one end of 191-9223 Hose As (47) to the connector in port "BR" on the 204-9047 Valve (26). The hose assembly has a pink sleeve (36) .

14. Connect the 90 degree coupling that is on one end of 192-3215 Hose As (48) to the connector in port "TL" on the 204-9047 Valve (26). The hose assembly has a yellow sleeve (33) .

15. Connect the 90 degree coupling that is on one end of 191-9224 Hose As (49) to the connector in port "TR" on the 204-9047 Valve . The hose assembly has a blue sleeve (34) .

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Illustration 32	g00784041

16. Remove the two hose from the top connectors on the control valve. Connect 191-9224 Hose As (47) with the pink sleeve to the connector on one port. Connect 191-9224 Hose As (49) with the blue sleeve to the connector on the other port. Refer to Illustration 32.

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Illustration 33	g00784044

17. Remove the two hoses from the bottom connectors on the control valve. Connect 192-3214 Hose As (46) with the orange sleeve to the connector on one port. Connect 192-3215 Hose As (48) with the yellow sleeve to the connector on the other port. Refer to Illustration 33.

Installing the Hose Assemblies

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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 product. 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 on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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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.

Note: Remove the existing cable straps before you disconnect any of the hose assemblies in the following procedure.

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Illustration 34	g00781711

1. Connect the 90 degree coupling that is on one end of 192-2553 Hose As (40) to the connector that is in port "PT" on 204-9047 Valve (26). Route the hose assembly alongside the existing hose assemblies toward the control valve.

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Illustration 35	g00781738

2. Disconnect the existing hose assembly that is labelled as "PS2" from Tee Fitting (105). Do not disconnect the other end of the existing hose assembly at this stage. Connect 192-2553 Hose As (40) to the tee fitting.

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Illustration 36	g00781757

3. Connect 165-6834 Hose Assembly (41) to the connector in port "JS" on 204-9047 Valve (26). Route the hose assembly alongside the existing hose assemblies toward the cab. Ensure that the hose assembly passes through the support bracket that is mounted on the bottom of the chassis.

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Illustration 37	g00815883

4. Remove the screws and Access Plate (106) in order to provide light between the cab floor and the hydraulic tank. Retain the parts.

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Illustration 38	g00782884

5. Disconnect existing Hose Assembly (107) that is labelled as "PS2" from joystick control (108). Remove the existing hose assembly and discard the existing hose assembly.

6. Continue to route 165-6834 Hose Assembly (41) through the space that is between the floor of the cab and the hydraulic tank. Route the hose assembly alongside the existing nylon tubing to the bottom of the joystick control. Ensure that the hose assembly passes through the U-shaped bar that is located on the underside of the cab floor.

7. Connect the 165-6834 Hose Assembly (41) to the adapter that was connected to the discarded hose assembly (107) .

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Illustration 39	g00784114

8. Connect the existing hose (87) to the connector (24) in port "T1" on 193-7304 Solenoid Valve Gp .

9. Disconnect the two hoses on ports (1) and (3) on the bottom of the joystick control (108). Discard the two hoses.

10. Route the new 171-7024 Hose Assembly (44) with the orange sleeve and the new 171-7024 Hose Assembly (44) with the pink sleeve from the ports "JBR" and "JBL" on 204-9047 Valve around the rear of the subframe.

11. Route the new 171-7024 Hose Assembly (44) with the orange sleeve through the space that is between the floor of the cab and the hydraulic tank. Route the hose assembly alongside the existing nylon tubing to the bottom of the joystick control. Ensure that the hose assembly passes through the U-shaped bar that is located on the underside of the cab floor. Connect the hose to the coupling in port "1" on the underside of the joystick control.

12. Route the new 171-7024 Hose Assembly (44) with the pink sleeve through the space that is between the floor of the cab and the hydraulic tank. Route the hose assembly alongside the existing nylon tubing to the bottom of the joystick control. Ensure that the hose assembly passes through the U-shaped bar that is located on the underside of the cab floor. Connect the hose to the coupling in port "3" on the underside of the joystick control.

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Illustration 40	g00782891

13. Connect 165-6835 Hose Assembly (42) to the connector in port "T" on 204-9047 Valve (26). Route the hose assembly alongside the existing hose assemblies to the hydraulic tank. Ensure that the hose assembly is routed over the bracket that supports the transfer gear case.

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Illustration 41	g00781789

Note: When you perform the following instruction, some oil may be lost from the hydraulic tank. Ensure that you are properly prepared in order to perform this instruction as quickly as possible.

14. Replace the existing plug in the hydraulic tank with 148-8336 Connector (24). Discard the plug. Connect 165-6835 Hose Assembly (42) to the connector.

15. Install the 7K-1181 Cable Straps in order to secure the nylon tubing and the hose assemblies. When possible, secure the nylon tubing to the hose assemblies.

Removing the existing Stabilizer Control Valve

Remove the existing stabilizer control valve from the machine.

Refer to Disassembly and Assembly, RENR3437, "TH62. TH63, TH82, TH83 and TH103 Telehandlers Machine Systems", "Stabilizer Control Valve - Remove and Install".

Discard the valve.

Installing the 202-5297 Valve

Install the new valve (110) for the stabilizers.

Refer to Disassembly and Assembly, RENR3437, "TH62. TH63, TH82, TH83 and TH103 Telehandlers Machine Systems", "Stabilizer Control Valve - Remove and Install".

Note: The hydraulic connections and the electrical connections on the new valve are in the same position as the connections on the original valve.

Installing the 213-6826 Stabilizer Control Valve Gp

1. Put identification marks on all hoses, on all tubes, and on all lines for installation purposes. Plug all hoses, all hoses, and all tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

2. Remove the right side stabilizer cylinder from the machine. Refer to Disassembly and Assembly, RENR3437, "TH62, TH63, TH82, TH83 & TH103 Telehandlers Machine Systems", "Stabilizer Cylinder - Remove".

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Illustration 42	g00836494

3. Place the stabilizer cylinder (120) on a suitable work bench. Disconnect the two hoses (121) and (122) from the load control valve (123). Discard hose (121) and retain hose (122) .

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Illustration 43	g00835767

4. Loosen locknut (124) on counterbalance valve (125) and use a suitable allen wrench to turn screw (126) in a counterclockwise direction. This will relieve the pressure which is trapped in the load control valve. Refer to Disassembly and Assembly, RENR3437, "TH62, TH63, TH82, TH83 & TH103 Telehandlers Machine Systems", "Hydraulic System Pressure - Release". Remove three bolts (127) and three washer (128). Discard the bolts and the washers.

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Illustration 44	g00835771

5. Lift load control valve (123) away from stabilizer cylinder. Discard the load control valve.

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Illustration 45	g00835811

6. Install the new stabilizer valve (119) onto the stabilizer cylinder. Install a connector (117) into port "V1" and port "V2" on the stabilizer valve. Install one O-ring seal (113) and one pressure switch (116) into port "PS" on the stabilizer valve.

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Illustration 46	g00836102

7. Install plate (118) on the stabilizer valve. Secure the stabilizer valve and the plate onto the stabilizer cylinder with three bolts (115) and three washers (114) .

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Illustration 47	g00836112

8. Connect the new hose (112) and hose (122) to the stabilizer valve and tighten the retaining nuts. Connect the electrical connector (129) on the pressure switch to one of the electrical connectors on the new harness.

9. Install the right side stabilizer cylinder onto the machine. Route the harness through the stabilizer beam to the stabilizer valve. Refer to Disassembly and Assembly, RENR3437, "TH62, TH63, TH82, TH83 & TH103 Telehandlers Machine Systems", "Stabilizer Cylinder - Install".

10. Remove the left side stabilizer cylinder from the machine. Refer to Disassembly and Assembly, RENR3437, "TH62, TH63, TH82, TH83 & TH103 Telehandlers Machine Systems", "Stabilizer Cylinder - Remove".

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Illustration 48	g00835442

11. Place the stabilizer cylinder on a suitable work bench. Disconnect the two hoses (130) and (131) from the load control valve (132). Retain both hoses.

12. Repeat steps 4 to 7.

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Illustration 49	g00836111

13. Connect hose (130) and hose (131) to stabilizer valve (119) and tighten the retaining nuts. Connect the electrical connector (132) on the pressure switch to one of the electrical connectors on the new harness.

14. Install the left side stabilizer cylinder onto the machine. Route the harness through the stabilizer beam to the stabilizer valve. Refer to Disassembly and Assembly, RENR3437, "TH62, TH63, TH82, TH83 & TH103 Telehandlers Machine Systems", "Stabilizer Cylinder - Install".

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Illustration 50	g00836114

15. Route the harness (111) through the hole in the rear of the stabilizer housing.

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Illustration 51	g00836115

16. Ensure that harness (111) passes through the support bracket in the center of the chassis. Secure the harness with suitable cable straps. Ensure that the harness is not in contact with any moving parts.

17. Route harnesses (111) to the new 204-9047 Valve As .

18. Disconnect the plug without a sleeve from the receptacle for Solenoid (102) on the Valve As. Refer to Illustration 29. Connect one plug on the 195-9537 Harness to the receptacle for Solenoid (102). Connect the other plug on the 195-9537 Harness to the plug without a sleeve.

Installing the Films for the Access Platform

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Illustration 52	g00782905

1. Replace the existing film at the left side of the boom head with new 168-5302 Film (43). Replace the existing film at the right side of the boom head with the new 168-5302 Film .

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Illustration 53	g00782911

2. Replace the existing film on the dash panel with new 168-5302 Film (43) .

Reinstalling the Parts that have been Retained

1. Close the engine enclosure.

2. Reinstall the access plate and the screws to the cab floor.

   Note: Before you reinstall the following parts, ensure that you have validated the installation of the 209-7561 Access Platform Conversion Ar . Ensure that you have made any necessary adjustments. Refer to the "Validating" section in this Special Instruction for more information.

3. Reinstall the bolts, the washers, and the guard plate. If the guard plate is equipped with insulation material, cut off a strip 150 mm (6 inch) wide in order to avoid contact with the 204-9047 Valve .

4. Reinstall the bolts, the washers, and the access plate for the control valve.

5. Reinstall the side trim and the top trim. Reinstall the screws and the nuts for the trims.

6. Reinstall the floormat and the two fasteners for the side trim. Reinstall the plate and the two bolts for the left side of the seat support. Reinstall the strip and the five bolts for the entrance to the cab.

7. Remove the "Do Not Operate" tag from the engine start switch key.

Validating

The following procedure describes the method that is used to validate the installation of the 209-7561 Access Platform Conversion Ar . Ensure that you fully understand the following procedure before you attempt to validate the installation of the 209-7561 Access Platform Conversion Ar .

1. Ensure that the parking brake is engaged. Start the engine. Ensure that you are clear of the machine and look for oil leaks. If necessary, shut off the engine and tighten the hydraulic connections.

2. Check that the machine is able to travel in forward and reverse.

3. Check the operation of the following functions:
   • Boom raise

   • Boom lower

   • Boom extend

   • Boom Retract

   • Quick Coupler

   If the boom does not raise or the boom does not lower Refer to Step 9 in ""Control Switches for the Access Platform" " for further information.

4. Shut off the engine. Check the new hydraulic connections for oil leaks. If necessary, tighten the connection and repeat Steps 3 and 4.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

5. Install the access platform (work tool) to the quick coupler. Refer to the following information for the installation and the operation of the access platform (work tool).
   • Operation and Maintenance Manual, SEBU7370, "Quick Coupler (Hydraulic)" or

   • Operation and Maintenance Manual, SEBU7370, "Quick Coupler (Manual)"

   • Operation and Maintenance Manual, SEBU7370, "Access Platform".

   • Operation and Maintenance Manual, SEBU7370, "Access Platform Control".

   • Operation and Maintenance Manual, SEBU7370, "Before Operating Machine".

Travel

1. Ensure that the parking brake is engaged and that the transmission control is in the NEUTRAL position. Ensure that the key switch for the lockout system is turned as far as possible in a counterclockwise direction.

2. Ensure that the access platform (work tool) is in the TRAVEL position. When the machine is in the TRAVEL position, the boom is fully retracted and the floor of the access platform (work tool) is within 450 mm (18 inch) of the ground. Check the LED on both of the position sensors and ensure that the LED is on. Disengage the parking brake and move the transmission control to the FORWARD position. Check that the machine travels.

3. Leave the transmission control in the FORWARD position. Raise the access platform (work tool) from the TRAVEL position until the LED on the rear position sensor is off. Check that the machine does not travel.

4. Leave the transmission control in the FORWARD position and lower the boom in order to return the access platform (work tool) to the TRAVEL position. Check that the machine does not travel.

5. Move the transmission control to the NEUTRAL position. Engage the parking brake and then disengage the parking brake. Move the transmission control to the FORWARD position. Check that the machine travels.

6. Leave the transmission control in the FORWARD position and extend the boom from the TRAVEL position until the LED on the front position sensor is off. Check that the machine does not travel.

7. Leave the transmission control in the FORWARD position and retract the boom in order to return the access platform (work tool) to the TRAVEL position. Check that the machine does not travel.

8. Repeat Step 5.

9. Shut off the engine.

Lockout of Access Platform Control Switches

1. Ensure that the key switch for the lockout system is turned as far as possible in a counterclockwise direction.

2. Ensure that the push button for stopping the engine from the access platform (work tool) is in the ON position. When the push button is out, the engine can be started. Operate the push button for starting the engine from the access platform (work tool). Check that the engine does not start.

3. Start the engine from the cab. Operate the switches that control the boom functions from the access platform. Check that the boom functions do not operate.

4. Shut off the engine from the cab.

Lockout of Machine Functions

1. Lower the stabilizers.

2. Ensure that the key switch for the lockout system is turned as far as possible in a clockwise direction.

3. Ensure that the push button for stopping the engine from the access platform (work tool) is in the ON position. Start the engine from the cab. Check that the following machine functions do not operate from the cab:
   • Boom Raise

   • Boom Lower

   • Boom Extend

   • Boom Retract

   • Stabilizers

   • Frame level

   • Quick Coupler

4. Raise the stabilizers.

5. Disengage the parking brake and move the transmission control to the FORWARD position. Check that the machine does not travel.

6. Press the push button for stopping the engine from the access platform (work tool). Check that the engine stops.

7. Do not reset the push button for stopping the engine. Press the push button for starting the engine. Check that the engine does not start.

8. Do not reset the push button for stopping the engine. Check that the engine does not start from the cab.

9. Pull out the push button for stopping the engine.

Control Switches for the Access Platform

1. Check that the access platform (work tool) is installed correctly. Start the engine from the cab and ensure that the key switch for the lockout system is turned as far as possible in a counterclockwise direction. Ensure that the following conditions are met.
   • The machine is laterally level.

   • The stabilizers are down on firm level ground and the tires are off the ground.

   Refer to the above topics in Operation and Maintenance Manual, SEBU7370.

2. Shut off the engine.

3. Ensure that the parking brake is engaged and that the engine start switch in the cab is in the ON position. Ensure that the key switch for the lockout system is turned as far as possible in a clockwise direction.

4. Ensure that the following conditions are met before you operate the control switches for the access platform .
   • You are wearing a body harness that is properly secured to the access platform (work tool).

   • The payload does not exceed 250 kg (551 lb).

   • You fully understand the information that is contained in the Operation and Maintenance Manual.

   • The area around the machine is clear of obstructions.

   • The area around the machine is clear of any overhead cables.

5. Ensure that the push button for stopping the engine is in the ON position. Press the push button for starting the engine in order to check that the engine starts.

6. Check the operation of the boom functions in the following order. Operate each of the following boom functions for 5 seconds at slow speed.
   • Boom raise

   • Boom lower

   • Boom extend

   • Boom retract

   Note: If the boom functions do not operate, refer to Step 9 in order to increase the speed of the boom.

7. Check the operation of the boom in the following order. Make periodic checks on the access platform drum.
   • Raise the boom at fast speed and stop the boom at an angle of 45 degrees.

   • Fully raise the boom at slow speed.

   • Extend the boom at fast speed. Stop the boom after the boom is approximately halfway toward the full extension.

   • Fully extend the boom at slow speed.

   • Retract the boom at fast speed. Stop the boom after the boom is approximately halfway from the full extension.

   • Fully retract the boom at slow speed.

   • Lower the boom to the travel position.

8. With the machine at normal working temperature, record the cycle time for the following operation.
   • Fully raise the boom.

   • Fully lower the boom.

   The cycle time for lowering the boom should be between 60 and 90 seconds. If necessary, perform Step 9.

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Illustration 54	g00781874

9. Loosen locknut (108) on 204-9047 Valve (26). Use a suitable allen wrench in order to turn the hex socket screw (109). Turn hex socket screw (109) clockwise in order to increase the speed of the boom functions. Turn the hex socket screw counterclockwise in order to decrease the speed of the boom functions. Repeat Step 8 in order to record the cycle time again.

   Note: When the nut is turned in any direction, the speed is adjusted for all of the boom functions when the boom is operated at slow speed.

10. Tighten locknut (108) when the correct time for the boom lower is achieved.

11. When a swivel access platform has been installed on the machine you must check the operation of the swivel access platform. Rotate the access platform to the left and rotate the access platform to the right. Refer to the topic in the Operation and Maintenance Manual.