Installation of the 288-6536 Control Valve Conversion Gp (Third Valve Kit){5051} Caterpillar

Wheel Loader:

950H (S/N: N1A1-UP; JAD1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP; MAL1-UP)

Introduction

This publication contains the information for installation of the kit for the control valve conversion group. A complete listing of the parts that are contained in this kit are listed in the Parts Manual, SEBC1466. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Do not perform any procedure or order parts outlined in this publication until you understand the information contained in this document.

Note: The implement for the third function must be available so that this installation procedure may be completed. This procedure is necessary so that final calibration of the control lever and valve may be completed with the use of ET.

Machine Preparation

Note: The following preparation must be done before starting this procedure.

1. Connect the steering frame lock. Refer to Disassembly and Assembly, RENR8881, "IT62H Integrated Toolcarrier and 950H and 962H Wheel Loaders Machine Systems ", "Steering Frame Lock - Separate and Connect".

2. Drain the implement hydraulic system. Refer to Operation and Maintenance Manual, SEBU7889, "IT62H Integrated Toolcarrier and 950H and 962H Wheel Loaders", "Hydraulic System Oil - Change" for the correct procedure.

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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 work tools have been lowered to the ground, 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.

Installation of the 288-6536 Control Valve Conversion Gp (Third Valve Kit)

Conversion of the Electrohydraulic Control Gp with two Functions into an Electrohydraulic Control Gp with three Functions

Note: Refer to Disassembly and Assembly, RENR8881, "IT62H Integrated Toolcarrier and 950H and 962H Wheel Loaders Machine Systems ", "Electrohydraulic Control - Remove and Electrohydraulic Control - Install" in order to assist in the following steps.

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Illustration 1	g01259089
View of the electrohydraulic control group

1. Remove the existing cover from the electrohydraulic control group.

2. Use four 9X-2044 Screws (2) and install the 307-4671 Handle Control Gp (Auxiliary) (1) .

3. Connect the plug that is on the 307-4671 Handle Control Gp (Auxiliary) (1) to the wiring group for the cab.

4. Install the 6V-3987 Seal (6) onto each end of the electrohydraulic control group.

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Illustration 2	g01260349
View of the electrohydraulic control group with cover

5. Install the four 4E-8722 Nuts (5) onto the 262-5237 Cover (3) .

6. Use the two 6R-7653 Screws (4) and install the 262-5237 Cover (3) .

7. Remount the cushion assembly onto the 262-5237 Cover (3) .

8. Install the 201-5563 Film (7) onto the 262-5237 Cover (3) .

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Illustration 3	g01375110
View of front panel

9. Remove the rocker switch plug and install the 256-7822 Rocker Switch (Third Function Select) (8) into the front panel.

Conversion of the Main Control Valve Gp with two Functions into a Main Control Valve Gp with three Functions

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Illustration 4	g01287644
View of original main control valve (A) Hose (B) Tube (C) Identification plate (D) Rod (E) Washer (F) Nut (G) Shuttle valve (H) Valve

1. Remove the following parts from the original main control valve:
   • One Hose (A)

   • One Tube (B)

   • One Identification Plate (C)

   • Four Rods (D)

   • Eight Washers (E)

   • Eight Nuts (F)

2. If shuttle valve (G) is present, remove shuttle valve (G) .

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Illustration 5	g01373180
Bottom view of the valve (H) in Illustration 4

3. Remove the plug (J) from the bottom of valve (H).

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Illustration 6	g01288269
Bottom view of the 261-0017 Control Valve Gp

Note: The 261-0017 Control Valve Gp may not contain a shuttle valve. The next two steps will not be necessary if the 261-0017 Control Valve Gp does not contain a shuttle valve.

4. Remove shuttle valve (K) from the bottom of the 261-0017 Control Valve Gp .

5. Install plug (J) into the bottom of the 261-0017 Control Valve Gp . Tighten the plug to 16 ± 3 N·m (11.80 ± 2.21 lb ft).

6. Install the valve (K) into the bottom of the valve (H). Tighten the valve to 16 ± 3 N·m (11.80 ± 2.21 lb ft).

7. For proper operation, the following three valve sections should contain a shuttle valve:
   • Lift valve section

   • Tilt valve section

   • Ride control valve section

   The third function valve must be plugged without a shuttle valve.

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Illustration 7	g01375116
A view of main control valve after the third valve has been installed.

8. Use the following hardware and install the 261-0017 Control Valve Gp (Auxiliary) (12) onto the main control valve:
   • Four 7X-2553 Bolts (13)

   • Four 238-1796 Rods (14)

   • Eight 8T-4132 Nuts (15)

   • Eight 9X-8257 Washers (16)

9. If shuttle valve (G) was removed in Step 2, install the 150-4043 Connector As (18). Reconnect the elbow and hose.

10. Refer to hose (A) in Illustration 4. Use original seals and install the 249-0368 Hose As (9) in place of hose (A) .

11. Use original seals and install the 259-1970 Tube As (10) .

12. Use the original screw and install the 279-4514 Identification Plate (17) .

Modification of the Standard Arm Assembly

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Illustration 8	g01575395
Top view of standard arm assembly

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Illustration 9	g01575396
View of Section "A-A" in Illustration 8 (A) 246.1 ± 3 mm (9.6890 ± 0.1181 inch) (B) 230 ± 3 mm (9.0551 ± 0.1181 inch) (C) 205.2 ± 3 mm (8.0787 ± 0.1181 inch) (D) 173.1 ± 3 mm (6.8149 ± 0.1181 inch) (E) 103 ± 1 mm (4.0551 ± 0.0394 inch) (F) 18.4 ± 1 mm (0.7244 ± 0.0394 inch) (G) 182.2 ± 1 mm (7.1732 ± 0.0394 inch) (H) 481.1 ± 3 mm (18.9409 ± 0.1181 inch) (J) 669.7 ± 3 mm (26.3661 ± 0.1181 inch) (K) 1027 ± 3 mm (40.4330 ± 0.1181 inch) (L) 35.9 ± 3 mm (1.4134 ± 0.1181 inch) (M) 1923.6 ± 3 mm (75.7321 ± 0.1181 inch) (N) 2172.3 ± 3 mm (85.5235 ± 0.1181 inch) (P) 2467.8 ± 3 mm (97.1573 ± 0.1181 inch) (R) 27 ± 3 mm (1.0630 ± 0.1181 inch) (S) 10.5 ± 3 mm (0.4134 ± 0.1181 inch) (T) 26.2 ± 3 mm (1.0315 ± 0.1181 inch) (U) 55 ± 3 mm (2.1654 ± 0.1181 inch) (V) 115.8 ± 3 mm (4.5590 ± 0.1181 inch) (W) 163.3 ± 3 mm (6.4291 ± 0.1181 inch) (X) 279.6 ± 3 mm (11.0079 ± 0.1181 inch) (Y) 1946.2 ± 3 mm (76.6219 ± 0.1181 inch) (Z) 1792.2 ± 3 mm (70.5589 ± 0.1181 inch) (AA) 1702.7 ± 3 mm (67.0353 ± 0.1181 inch) (BB) 1105.7 ± 3 mm (43.5314 ± 0.1181 inch) (CC) 151.4 ± 1 mm (5.9606 ± 0.0394 inch) (DD) 307.2 ± 3 mm (12.0945 ± 0.1181 inch)

1. Locate the position for the following parts and weld the parts onto the standard arm assembly per instructions in Illustration 9:
   • One 148-8062 Block (2)

   • Two 106-0421 Bosses (3)

   • One 163-9662 Boss (4)

   • One 7V-2882 Plate As (5)

   • Two 9C-4935 Plates (6)

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Illustration 10	g01575397
View of Section "B-B" in Illustration 8 (EE) 279.6 ± 3 mm (11.0079 ± 0.1181 inch) (FF) 1105.7 ± 3 mm (43.5314 ± 0.1181 inch) (GG) 720 ± 3 mm (28.3464 ± 0.1181 inch) (HH) 229.1 ± 3 mm (9.0197 ± 0.1181 inch) (JJ) 252.3 ± 3 mm (9.9331 ± 0.1181 inch) (KK) 307.2 ± 3 mm (12.0945 ± 0.1181 inch) (LL) 459 ± 1 mm (18.0708 ± 0.0394 inch) (MM) 708.3 ± 3 mm (27.8858 ± 0.1181 inch) (NN) 1045.6 ± 1 mm (41.1653 ± 0.0394 inch) (PP) 1702.7 ± 3 mm (67.0353 ± 0.1181 inch)

2. Locate the position for the following parts and weld the parts onto the standard arm assembly per instructions in Illustration 10:
   • One 102-8702 Plate As (1)

   • Two 106-0421 Bosses (3)

Installation of the Front Lines Group

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Illustration 11	g01573005
Top view of front lines group

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Illustration 12	g01574253
Right side view of front lines group

1. Install the following parts onto the 313-9077 Tube As (6) :
   • One 6V-0852 Dust Cap (2)

   • One 164-5567 Fitting As (Quick Disconnect) (8)

   • One 164-5598 Plug As (18)

2. Use the following parts and install the 313-9077 Tube As (6) :
   • One 1P-3705 Rectangular Seal (9)

   • Four 8T-4223 Hard Washers (16)

   • Four 8T-4910 Bolts (17)

3. Use the following parts and secure the 313-9077 Tube As (6) onto the arm assembly:
   • One 313-9083 Bracket As (21)

   • Four 7X-7729 Washer (19)

   • One 8T-4195 Bolt (20)

4. Install the following parts onto the 313-9076 Tube As (5) :
   • One 6V-0852 Dust Cap (2)

   • One 164-5567 Fitting As (Quick Disconnect) (8)

   • One 164-5598 Plug As (18)

5. Use the following parts and install the 313-9076 Tube As (5) :
   • One 1P-3705 Rectangular Seal (9)

   • Four 8T-4223 Hard Washers (16)

   • Four 8T-4910 Bolts (17)

6. Use the following parts and secure the 313-9076 Tube As (5) onto the arm assembly:
   • One 313-9083 Bracket As (21)

   • Four 7X-7729 Washer (19)

   • Four 8T-4195 Bolt (20)

7. Use the following parts and install one 5H-4020 Cover (1) onto the 319-6635 Tube Assembly (4).
   • Four 197-3295 Half Flanges (3)

   • Two 4J-0522 O-Ring Seals (10)

   • Eight 8T-4183 Bolts (14)

   • Eight 7X-3392 Hard Washers (23)

8. Use the following parts and install the 319-6635 Tube Assembly (4) onto the arm assembly:
   • Two 8S-0023 Clips (11)

   • Two 8S-0024 Clips (12)

   • Two 8T-4139 Bolts (13)

   • Two 8T-4223 Hard Washers (16)

9. Use the following parts and install one 5H-4020 Cover (1) onto the 319-6636 Tube Assembly (15) .
   • Four 197-3295 Half Flanges (3)

   • Two 4J-0522 O-Ring Seals (10)

   • Eight 8T-4183 Bolts (14)

   • Eight 7X-3392 Hard Washers (23)

10. Use the following parts and install the 319-6636 Tube Assembly (4) onto the arm assembly:
    • Two 8S-0023 Clips (11)

    • Two 8S-0024 Clips (12)

    • Two 8T-4139 Bolts (13)

    • Two 8T-4223 Hard Washers (16)

11. Use the following parts and connect the two lower 313-9081 Hose Assemblies (7) to the Tube Assemblies:
    • Four 197-3295 Half Flange (3)

    • Two 4J-0522 O-Ring Seal (10)

    • Eight 8T-4183 Bolt (14)

    • Eight 7X-3392 Hard Washers (23)

12. Use the following parts and connect the two upper 313-9081 Hose Assemblies (7) to the Tube Assemblies:
    • Four 8C-3206 Half Flanges (25)

    • Two 4J-0520 O-Ring Seal (26)

    • Eight 8T-4186 Bolt (22)

    • Eight 8T-4121 Hard Washers (24)

Software configuration and calibration of the Control Lever and Valve

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

Note: The implement for the third function must be available so that this installation procedure may be completed. This procedure is necessary so that final calibration of the control lever and valve may be completed.

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: This feature will be activated on the next power cycle.