Installation of the 290-3538 Control Valve Conversion Gp (Third Valve Kit){5051, 5057, 5059, 5063} Caterpillar


Installation of the 290-3538 Control Valve Conversion Gp (Third Valve Kit){5051, 5057, 5059, 5063}

Usage:

966H A6D


Wheel Loader:
966H (S/N: A6D1-UP; A6J1-UP)
972H (S/N: A7D1-UP; A7J1-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, SEBC1470. 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 that are outlined in this publication until you understand the information that is contained in this document.

Note: The implement for the third function must be available so that this installation procedure may be completed. This step 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, RENR8859, "966H and 972H Wheel Loaders Machine Systems ", "Steering Frame Lock - Separate and Connect".

  1. Drain the implement hydraulic system. Refer to Operation and Maintenance Manual, SEBU7887, "966H and 972H Wheel Loaders", "Hydraulic System Oil - Change" for the correct procedure.


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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.


------ WARNING! ------

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 290-3538 Control Valve Conversion Gp

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

Note: Refer to Disassembly and Assembly, RENR8859, "966H and 972H Wheel Loaders Machine Systems ", "Electrohydraulic Control - Remove" and Disassembly and Assembly, RENR8859, "966H and 972H Wheel Loaders Machine Systems ", "Electrohydraulic Control - Install" in order to assist in the following steps.




    Illustration 1g01263454

    View of the electrohydraulic control group

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

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

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



    Illustration 2g01384011

    View of the electrohydraulic control group

  1. Remove the original four Nuts (5) from the original cover and install the original four Nuts onto the 262-5237 Cover (3) .

  1. Use the original four Screws (4) and install the 262-5237 Cover (3) .

  1. Remount the cushion assembly onto the 262-5237 Cover (3) by using the original screws.

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



    Illustration 3g01313781

    View of front panel

  1. Remove the rocker switch plug and install the 256-7822 Rocker Switch (3RD 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




    Illustration 4g01363362

    View of original main control valve

    (A) Hose

    (B) Tube

    (C) Identification plate

    (D) Rod

    (E) Washer

    (F) Nut

    (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)




    Illustration 5g01363369

    Bottom view of the valve (H) in Illustration 4

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



    Illustration 6g01363373

    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.

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

  1. 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).

  1. Install a 260-8590 Shuttle Valve into the bottom of the valve (H). Tighten the valve to 16 ± 3 N·m (11.80 ± 2.21 lb ft).

  1. 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.




    Illustration 7g02415336

    Top view of main control valve after the third valve has been installed.

  1. Use the following hardware and install the 261-0017 Control Valve Gp (AUXILIARY) (12) onto the main control valve:




    Illustration 8g01591674

  1. Tighten nuts (7) in the sequence that is shown to a torque of 50 ± 5 N·m (37 ± 4 lb ft).

  1. Tighten nuts (7) in the sequence that is shown by an additional 180°.

    Note: Nuts (7) on the opposite end of the valve must not rotate. Secure the nuts in order to prevent rotation.

  1. Use original seals and install the 249-0368 Hose As (1) .

  1. Use original seals and install the 259-1970 Tube As (2) .

Modification of the Standard Arm Assembly




    Illustration 9g01263529

    Top view of standard arm assembly




    Illustration 10g01524525

    View of Section A-A and Section B-B in Illustration 9

    (A) 247.5 ± 3 mm (9.7441 ± 0.1181 inch)

    (B) 468.6 ± 3 mm (18.4448 ± 0.1181 inch)

    (C) 95.6 ± 3 mm (3.7638 ± 0.1181 inch)

    (D) 1056.6 ± 3 mm (41.5983 ± 0.1181 inch)

    (E) 402.7 ± 3 mm (15.8543 ± 0.1181 inch)

    (F) 1121.9 ± 3 mm (44.1692 ± 0.1181 inch)

    (G) 276.7 ± 3 mm (10.8937 ± 0.1181 inch)

    (H) 1823.7 ± 3 mm (71.7991 ± 0.1181 inch)

    (J) 1882.3 ± 3 mm (74.1062 ± 0.1181 inch)

    (K) 57.8 ± 3 mm (2.2756 ± 0.1181 inch)

    (L) 1909.5 ± 3 mm (75.1770 ± 0.1181 inch)

    (M) 2058.9 ± 3 mm (81.0589 ± 0.1181 inch)

    (N) 38 ± 3 mm (1.4961 ± 0.1181 inch)

    (P) 4.1 ± 3 mm (0.1614 ± 0.1181 inch)

    (R) 34.8 ± 3 mm (1.3701 ± 0.1181 inch)

    (S) 94.9 ± 3 mm (3.7362 ± 0.1181 inch)

    (T) 2691 ± 3 mm (105.9447 ± 0.1181 inch)

    (U) 2078.9 ± 3 mm (81.8463 ± 0.1181 inch)

    (V) 2019.6 ± 3 mm (79.5117 ± 0.1181 inch)

    (y) 2330.5 ± 3 mm (91.7518 ± 0.1181 inch)

    (Z) 47.3 ± 3 mm (1.8622 ± 0.1181 inch)

    (AA) 1121.9 ± 3 mm (44.1692 ± 0.1181 inch)

    (BB) 402.7 ± 3 mm (15.8543 ± 0.1181 inch)

    (CC) 276.7 ± 3 mm (10.8937 ± 0.1181 inch)

    (DD) 1823.7 ± 3 mm (71.7991 ± 0.1181 inch)

  1. Locate the position for the following parts and weld the parts onto the standard arm assembly per instructions in the following Illustration: 9, 10:




    Illustration 11g01313789

    Right side view of standard arm assembly

    (W) 155 ± 3 mm (6.1024 ± 0.1181 inch)

    (X) 1412 ± 3 mm (55.5904 ± 0.1181 inch)

  1. Locate the position for the following part and weld the part onto the standard arm. assembly per instructions in the following Illustration 11:

Installation of the Front Lines Group




    Illustration 12g01515316

    Right side and top view of front frame

  1. Use the following parts and install the 319-2440 Tube As (6) :

  1. Use the following parts in order to secure the 319-2440 Tube As (6) onto the arm assembly:

  1. Use the following parts and install the 319-2439 Tube As (7) :

  1. Use the following parts and secure the 319-2439 Tube As (7) onto the arm assembly:

  1. Use the following parts and install the 5H-4020 Covers (12) onto the 319-6666 Tube Assemblies (2) :

  1. Use the following parts and install the 319-6666 Tube Assemblies (2) onto the arm assembly:

  1. Use the following parts in order to secure the 319-6666 Tube Assemblies (2) onto the arm assembly:

  1. Use the following parts and connect the two 233-8646 Hose Assemblies (5) onto the lower Tube Assemblies:

  1. Use the following parts and connect the two 233-8646 Hose Assemblies (5) onto the upper Tube Assemblies:

  1. Install the following parts onto the 319-2439 Tube Assembly (7) and the 319-2440 Tube Assembly (6) :

Software Configuration and Calibration of the Control Lever and Valve

Note: This feature is configurable and must be activated with the Product Software Programming System or a service tool.

Note: The implement for the third function must be available so that this installation procedure may be completed. This step 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.

  1. Select "SERVICE" from the menu.

  1. Select "CONFIGURATION" from the menu.

  1. Double click on the desired feature on the configuration screen.

  1. Select the desired status of the feature and click "OK".

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

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