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

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".

2. 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.

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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 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.

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Illustration 1	g01263454
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.

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Illustration 2	g01384011
View of the electrohydraulic control group

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

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

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

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

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Illustration 3	g01313781
View of front panel

8. 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

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Illustration 4	g01363362
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)

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Illustration 5	g01363369
Bottom view of the valve (H) in Illustration 4

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

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Illustration 6	g01363373
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.

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

4. 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).

5. 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).

6. 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	g02415336
Top view of main control valve after the third valve has been installed.

7. Use the following hardware and install the 261-0017 Control Valve Gp (AUXILIARY) (12) onto the main control valve:
   • Four 238-1796 Rods (6)

   • Eight 8T-4132 Nuts (7)

   • Eight 9X-8257 Washers (8)

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Illustration 8	g01591674

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

9. 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.

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

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

Modification of the Standard Arm Assembly

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Illustration 9	g01263529
Top view of standard arm assembly

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Illustration 10	g01524525
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:
   • One 7V-2882 Plate As (1)

   • Two 9C-4935 Plates (3)

   • Three 9R-2613 Weld Boss (4)

   • Four 106-0421 Bosses (5)

   • One 163-9662 Boss (6)

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Illustration 11	g01313789
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)

2. Locate the position for the following part and weld the part onto the standard arm. assembly per instructions in the following Illustration 11:
   • One 7X-0752 Weld Boss (2)

Installation of the Front Lines Group

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Illustration 12	g01515316
Right side and top view of front frame

1. Use the following parts and install the 319-2440 Tube As (6) :
   • One 1P-3704 Rectangular Seal (10)

   • Four 8T-4223 Hard Washers (16)

   • Four 8T-4648 Bolts (17)

2. Use the following parts in order to secure the 319-2440 Tube As (6) onto the arm assembly:
   • One 319-2445 Bracket (14)

   • Eight 8T-4139 Bolt (18)

   • Eight 8T-4223 Hard Washers (16)

3. Use the following parts and install the 319-2439 Tube As (7) :
   • One 1P-3704 Rectangular Seal (10)

   • Four 8T-4223 Hard Washers (16)

   • Four 8T-4648 Bolts (17)

4. Use the following parts and secure the 319-2439 Tube As (7) onto the arm assembly:
   • One 319-2445 Bracket (14)

   • Eight 8T-4139 Bolt (18)

   • Eight 8T-4223 Hard Washers (16)

5. Use the following parts and install the 5H-4020 Covers (12) onto the 319-6666 Tube Assemblies (2) :
   • Two 197-3295 Half Flanges (4)

   • One 4J-0522 O-Ring Seals (11)

   • Four 8T-4956 Bolts (18)

   • Four 7X-3392 Hard Washers (13)

6. Use the following parts and install the 319-6666 Tube Assemblies (2) onto the arm assembly:
   • Two 197-3295 Half Flanges (4)

   • One 4J-0522 O-Ring Seals (11)

   • Four 8T-4183 Bolts (19)

   • Four 7X-3392 Hard Washers (13)

7. Use the following parts in order to secure the 319-6666 Tube Assemblies (2) onto the arm assembly:
   • Four 8S-0023 Clips (3)

   • Four 8S-0024 Clips (8)

   • Four 8T-4139 Bolts (15)

   • Four 8T-4223 Hard Washers (16)

8. Use the following parts and connect the two 233-8646 Hose Assemblies (5) onto the lower Tube Assemblies:
   • Four 197-3295 Half Flanges (4)

   • Two 4J-0522 O-Ring Seals (11)

   • Eight 8T-4956 Bolts (18)

   • Eight 7X-3392 Hard Washers (13)

9. Use the following parts and connect the two 233-8646 Hose Assemblies (5) onto the upper Tube Assemblies:
   • Eight 197-3295 Half Flanges (4)

   • Two 4J-0522 O-Ring Seals (11)

   • Eight 8T-4183 Bolts (18)

   • Eight 7X-3392 Hard Washers (13)

10. Install the following parts onto the 319-2439 Tube Assembly (7) and the 319-2440 Tube Assembly (6) :
    • One 6V-0852 Dust Cap (1)

    • One 164-5567 Fitting As (QUICK DISCONNECT) (9)

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.

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.