Installation Procedure to Retrofit a Boom Lowering Control Valve on Certain 325D Forestry Machines {5057, 5147, 5811} Caterpillar


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Installation Procedure to Retrofit a Boom Lowering Control Valve on Certain 325D Forestry Machines {5057, 5147, 5811} [M0067248]
HYDRAULIC SYSTEM
LINES GP-BOOM
Installation Procedure to Retrofit a Boom Lowering Control Valve on Certain 325D Forestry Machines {5057, 5147, 5811}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Machine Preparation
5.1. Installation Procedure
Forest Machine
325D (S/N: C8L1-UP)

Introduction

This Special Instruction outlines the installation procedure to retrofit a boom lowering control valve on the 325D Forestry Machine.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section


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! ------

Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted.

When possible, the bucket or attachment must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and bucket or attachment have correct support.

The swing lock (if equipped) must be engaged before service is started.

Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.


Required Parts

Table 1
Required Parts 
Item  New Part Number  Description  Qty 
185-0488  Block 
1P-3703  Rectangular Seal 
4J-5268  O-Ring Seal 
4I-0818  Hose As 
104-8774  Hose As 
297-7977  Elbow As 
313-2283  Hose As 
398-5606  Tee As 
426-4029  Elbow As 
10  4I-0800  Hose As 
11  4I-8826  Hose As 
12  207-6449  Block 
13  5K-9090  O-Ring Seal 
14  7M-8485  O-Ring Seal 
15  148-8411  Plug As 
16  6V-9746  O-Ring Seal 
17  278-6604  Hose As 
18  278-6590  Support As 
19  278-8659  Support As 
20  8T-4956  Bolt 
21  8T-4223  Hard Washer  10 
22  292-7588  Block 
23  8T-4136  Bolt 
24  8T-4121  Hard Washer  26 
25  148-8435  Tee As 
26  148-8390  Elbow As 
27  148-8378  Elbow As 
28  164-5578  Tee As 
29  4I-1674  Clip 
30  8T-4139  Bolt 
31  199-1922  Tube As 
32  8T-6466  Bolt 
33  6V-9833  Cap As 
34  199-1924  Tube As 
35  490-6559  Support As 
36  490-6560  Support As 
37  115-8858  Support 
38  8T-4196  Bolt  24 
39  8T-3490  Weld Nut  24 
40  149-1738  Clip 
41  492-3444  Guard As 
42  492-3442  Support As 
43  492-3437  Support 
44  492-3438  Support 
45  7X-0590  Hard Washer 
46  8T-4183  Bolt 
47  263-1962  Load Control Valve Gp 
48  108-3819  Bolt 
49  148-8361  Elbow As 
50  148-8341  Connector As 
51  148-8336  Connector As 
52  490-6555  Tube As 
53  490-6556  Tube As 
54  1P-3704  Rectangular Seal 
55  8T-4910  Bolt 
56  490-6557  Tube As 
57  490-6558  Tube As 
58  7J-9108  O-Ring Seal 
59  292-7581  Hose As 
60  292-7584  Hose As 
61  278-6593  Hose As 
62  292-7258  Hose As 
63  7K-1181  Cable Strap  16 

Machine Preparation

  1. Position the machine on level ground.

  2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the ground. Lower the boom until the bucket is flat on the ground.

  3. Shut off the engine.

  4. Release the pressure in the hydraulic system. Refer to the appropriate Testing and Adjusting, Hydraulic System Pressure - Release

Installation Procedure



    Illustration 1g06023624
    Location on Machine


    Illustration 2g06027021
    (64) 255-5683 Load Control Valve Gp
    (65) 1P-3703 Rectangular Seal
    (66) 4J-5268 O-Ring Seal

  1. Remove load control valve group (64) and seals (65) and (66).


    Illustration 3g06023630
    (1) 185-0488 Block
    (2) 1P-3703 Rectangular Seal
    (3) 4J-5268 O-Ring Seal

  2. Install seals (2) and (3) on block (1)


    Illustration 4g06023652
    ( 1) 185-0488 Block
    (67) Two 101-7403 Bolts
    (68) 101-7404 Bolt
    (69) Three 199-1286 Bolts

  3. Reuse bolts (67), (68), and (69), and install block (1) on the main control valve.


    Illustration 5g06023647
    Location on Machine


    Illustration 6g06023845
    (70) 108-7372 Hose As
    (71) 087-5774 Hose As
    (72) 087-5772 Hose As
    (73) 148-8433 Tee As

  4. Detach hose (70), (71), and (72) and remove tee assembly (73).


    Illustration 7g06023935
    Location on Machine
    (74) 4I-6003 Hose As
    (75) 148-8363 Elbow As

  5. Disconnect hose (74) and move out of the way. Remove elbow (75).


    Illustration 8g06023965
    Location on Machine
    (4) Two 4I-0818 Hose As
    (5) 104-8774 Hose As
    (70) 108-7372 Hose As
    (73) 148-8433 Tee As

  6. Reinstall tee assembly (73) and attach existing hose (70). Install hoses (4) and (5).


    Illustration 9g06023982
    Location on Machine
    (6) 297-7977 Elbow As
    (7) 313-2283 Hose As
    (8) 398-5606 Tee As
    (9) 426-4029 Elbow As
    (74) 4I-6003 Hose As

  7. Install tee assembly (8). On one side of tee (8), install elbow (6) and hose (7). On the other side of tee (8), install elbow (9) and connect existing hose (74) from Step 5.


    Illustration 10g06024662
    Location on Machine
    (5) 104-8774 Hose As
    (74) 4I-6003 Hose As

  8. Connect the other ends of hoses (74) and (5) as shown in Illustration 10.


    Illustration 11g06024669
    Location on Machine


    Illustration 12g06024676
    (76) 148-8435 Tee As
    (77) 087-5762 Hose As
    (78) 087-4531 Hose As

  9. Remove hoses (77) and (78) and tee (76). Refer to Illustrations 11 and 12.


    Illustration 13g06024720
    Location on Machine


    Illustration 14g06024756
    (10) 4I-0800 Hose As

  10. Install hose (10) as shown in Illustrations 13 and 14.


    Illustration 15g06024794
    Location on machine
    (79) 260-7940 Hose As
    (80) 148-8355 Elbow As

  11. Remove hose (79) and elbow (80) as shown in Illustration 15.


    Illustration 16g06024806
    (11) 4I-8826 Hose As
    (12) 207-6449 Block
    (A) See detailed view of area


    Illustration 17g06024814
    Detailed View of Area A
    (11) 4I-8826 Hose As
    (12) 207-6449 Block
    (13) 5K-9090 O-Ring Seal
    (14) Two 7M-8485 O-Ring Seal
    (15) 148-8411 Plug As
    (80) 148-8355 Elbow As

  12. Install block (12) and O-ring (14) as shown in Illustrations 16 and 17.

  13. Install hose (11) as shown in Illustration 16. When connecting hose (11) to block (12), use new O-rings (13) and (14) and reuse elbow (80).

  14. Install plug (15) to the top of block (12).


    Illustration 18g06025292
    (12) 207-6449 Block
    (16) 6V-9746 O-Ring Seal
    (17) 278-6604 Hose As
    (B) See detailed view of area


    Illustration 19g06025337
    Detailed View of Area B
    (17) 278-6604 Hose As

  15. Install hose (17) and O-ring (16). Connect one end of hose (17) to block (12) as shown in Illustration 18.


    Illustration 20g06025342
    Location on Machine
    (81) Two 8T-4223 Hard Washers
    (82) Two 8T-4139 Bolts
    (83) 255-1787 Support As

  16. Remove support assembly (83) and mounting hardware (81) and (82).


    Illustration 21g06025655
    (15) 148-8411 Plug As
    (18) 278-6590 Support As
    (19) 278-8659 Support As
    (20) Four 8T-4956 Bolts
    (21) Two 8T-4223 Hard Washers
    (22) 292-7588 Block
    (23) Two 8T-4136 Bolts
    (24) Two 8T-4121 Hard Washers
    (25) Two 148-8435 Tee As
    (26) 148-8390 Elbow As
    (27) Four 148-8378 Elbow As
    (28) 164-5578 Tee As
    (81) Two 8T-4223 Hard Washers

  17. Install support assembly (18), mount using bolts (20) and reuse washers (81).

  18. Install parts (15) through (28) onto support assembly (18). Refer to Illustration 21.


    Illustration 22g06025700
    Location on Machine
    (84) 255-1786 Tube As
    (C) See detailed view of area
    (D) See detailed view of area


    Illustration 23g06025730
    Detailed View of Area C
    (85) 9F-2167 Purge Screw
    (86) Four 101-7398 Bolts
    (87) 1P-3703 O-Ring Seal


    Illustration 24g06025735
    Detailed View of Area D
    (88) Two 6V-9746 O-Ring Seals

  19. Remove parts (84) through (88). Refer to Illustrations 22, 23, and 24.


    Illustration 25g06025742
    (89) Two 4I-1674 Clips
    (90) Two 8T-4139 Bolts
    (91) Two 8T-4223 Hard Washers

  20. Reuse mounting hardware (89) through (91) when installing the new tube assembly.


    Illustration 26g06025821
    Location on Machine
    (2) 1P-3703 Rectangular Seal
    (13) Two 5K-9090 O-Ring Seals
    (16) Two 6V-9746 O-Ring Seals
    (31) 199-1922 Tube As
    (32) Four 8T-6466 Bolts
    (33) 6V-9833 Cap As
    (34) 199-1924 Tube As

  21. Install parts (2) through (34). Refer to Illustration 26.


    Illustration 27g06025849
    (21) Eight 8T-4223 Hard Washers
    (24) Eight 8T-4121 Hard Washers
    (29) Four 4I-1674 Clips
    (30) Eight 8T-4139 Bolts
    (35) 490-6559 Support As
    (36) 490-6560 Support As
    (37) Two 115-8858 Supports
    (38) Eight 8T-4196 Bolts
    (39) Eight 8T-3490 Weld Nuts
    (40) Four 149-1738 Clips

  22. Install parts (21) through (40) at the foot of the boom. Refer to Illustration 27.


    Illustration 28g06025865
    (24) Sixteen 8T-4121 Hard Washers
    (38) Sixteen 8T-4196 Bolts
    (39) Sixteen 8T-3490 Weld Nuts
    (41) 492-3444 Guard As
    (42) Four 492-3442 Support As
    (43) Two 492-3437 Supports
    (44) Two 492-3438 Supports
    (45) Eight 7X-0590 Hard Washers
    (46) Eight 8T-4183 Bolts

  23. Install parts (24) through (46) at the foot of the boom. Refer to Illustration 28.

    Note: Supports (44) must be placed on the boom cylinder prior to assembling the valve.



    Illustration 29g06025933
    177-7557 Boom Cylinder and Lines Gp
    (92) Four 8T-4196 Bolts
    (93) Four 8T-4121 Hard Washers
    (94) 115-8856 Support As
    (95) Four 8T-4910 Bolts
    (96) 1P-3704 Rectangular Seal
    (97) 162-9224 Tube As
    (98) 6V-9746 O-Ring Seal
    (99) Two 8T-4139 Bolts
    (100) Two 8T-4223 Hard Washers
    (101) 4I-1676 Clip
    (102) 162-7105 Support As


    Illustration 30g06026183
    177-7558 Boom Cylinder and Lines Gp
    (92) Four 8T-4196 Bolts
    (93) Four 8T-4121 Hard Washers
    (94) 115-8856 Support As
    (95) Four 8T-4910 Bolts
    (96) 1P-3704 Rectangular Seal
    (98) 6V-9746 O-Ring Seal
    (99) Two 8T-4139 Bolts
    (100) Two 8T-4223 Hard Washers
    (101) 4I-1676 Clip
    (102) 162-7105 Support As
    (103) 162-9226 Tube As

  24. Remove parts (92) through (103) on the two boom cylinders. Refer to Illustrations 29and 30.


    Illustration 31g06026226
    (47) 263-1962 Load Control Valve Gp
    (104) Two 178-7873 Bolt
    (105) Two 8T-4179 Bolts
    (106) 234-2089 Cover
    (107) 234-2090 Gasket
    (108) Two 1P-1670 Seal Plugs
    (109) 9S-7725 Seal Plug
    (110) 225-4820 Plug As
    (111) 4D-2886 Clip
    (112) Two 8T-4244 Nuts
    (113) 7J-7666 Cover

  25. Remove parts (104) through (113) from load control valve group (47). Refer to Illustration 31. Remove the same number of parts from the second load control valve on the other boom cylinder.


    Illustration 32g06026253
    (47) 263-1962 Load Control Valve Gp
    (48) Four 108-3819 Bolts
    (49) 148-8361 Elbow As
    (50) 148-8341 Connector As
    (51) Two 148-8336 Connector As

  26. Install parts (48) through (51) on load control valve group (47). Install the same number of parts on the second load control valve on the other boom cylinder. Refer to Illustration 32.


    Illustration 33g06026308
    (16) Two 6V-9746 O-Ring Seal
    (52) 490-6555 Tube As
    (53) 490-6556 Tube As
    (54) Two 1P-3704 Rectangular Seals
    (55) Eight 8T-4910 Bolts

  27. At the foot of the boom, install parts (16) and (52) through (55).


    Illustration 34g06026338
    (56) 490-6557 Tube As
    (57) 490-6558 Tube As
    (58) Two 7J-9108 O-Ring Seals

  28. Install parts (56) through (58).


    Illustration 35g06026370
    Left-Side Boom Cylinder
    (47) 263-1962 Load Control Valve Gp
    (59) 292-7581 Hose As
    (E) See detailed view of area


    Illustration 36g06026478
    Detailed View of Area E
    (22) 292-7588 Block
    (59) 292-7581 Hose As

  29. On the left boom cylinder, install hose assembly (59). Connect one end of hose (59) to load control valve group (47). Refer to Illustrations 35.

  30. Connect the other end of hose (59) to block (22). Refer to Illustration 36.


    Illustration 37g06026487
    Right-Side Boom Cylinder
    (47) 263-1962 Load Control Valve Gp
    (59) 292-7581 Hose As


    Illustration 38g06026490
    (22) 292-7588 Block
    (59) 292-7581 Hose As

  31. On the right boom cylinder, install hose assembly (59). Connect one end of hose (59) to load control valve (47). Refer to Illustration 37.

  32. Connect the other end of hose (59) to block (22). Refer to Illustration 38.


    Illustration 39g06026495
    Left-Side Boom Cylinder
    (47) 263-1962 Load Control Valve Gp
    (60) 292-7584 Hose As
    (F) See detailed view of area


    Illustration 40g06026500
    Detailed View of Area F
    (22) 292-7588 Block
    (60) 292-7584 Hose As

  33. On the left boom cylinder, install hose assembly (60). Connect one end of hose (60) to load control valve (47). Refer to Illustration 39.

  34. Connect the other end of hose (60) to block (22). Refer to Illustration 40.


    Illustration 41g06026532
    Right-Side Boom Cylinder
    (47) 263-1962 Load Control Valve Gp
    (60) 292-7584 Hose As
    (G) See detailed view of area


    Illustration 42g06026539
    Detailed View of Area G
    (22) 292-7588 Block
    (60) 292-7584 Hose As

  35. On the right boom cylinder, install hose assembly (60). Connect one end of hose (60) to load control valve (47). Refer to Illustration 41.

  36. Connect the other end of hose (60) to block (22). Refer to Illustration 42.


    Illustration 43g06026548
    (22) 292-7588 Block
    (61) Two 278-6593 Hose As
    (114) Four 7Y-7904 Hose As

  37. Reinstall existing hose assemblies (114) and install new hose assemblies (61). Refer to Illustration 43.


    Illustration 44g06026557
    (22) 292-7588 Block
    (47) 263-1962 Load Control Valve Gp
    (62) Two 292-7258 Hose As
    (63) Sixteen 7K-1181 Cable Straps

  38. Install hose assemblies (62).

  39. Secure of the newly installed hoses using straps (63). Refer to Illustration 44 for locations.

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