Installation Procedure to Retrofit a Boom Lowering Control Valve on Certain 568 LL Forestry Machines {1329, 1439, 1916, 1917, 1923, 1924, 5001, 5117, 5130, 5264, 5453} Caterpillar


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Installation Procedure to Retrofit a Boom Lowering Control Valve on Certain 568 LL Forestry Machines {1329, 1439, 1916, 1917, 1923, 1924, 5001, 5117, 5130, 5264, 5453} [M0067264]
ELECTRICAL AND STARTING SYSTEM
SENSOR GP
Installation Procedure to Retrofit a Boom Lowering Control Valve on Certain 568 LL Forestry Machines {1329, 1439, 1916, 1917, 1923, 1924, 5001, 5117, 5130, 5264, 5453}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Machine Preparation
5.1. Installation Procedure
Forest Machine
568 (S/N: BRB1-UP)

Introduction

This Special Instruction outlines the installation procedure to retrofit a boom lowering control valve on the 568 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 
500-6613  Support As 
245-5122  Block 
8T-4185  Bolt 
8T-4121  Hard Washer  26 
6V-8636  Connector 
6V-8724  Elbow 
8C-8988  Elbow 
6V-9001  Elbow 
335-0512  Manual Valve Gp 
10  8T-4176  Bolt 
11  8T-4223  Hard Washer  22 
12  6V-9007  Elbow 
13  085-7356  Fitting 
14  8T-7970  Elbow 
15  344-7392  Pressure Sensor Gp 
16  3D-2824  O-Ring Seal 
17  3J-1907  O-Ring Seal  15 
18  6V-8397  O-Ring Seal  20 
19  9S-4191  Plug 
20  323-7604  Hydraulic Block Gp 
21  5P-3108  O-Ring Seal 
22  1P-3703  Rectangular Seal 
23  287-7324  Tee 
24  199-1913  Hose As 
25  3K-0360  O-Ring Seal 
26  6V-8398  O-Ring Seal 
27  356-9229  Hose As 
28  6V-9836  Swivel Tee 
29  4I-3988  Hose As 
30  501-4622  Hose As 
31  6V-8785  Tee 
32  363-2406  Hose As 
33  6V-9854  Elbow 
34  5K-9090  O-Ring Seal 
35  7M-8485  O-Ring Seal 
36  352-7143  Check and Relief Valve Gp 
37  108-3819  Bolt 
38  6V-9200  Elbow 
39  6V-8637  Connector 
40  3J-7354  O-Ring Seal 
41  465-8771  Support As 
42  500-6621  Support As 
43  8T-4196  Bolt  24 
44  8T-4139  Bolt 
45  108-7550  Hard Washer 
46  500-6591  Support As 
47  500-6594  Support As 
48  500-6607  Support As 
49  500-6622  Tube As 
50  500-6623  Tube As 
51  1P-3704  Rectangular Seal 
52  8T-4648  Bolt  16 
53  351-5061  Tube As 
54  351-5062  Tube As 
55  500-6624  Hose As 
56  337-2645  Hose As 
57  500-6617  Hose As 
58  7K-1181  Cable Strap  12 
59  6V-9746  O-Ring Seal 
60  275-1713  Hose As 
61  4I-9522  Marker Band 
62  4I-9526  Marker Band 
63  292-7584  Hose As 
64  4I-9521  Marker Band 
65  4I-9525  Marker Band 
66  492-3444  Guard As 
67  7X-0590  Hard Washer 
68  8T-4183  Bolt 
69  5B-5840  Spacer 

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 1g06026875
    Location on Machine
    (70) 325-8997 Hose As
    (71) Sixteen 6V-0400 Half Flanges
    (72) Thirty-two 8T-4194 Bolts
    (73) Thirty-two 8T-4223 Hard Washers

  1. Remove and discard hose assembly (70). Remove and retain for future use half flanges (71), bolts (72), and washers (73).


    Illustration 2g06026881
    Location on Machine
    (74) Two 8T-4956 Bolts
    (75) Four 8T-4223 Hard Washers
    (76) 108-7550 Clip
    (77) 325-8995 Support As
    (78) Two 8T-4139 Bolts

  2. Remove and discard support assembly (77). Remove and retain mounting hardware (74), (75), (76), and (78).


    Illustration 3g06026908
    (1) 500-6613 Support As
    (2) 245-5122 Block
    (3) Two 8T-4185 Bolts
    (4) Two 8T-4121 Hard Washers
    (5) Three 6V-8636 Connectors
    (6) Four 6V-8724 Elbows
    (7) 8C-8988 Elbow
    (8) 6V-9001 Elbow
    (9) 335-0512 Manual Valve Gp
    (10) Two 8T-4176 Bolts
    (11) Two 8T-4223 Hard Washers
    (12) Two 6V-9007 Elbows
    (13) 085-7356 Fitting
    (14) 8T-7970 Elbow
    (15) 344-7392 Pressure Sensor Gp
    (16) Three 3D-2824 O-Ring Seals
    (17) Ten 3J-1907 O-Ring Seals
    (18) 6V-8397 O-Ring Seal

  3. Sub-assemble support assembly (1), install parts (2) through (18).


    Illustration 4g06026917
    Location on Machine
    (1) 500-6613 Support As
    (74) Two 8T-4956 Bolts
    (75) Four 8T-4223 Hard Washers
    (76) 108-7550 Clip
    (78) Two 8T-4139 Bolts

  4. Install support assembly (1), use mounting hardware retained from Step 2.


    Illustration 5g06026929
    Location on Machine


    Illustration 6g06026932
    (79) 448-0814 Hose As
    (80) 6V-8774 Tee
    (81) 448-0819 Hose As
    (82) 6V-8724 Elbow
    (83) 307-5103 Hose As

  5. Remove and discard parts (79) through (83).


    Illustration 7g06026934
    Location on Machine
    (17) 3J-1907 O-Ring Seal
    (19) 9S-4191 Plug
    (83) 307-5103 Hose As
    (84) 148-8336 Connector As

  6. Remove and discard hose (83) and connector (84).

  7. At the same port, install O-ring (17) and plug (19).


    Illustration 8g06026956
    Location on Machine
    (85) Four 108-3819
    (86) Four 108-1781
    (87) 323-7611 Control Valve Gp
    (88) 5P-3108 O-Ring Seal
    (89) 1P-3703 Rectangular Seal

  8. Remove control valve group (87), seals (88) and (89), and bolts (85) and (86). Retain bolts for installing new block.


    Illustration 9g06026962
    (20) 323-7604 Hydraulic Block Gp
    (21) 5P-3108 O-Ring Seal
    (22) 1P-3703 Rectangular Seal
    (85) Four 108-3819
    (86) Four 108-1781

  9. Install new hydraulic block group (20), use new seals (21) and (22). Mount using bolts (85) and (86) retained from Step 8.


    Illustration 10g06026968
    Location on Machine
    (90) 178-5908 Hose As
    (91) 6V-8625 Elbow

  10. Disconnect hose (90) and set aside. Remove elbow (91) and discard.


    Illustration 11g06026976
    Location on Machine
    (18) 6V-8397 O-Ring Seal
    (23) 287-7324 Tee
    (24) 199-1913 Hose As
    (25) 3K-0360 O-Ring Seal
    (26) 6V-8398 O-Ring Seal
    (90) 178-5908 Hose As

  11. Install tee (23) and seal (25). On one side of tee (23), install hose (24) and seal (18). On the other side of tee (23), install seal (26) and connect existing hose (90) from Step 10.


    Illustration 12g06026998
    Location on Machine
    (18) Four 6V-8397 O-Ring Seals
    (27) 356-9229 Hose As
    (28) 6V-9836 Swivel Tee
    (29) 4I-3988 Hose As

  12. Install swivel tee (28) and seal (18). On one side of tee (28), install hose (29) and seal (18). On the other side of tee (28), install hose (27) and seal (18).

  13. Connect the other side of hose (27) with seal (18) as shown in Illustration 12.


    Illustration 13g06027252
    Location on Machine
    (18) Two 6V-8397 O-Ring Seals
    (24) 199-1913 Hose As
    (29) 4I-3988 Hose As

  14. Connect the other ends of hoses (24) and (29) with seals (18). Refer to Illustration 13.


    Illustration 14g06027257
    Location on Machine
    (92) 288-6213 Hose As
    (93) 148-8330 Connector As

  15. Remove hose (92) and connector (93) and discard.


    Illustration 15g06027273
    (30) 501-4622 Hose As
    (31) 6V-8785 Tee
    (32) 363-2406 Hose As
    (34) Three 5K-9090 O-Ring Seals
    (35) 7M-8485 O-Ring Seal
    (94) 148-8429 Tee As


    Illustration 16g06027277
    (30) 501-4622 Hose As
    (33) 6V-9854 Elbow
    (34) Two 5K-9090 O-Ring Seals

  16. Install parts (30) through (35). Re-orient tee (94) as needed.


    Illustration 17g06027291
    Location on Machine
    (95) Four 135-0806 Plates
    (96) Eight 135-0807 Clamps
    (97) Eight 8T-4956 Bolts
    (98) Sixteen 8T-4223 Hard Washers
    (99) Four 8C-6986 Locking Bolts
    (100) Four 8T-4244 Nuts
    (101) 158-8725 Guard As
    (102) Eight 8T-4183 Bolts
    (103) Eight 086-0297 Washers

  17. Remove parts (95) through (100) and discard. Remove parts (101) through (103).


    Illustration 18g06027294
    (104) Sixteen 8T-4648 Bolts
    (105) 438-3090 Tube As
    (106) 438-3088 Tube As
    (107) Two 087-5679 Support As
    (108) Eight 8T-4195 Bolts
    (109) Eight 8T-4121 Hard Washers
    (110) 438-3091 Tube As
    (111) Two 346-9089 Support As
    (112) Eight 8T-4139 Bolts
    (113) Eight 8T-4223 Hard Washers
    (114) 438-3089 Tube As

  18. Remove part (104) through (114) from the boom cylinders and discard.


    Illustration 19g06027309
    (36) 352-7143 Check and Relief Valve Gp
    (115) 178-7873 Bolt
    (116) Two 1P-1670 Seal Plugs
    (117) 9S-7725 Seal Plug
    (118) 225-4820 Plug As
    (119) 4D-2886 Clip
    (120) Two 8T-4244 Nuts
    (121) 7J-7666 Cover
    (122) 307-3493 Gasket

  19. Remove part (115) through (122) from check and relief valve group (36) and discard. Refer to Illustration 19. Remove the same number of parts from the second check and relief valve and discard.


    Illustration 20g06027322
    (5) Two 6V-8636 Connectors
    (16) 3D-2824 O-Ring Seal
    (17) Two 3J-1907 O-Ring Seals
    (36) 352-7143 Check and Relief Valve Gp
    (37) Four 108-3819 Bolts
    (38) 6V-9200 Elbow
    (39) 6V-8637 Connector
    (40) 3J-7354 O-Ring Seal

  20. Install parts (5) through (40) on check and relief valve group (36). Install the same number of parts on the second relief valve group on the other boom cylinder. Refer to Illustration 20.


    Illustration 21g06027324
    (4) Eight 8T-4121 Hard Washers
    (11) Four 8T-4223 Hard Washers
    (36) Two 352-7143 Check and Relief Valve Gp
    (41) Two 465-8771 Support As
    (42) Two 500-6621 Support As
    (43) Eight 8T-4196 Bolts
    (44) Four 8T-4139 Bolts
    (45) Four 108-7550 Clips

  21. Install parts (4) through (45) at the foot of the boom. Refer to Illustration 21.


    Illustration 22g06027330
    (4) Sixteen 8T-4121 Hard Washers
    (41) Two 465-8771 Support As
    (43) Sixteen 8T-4196 Bolts
    (46) Four 500-6591 Support As
    (47) 500-6594 Support As
    (48) 500-6607500-6607 Support As

  22. Install parts (4) through (48) at the foot of the boom. Refer to Illustration 22.


    Illustration 23g06027333
    (11) Eight 8T-4223 Hard Washers
    (49) 500-6622 Tube As
    (50) 500-6623 Tube As
    (51) Two 1P-3704 Rectangular Seal
    (52) Eight 8T-4648 Bolts
    (122) Four 8T-4179 Bolts
    (123) Two 234-2089 Covers
    (124) Two 234-2090 Gaskets

  23. Install parts (11) through (52) on the boom cylinders. Refer to Illustration 23.

  24. Remove parts (122) through (124) and discard. Refer to Illustration 23.


    Illustration 24g06027336
    (11) Eight 8T-4223 Hard Washers
    (51) Two 1P-3704 Rectangular Seal
    (52) Eight 8T-4648 Bolts
    (53) 351-5061 Tube As
    (54) 351-5062 Tube As

  25. Install parts (11) through (54) at the foot of the boom. Refer to Illustration 24.


    Illustration 25g06027339
    (22) Eight 1P-3703 Rectangular Seals
    (55) Four 500-6624 Hose As
    (71) Sixteen 6V-0400 Half Flanges
    (72) Thirty-two 8T-4194 Bolts
    (73) Thirty-two 8T-4223 Hard Washers

  26. Install hoses (52) with seals (22). Reuse parts (71) through (73) from Step 1.


    Illustration 26g06027345
    (18) Four 6V-8397 O-Ring Seals
    (56) Two 337-2645 Hose As
    (57) Two 500-6617 Hose As
    (58) Six 7K-1181 Cable Straps
    (59) Four 6V-9746 O-Ring Seals

  27. Install hoses (56) and (57) with seals (18) and (59). Secure using cable straps (58).


    Illustration 27g06027353
    Left-Side Boom Cylinder
    (18) Two 6V-8397 O-Ring Seals
    (60) 275-1713 Hose As
    (61) Two 4I-9522 Marker Bands

  28. On the left boom cylinder, install hose (60) with seals (18) and bands (61). Refer to Illustration 27.


    Illustration 28g06027354
    Right-Side Boom Cylinder
    (18) Two 6V-8397 O-Ring Seals
    (60) 275-1713 Hose As
    (62) Two 4I-9526 Marker Bands

  29. On the right boom cylinder, install hose (60) with seals (18) and bands (62). Refer to Illustration 28.


    Illustration 29g06027358
    Left-Side Boom Cylinder
    (18) Two 6V-8397 O-Ring Seals
    (58) Three 7K-1181 Cable Straps
    (63) 292-7584 Hose As
    (64) Two 4I-9521 Marker Bands

  30. On the left boom cylinder, install hose (63) with seals (18) and bands (64). Secure with cable straps (58). Refer to Illustration 29.


    Illustration 30g06027360
    Right-Side Boom Cylinder
    (18) Two 6V-8397 O-Ring Seals
    (58) Three 7K-1181 Cable Straps
    (63) 292-7584 Hose As
    (65) Two 4I-9525 Marker Bands

  31. On the right boom cylinder, install hose (63) with seals (18) and bands (65). Secure with cable straps (58). Refer to Illustration 30.


    Illustration 31g06027365
    (66) 492-3444 Guard As
    (67) Eight 7X-0590 Hard Washers
    (68) Eight 8T-4183 Bolts
    (69) Four 5B-5840 Spacers

  32. Install parts (66) through (69).

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