Start By:
a. Release the hydraulic system pressure.
NOTICE |
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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. |
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes to prevent fluid loss and to keep contaminants from entering the system.
Note: Before you begin the following procedure, swing the upper structure to gain access to the cover that is located under the cab.
- Loosen bolts (3).
- Remove bolts (1) to remove cover (2).
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Illustration 2 g00704095 - Disconnect hose assemblies (4) from the pilot valve.
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Illustration 3 g00704100 - Disconnect hose assemblies (5) from the pilot valve.
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Illustration 4 g00704108 - Disconnect harness assembly (6). Remove the harness assembly from the clip.
- Remove left travel pressure switch (7).
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Illustration 5 g00704110 - Disconnect harness assembly (8). Remove the harness assembly from the clip.
- Remove right travel pressure switch (9).
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Illustration 6 g00704117 Note: Mark the location of hydraulic connector (11) that has a filter for installation purposes.
- Remove hydraulic connector (11) from the pilot valve.
- Remove hydraulic connector (10) from the pilot valve.
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Illustration 7 g01208315 - Remove rubber floor mat (12) from the travel pedals.
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Illustration 8 g00704120 - Remove rubber pedal (13).
- Remove rubber pedal (14).
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Illustration 9 g00704123 - Remove bolts (17) and left travel pedal (15).
- Remove bolts (18) and right travel pedal (16).
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Illustration 10 g00704128 - Remove bellows (19) from the pilot valve.
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Illustration 11 g00704131 - Remove bolts (20).
- Remove pilot valves (21).
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Illustration 1 | g00704086 |
- Install pilot valves (21).
- Install bolts (20).
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Illustration 13 g00704128 - Install bellows (19) on the pilot valve.
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Illustration 14 g00704123 - Position right travel pedal (16) on the pilot valve. Install bolts (18). Tighten the bolts to a torque of
33 ± 3 N·m (25 ± 3 lb ft) . - Position left travel pedal (15) on the pilot valve. Install bolts (17). Tighten the bolts to a torque of
33 ± 3 N·m (25 ± 3 lb ft) .Show/hide tableIllustration 15 g00704120 - Install rubber pedal (14).
- Install rubber pedal (13).
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Illustration 16 g01208315 - Install rubber floor mat (12) around the travel pedals.
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Illustration 17 g00704117 - Install hydraulic fitting (10) in the pilot valve.
Note: The bottom hydraulic fitting is the hydraulic fitting with the filter.
- Install hydraulic fitting (11) in the pilot valve.
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Illustration 18 g00704110 - Install right travel pressure switch (9).
- Install the harness assembly in the clip. Connect harness assembly (8).
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Illustration 19 g00704108 - Install left travel pressure switch (7).
- Install the harness assembly in the clip. Connect harness assembly (6).
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Illustration 20 g00704100 - Connect hose assemblies (5) to the pilot valve. Tighten the hose assemblies to a torque of
37 ± 4 N·m (27 ± 3 lb ft) .Show/hide tableIllustration 21 g00704095 Note: Make sure that the hose assemblies are connected in the correct locations.
- Connect hose assemblies (4) to the pilot valve. Tighten the hose assemblies to a torque of
37 ± 4 N·m (27 ± 3 lb ft) . - Check the hydraulic system oil level. Refer to Operation and Maintenance Manual, "Hydraulic System Oil Level - Check".
- Start the engine, and check the operation of the pilot valve. Also, check for leaks. Stop the engine.
- Obtain a hydraulic oil sample from the main S·O·S port. Refer to Operation and Maintenance Manual, "Sampling Interval and Location of Sampling Valve".
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Illustration 22 g00704086 - Position cover (2) on the machine. Install the washers and bolts (1). Tighten bolts (3).
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Illustration 12 | g00704131 |
Note: Make sure that the ports of the valve are in the correct position.