Installation of the Two-Way Pilot Valve (Control Pattern Change) {5051, 5059}

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Stella Lindsey
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1 Page 1 of 13 Installation of the Two-Way Pilot Valve (Control Pattern Change) {5051, 5059} Excavator: 322B L (PIN: 1YS; 8NR) Introduction This Special Instruction outlines the basic steps and parts in order to install a two-way pilot valve. Installation of a two-way pilot valve allows the operator to change the machine control pattern. The operator has a choice of two patterns: Caterpillar SAE and the standard backhoe loader hydraulic system (BHL). The adaptability of the two-way pilot valve will enable the operator to be more productive with the 322B L Excavators. Do not carry out any of the installation procedures until you have read the information in this publication. Also refer to the appropriate Parts Manual, Operation and Maintenance Manual, and Service Manual for your machine. Required Parts For parts identification and ordering parts, refer to Table 1. Table 1 Required Parts Item Number Quantity Part Number Description Support Assembly 2 2 8T-4910 Bolt (M12)

2 Page 2 of T-4223 Washer Two-Way Pilot Valve 5 4 8T-4956 Bolt (M12) 6 2 4I-1037 Hose Assembly 7 1 4I-1783 Hose Assembly Hose Assembly 9 1 4I-3991 Hose Assembly Hose Assembly Hose Assembly Hose Assembly V-8397 Seal J-1907 Seal V-9001 Elbow I-9521 Band I-9523 Band I-9525 Band I-9527 Band Strap Guard Note: See Tables 5 and 6 for more parts information. Release of Pressure in the Hydraulic System Park the excavator on level ground in order to place the machine in the servicing 1. position.

3 Page 3 of 13 Illustration 1 g Before servicing, put the machine in the servicing position. 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 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 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 The servicing position is attained by lowering the boom until the bucket is flat on the ground. The stick should be in the vertical position when the bucket is flat on the ground. Refer to Illustration 1. Shut off the engine.

4 Page 4 of Move the control levers for the boom, the stick, the bucket, swing operation, and the left travel and the right travel to the full stroke positions. This movement will release any actuator pressure in the hydraulic lines. Move the hydraulic activation control lever to the UNLOCK position. This will release any pressure in the pilot system. Slowly loosen the fill/vent plug on the hydraulic tank in order to release the pressure in the tank. Installing the Two-Way Pilot Valve

5 5 of 13 Illustration 2 This is the hydraulic lines group for the two-way pilot valve. For identification of numbered parts, refer to Table control valve. (B) Left upper frame group. (C) Support under the cab Locate the main control valve (A). Find the plate (C) which supports the hydraulic pilot lines under the cab. Refer to Illustration 2 and Table 1 for parts identification. Install the support assembly (1) by fastening two bolts (2) and two washers (3) through the support assembly and into the left upper frame group (B). Refer to Illustration 2 for installation information. Install the two-way pilot valve (4) to the support assembly (1). Fasten four bolts (5) and four washers (3) through the support assembly and into the back of the two-way pilot valve. Refer to Illustration 2. Illustration 3 g This is the main control valve. Ports on the main control valve are numbered: (D) bl4, (E) bl3, (F) br2, (G) br3, (H) ar4, (J) al3, (K) ar2 and (L) ar3.

6 Page 6 of 13 Illustration 4 g This is the top view of the two-way pilot valve. The bolt (M) secures the lever (N) after a selection has been made. The operator has a choice of two distinct machine control patterns: Caterpillar SAE and the standard backhoe loader hydraulic system (BHL). Illustration 5 g

7 Page 7 of 13 Port locations on the two-way pilot valve Loosen the bolt (M) on top of the two-way pilot valve. Turn the bolt counterclockwise in order to loosen. Refer to Illustration 4. Move the lever (N) in Illustration 4 to the SAE position. In order to secure the lever in the SAE position, tighten the bolt in Illustration 4 by turning the bolt clockwise. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates Remove the hoses from these ports on the main control valve: ar4, bl4, br3 and ar3. Then remove these hoses from the support under the cab. Refer to Illustrations 2 and 3. Install four new hoses from the main control valve to the two-way pilot valve. Refer to Table 2 and Illustrations 2, 3, and 5 for routing information. Table 2 Hose Routing from the Main Control Valve to the Two-Way Pilot Valve Main Control Valve Band Port Function Number Color Item Number Item Number of Hose Port on the Two-Way Pilot Valve ar4 boom raise R1 orange 18 6 A bl4 boom down R3 green 19 8 B ar3 br3 stick out L1 red 16 6 D stick in L3 blue 17 7 C

8 Page 8 of 13 Note: Hose fittings should be tightened to a torque of 40 ± 5 N m (29.5 ± 3.7 lb ft). 9. Install four new hoses from the two-way pilot valve to the support under the cab according to Table 3. Also refer to Illustrations 2 and 5 for routing information. Table 3 Hose Routing from the Two-Way Pilot Valve to the Support under the Cab Port on the Two- Way Pilot Valve Number Band Color Item Number Item Number of Hose Color of Hose under the Cab 1 R1 2 R3 orange green orange green 4 L1 red red 3 L3 blue 17 9 blue Note: Hose fittings should be tightened to a torque of 40 ± 5 N m (29.5 ± 3.7 lb ft). 10. Check the hoses from the support under the cab to the control levers. The hoses must match with the hoses from the two-way pilot valve. Refer to Table 4 for correct hose connections. Table 4 Hose Routing to the Control Levers from the Support under the Cab Hoses from the Two-Way Valve Band Color Control Item Number Lever of Hose C 10 orange R1 orange JR1 11 green R3 green JR3 12 red L1 red JL1 9 blue L3 blue JL Strap the hoses together with the five straps (20). Avoid damage to the hoses by positioning the straps so that no sharp corners or no cutting edges come in contact with the hoses. Make sure that the hose assemblies are not strained or twisted. Place the two guards (21) on the upper frame assembly (B). The guards prevent damage to the hoses. Damage may occur when the hoses rub against the left upper frame assembly. Refer to Illustration 2. Fill the hydraulic oil tank with hydraulic oil according to the Operation and Maintenance Manual for your machine.

9 Page 9 of Tighten the fill/vent plug on the hydraulic tank. Start the engine at low idle. Purge the hydraulic lines during each movement of the control levers. The checking procedure confirms correct machine movements for the SAE pattern. Place the machine in the servicing position. Stop the engine. Check the hydraulic lines and fittings for leaks and torque. Hose fittings should be tightened to a torque of 40 ± 5 N m (29.5 ± 3.7 lb ft). Restart the engine. Raise engine speed up to normal speed. There should be no delay of response time when the control levers are operated. Put the excavator in the servicing position. Stop the engine. Maintain the hydraulic oil level between the marks on the sight gauge in the appropriate temperature range. Refer to the section on the hydraulic oil tank in your Operation and Maintenance Manual. The following procedures must be repeated when you select the BHL machine control pattern: ""Release of Pressure in the Hydraulic System" ", and Steps 4, 5, 6, 14, 18 and 22. CHECK MACHINE CONTROL PATTERN FOR CONFORMANCE TO PATTERN ON CARD IN CAB. IF NOT, CHANGE CARD TO MATCH PATTERN BEFORE OPERATING MACHINE. FAILURE TO DO SO COULD RESULT IN INJURY.

10 Page 10 of 13 Illustration 6 This is the correct placement for the instruction plates and the warning films. Refer to Tables 5 and 6 for part nu ordering. 22. Select the instruction film that matches the machine control pattern which is chosen. The instruction film must be installed on the outside of the cab. The correct instruction plate must also be installed in the cab. Refer to Illustration 6 for correct placement of the instruction plate and warning and instruction films. See Table 5 for ordering the required warning and instruction films and23. the instruction plate. Table 5 Required Parts Item Number Quantity Part Number Description I-2885 Case I-0455 Warning Film I-0456 Instruction Film I-0719 Instruction Plate I-1549 Warning Film Note: The case in Table 5 uses adhesive backing to adhere to the cab window. The instruction plate is stored in this case. Display the surface of the instruction plate which matches the machine control pattern.

Page 11 of 13 24. Match warning and instruction films with the operator's language. The films are printed in other languages. Refer to Table 6 for related part numbers.

7I-1551 7I-0462 German 7I-0463 7I-1552 7I-0464 Italian 7I-0465 7I-1553 7I-0466 Portuguese 7I-0467 7I-1554 7I-0468 Dutch 7I-0471 7I-1555 7I-0472 Greek 7I-0473 7I-1556 7I-0474 Danish 7I-0475 7I-1557

11 Page 11 of Match warning and instruction films with the operator's language. The films are printed in other languages. Refer to Table 6 for related part numbers. Table 6 Warning and Instruction Film in Other Languages Related Part Numbers Language Warning Film Instruction Film English 7I I I-0456 French 7I I I-0460 Spanish 7I I I-0462 German 7I I I-0464 Italian 7I I I-0466 Portuguese 7I I I-0468 Dutch 7I I I-0472 Greek 7I I I-0474 Danish 7I I I-0476 Machine Control Patterns A machine control pattern is selected by repositioning the lever on top of the two-way pilot valve. See Illustration 4 and Step 21 in ""Installing the Two-Way Pilot Valve" " for correct changing procedures. Use the following icons to learn the corresponding machine movements in Illustration 7. Each machine control pattern has specific movements. Stick Out (1) - Move the in order to move the stick outward. Swing Right (2) - Move the in order to turn the upper structure to the right.

12 Page 12 of 13 Stick In (3) - Move the in order to move the stick inward. Swing Left (4) - Move the in order to turn the upper structure to the left. Boom Lower (5) - Move the in order to lower the boom. Bucket Dump (6) - Move the in order to dump the bucket. Boom Raise (7) - Move the in order to raise the boom. Bucket Close (8) - Move the in order to close the bucket. HOLD (9) will stop the movements of the stick, the boom, the bucket, and the upper structure.

13 Page 13 of 13 Two incorporated functions may be performed at the same time by moving the appropriate control lever diagonally. If the machine is equipped with a hydraulic hammer, the functions of positions (6) and (8) are distinct. Hydraulic Hammer Raise (6) allows you to raise the hydraulic hammer. Hydraulic Hammer Lower (8) allows you to lower the hydraulic hammer. The two machine control patterns are shown in Illustration 7. Illustration 7 g The machine control patterns in the left column and the right column correspond to the left control lever and the right control lever: (A) SAE machine control pattern and (B) standard backhoe (BHL).

Filling and Flushing the Hydraulic System - Test

Filling and Flushing the Hydraulic System - Test Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid