Field Installation of the Joystick Conversion Kit (DUAL CONTROL){1408, 5057, 5059, 5264, 5705}

Transcription

1 Media Search - REHS Field Installation of the Joystick Conversion K Page 1 of 54 Special Instruction Field Installation of the Joystick Conversion Kit (DUAL CONTROL){1408, 5057, 5059, 5264, 5705} Media Number -REHS Publication Date -28/08/2007 Date Updated -29/08/2007 Field Installation of the Joystick Conversion Kit (DUAL CONTROL){1408, 5057, 5059, 5264, 5705} SMCS ; 5057; 5059; 5264; 5705 Skid Steer Loader: 236B (S/N: HEN1-UP) 246B (S/N: PAT1-UP) 252B (S/N: SCP1-UP) 262B (S/N: PDT1-UP) Introduction ReferenceOperation and Maintenance, SEBU7731, "216B, 226B, 232B, 236B, 242B, 246B, 248B, 252B, and 262B Skid Steer Loaders" i ReferenceDisassembly and Assembly, RENR4898, "Machine Systems - 216B, 226B, 232B and 242B Skid Steer Loaders" ReferenceSchematic, RENR6419, "232B, 242B, 252B, 262B, 216B, 226B, 236B, 246B, 248B and 268B Skid Steer Loaders and 247B, 257B, 267B, 277B and 287B Multi Terrain Loaders Electrical System" This Special Instruction provides the information that is necessary for the installation of the Joystick Conversion Kit (DUAL CONTROL). The installation of this kit provides dual directional control. The operator will be able to control the forward movement and the reverse movement of the left wheels by using the left joystick control. The operator will be able to control the forward movement and the reverse movement of the right wheels by using the right joystick control. The Joystick Conversion Kit (DUAL CONTROL) contains films for installation in the operator's compartment in order to provide operating instructions for each joystick control. For the left joystick control pattern, see Illustration 1 or Illustration 2. For the right joystick control pattern, see Illustration 3, Illustration 4, or Illustration 5.

2 Media Search - REHS Field Installation of the Joystick Conversion K Page 2 of 54 Note: The installation of the appropriate films in the operator's compartment are essential in order to inform the operator of the change in joystick control patterns. Illustration 1 g Left Joystick Control Pattern ( Film )

3 Media Search - REHS Field Installation of the Joystick Conversion K Page 3 of 54 Illustration 2 g Left Joystick Control Pattern ( Film ) Illustration 3 g Right Joystick Control Pattern ( Film )

4 Media Search - REHS Field Installation of the Joystick Conversion K Page 4 of 54 Illustration 4 g Right Joystick Control Pattern ( Film ) Illustration 5 g

5 Media Search - REHS Field Installation of the Joystick Conversion K Page 5 of 54 Right Joystick Control Pattern ( Film ) Do not begin installation until you have read the information that is contained in this instruction. Also obtain the Operation and Maintenance Manual and the Disassembly and Assembly Manual for additional instructions that are referenced herein. Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. The Joystick Conversion Kit (DUAL CONTROL) Configuration

6 Media Search - REHS Field Installation of the Joystick Conversion K Page 6 of 54 Illustration 6 The configuration of the Joystick Conversion Kit (DUAL CONTROL) (WW) Pilot valves (XX) Hydraulic lines (YY) Interlock manifold (ZZ) Harness assemblies The installation of the Joystick Conversion Kit (DUAL CONTROL) on your machine requires the following tasks. Kit Parts Removal of existing pilot valves, existing pilot lines, and certain hydraulic fittings Installation of new pilot valves, newpilot lines, new interlock manifold, and new harnesses The Joystick Conversion Kit (DUAL CONTROL) contains new parts for installation on your machine. The kit also reuses some of the parts that are removed during the installation of this kit. For a list of the new parts, refer to Table 7 in "Parts Information" in this instruction. For a list of the parts that are being removed and reused, refer to Table 8 in "Parts Information" in this instruction. Note: Information on service parts is also provided in "Parts Information" in this instruction. Preparing the Machine Park the machine. See "Machine Parking" in the Operation and Maintenance Manual for your machine. Raise the loader lift arms. Refer to the Operation and Maintenance Manual, "Loader Lift Arm Brace Operation". Raise the cab. Refer to the Disassembly and Assembly, "Cab - Tilt". Release hydraulic system pressure. Refer to the Disassembly and Assembly Manual, "Hydraulic System Pressure - Release". 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.

7 Media Search - REHS Field Installation of the Joystick Conversion K Page 7 of 54 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. 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. See Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 5. Pull a vacuum on the hydraulic tank or drain the hydraulic system in order to prevent loss of hydraulic oil from spillage. Removing the Joystick Controls and the Hydraulic Lines Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

8 Media Search - REHS Field Installation of the Joystick Conversion K Page 8 of 54 Illustration 7 g View of the left joystick control (C) 8T-0269 Bolt (D) 8T-1158 Bolt (G) 8T-4205 Hard Washer (K) Connector As (P) Pressure Switch (BACKUP ALARM)

9 Media Search - REHS Field Installation of the Joystick Conversion K Page 9 of 54 (R) Solenoid Valve Gp (S) Flange (NN) Connector As (RR) Strap (SS) Pilot Valve Perform Step 1.a through Step 1.f in order to remove the left joystick control 1. and mounting. a. b. c. d. Remove the cover from the front of the left hand support assembly. Retain the cover and the four 9X-2045 Screws for the reinstallation. Disconnect the electrical connectors from pilot valve (SS). Disconnect the six hydraulic lines from the connectors on the bottom of pilot valve (SS). Remove the strap (RR) that secures the boot to the control handle and lift up the boot. Discard the strap. See Illustration 7. Note: Do not remove the boot from the control handle. e. f. Remove the three bolts (C) and three hard washers (G) that secure the joystick control to the top of the left hand support assembly. Retain the bolts and the washers for the reinstallation. Remove pilot valve (SS) from the support assembly. Perform Step 2.a and Step 2.b in order to remove the handle from the left 2. pilot valve. a. b. Free the grommet and wire from the mounting assembly. Unscrew the control handle from the left pilot valve. Retain the control handle for the reinstallation Remove bolt (C), solenoid (R), and flange (S) from the pilot valve. Retain these components for the reinstallation. Remove pressure switch (P) that is used for the backup alarm (if equipped). Retain the pressure switch for the reinstallation. Remove five Connector As (K) from the pilot valve. Retain these five connectors for the reinstallation. Remove connector (NN) from the pilot valve. Discard this connector. Discard pilot valve (SS).

10 Media Search - REHS Field Installation of the Joystick Conversion Page 10 of 54 Illustration 8 Removal of the hoses for the left pilot valve (A) 5C-7261 Nut (M8x1.25) (F) 8T-4197 Bolt (H) 8T-4224 Hard Washer (K) Connector As (L) Elbow As (Q) Hose As (V) Hose As (W) Bracket (CC) Connector As (GG) Hose As

11 Media Search - REHS Field Installation of the Joystick Conversion Page 11 of 54 (LL) Hose As (NN) Connector As (UU) 7K-1181 Cable Strap Remove cable strap (UU) in order to free the hoses from bracket (W). Remove bolt (F), two washers (H), and nut (A) in order to remove bracket (W). Retain the bracket, the washers, the nut, and the bolt for the reinstallation. See Illustration 8. Remove the hoses that were connected to the left pilot valve. Follow the instructions that are provided in Table 1. Note: Plug the ports as you remove the hoses in order to prevent dirt from entering the system. Table 1 Instructions for removing the hoses that were connected to the Left Pilot Valve See Illustration 8. Item Part Number Action V Disconnect hose (V) from connector (CC) at Port X3 on hydrostatic pump 2. See Illustration 9. Remove connector (CC) from Port X3. Install elbow (14) in Port X3. (1) Install tee (20) in elbow (14). See Illustration 11. Install elbow (12) in tee (20). Retain hose (V). Discard connector (CC). Q Disconnect hose (Q) from the Connector As at Port X3 on hydrostatic pump 1. See Illustration 9. Do not remove the Connector As from Port X3. Install tee (20) in the Connector As. See Illustration 12. Retain hose (Q). GG Disconnect hose (GG) from elbow (L) at Port X4 on hydrostatic pump 2. Do not remove elbow (L). See Illustration 9. Reposition elbow (L), as shown. See Illustration 13. Discard hose (GG). GG Disconnect hose (GG) from the Elbow Gp at Port X4 on hydrostatic pump 1. Do not remove the elbow from Port X4. See Illustration 9. Discard hose (GG). Q Disconnect hose (Q) from the Fitting Gp at Port Y on hydrostatic pump 1. Do not remove the Fitting Gp, the Fitting As, nor the 6V-0852 Dust Cap. See Illustration 9. Retain hose (Q).

12 Media Search - REHS Field Installation of the Joystick Conversion Page 12 of 54 LL Disconnect hose (LL) from the Connector As on the drain manifold. Do not remove the Connector As. See Illustration 10. Discard hose (LL). ( 1 ) Remove the dust cap and remove the quick disconnect that is installed to Port MB in order to install elbow (14). Then, reinstall the quick disconnect fitting and the dust cap. Illustration 9 g View of hose connections for the hydrostatic pump

13 Media Search - REHS Field Installation of the Joystick Conversion Page 13 of 54 Illustration 10 g Removal of hose (LL) from the return manifold

14 Media Search - REHS Field Installation of the Joystick Conversion Page 14 of 54 Illustration 11 g Installation of fittings in Port X3 of hydrostatic pump 2 (12) Elbow Gp (14) Elbow As (20) Tee Gp

15 Media Search - REHS Field Installation of the Joystick Conversion Page 15 of 54 Illustration 12 g Installation of fitting in Port X3 of hydrostatic pump 1 (20) Tee Gp

16 Media Search - REHS Field Installation of the Joystick Conversion Page 16 of 54 Illustration 13 g Repositioning of elbow (L) in Port X4 of hydrostatic pump 2 (L) Elbow As (A1) 90 ± Perform Step 10.a through Step 10.f in order to remove the right joystick control and mounting.

17 Media Search - REHS Field Installation of the Joystick Conversion Page 17 of 54 Illustration 14 g View of the right joystick control (C) 8T-0269 Bolt (G) 8T-4205 Hard Washer (D) 8T-1158 Bolt (K) Connector As (R) Solenoid Valve Gp

18 Media Search - REHS Field Installation of the Joystick Conversion Page 18 of 54 (S) Flange (EE) Oil Line Adapter (RR) Strap (TT) Pilot Valve a. b. c. d. Remove the cover from the front of the right hand support assembly. Retain the cover and retain the four 9X-2045 Screws for the reinstallation. Disconnect the electrical connectors from pilot valve (TT). Disconnect the six hydraulic lines from the connectors on the bottom of pilot valve (TT). Remove the Strap (RR) that secures the boot to the control handle and lift up the boot. Discard the strap. See Illustration 14. Note: Do not remove the boot from the control handle. The control handle with the boot will be reinstalled in this procedure. e. f. Remove three 8T-0269 Bolts (C) and three 8T-4205 Hard Washer (G) that secure the joystick control to the top of the right hand support assembly. Retain the bolts and the washers for the reinstallation. Remove pilot valve (TT) from the support assembly. Perform Step 11.a and Step 11.b in order to remove the handle from the11. pilot valve. a. b. Free the grommet and wire from the mounting assembly. Unscrew the control handle from the pilot valve. Retain the control handle for the reinstallation Remove bolt (C), solenoid valve (R), and flange (S) from the pilot valve. Retain these components for the reinstallation. Remove five Connector As (K) from the pilot valve. Retain the five connectors for the reinstallation. Remove connector (EE) from the pilot valve. Discard the connector. Discard pilot valve (TT).

19 Media Search - REHS Field Installation of the Joystick Conversion Page 19 of 54 Illustration 15 Removal of the hoses for the right pilot valve (A) 5C-7261 Nut (M8x1.25) (E) 8T-4121 Hard Washer (J) 9D-1829 Clip (K) Connector As (M) Tee (N) Hose As (T) Hose As (U) Hose As (AA) 6D-3479 Clip (BB) 8T-4191 Bolt

20 Media Search - REHS Field Installation of the Joystick Conversion Page 20 of 54 (EE) Oil Line Adapter (FF) Hose As (JJ) Hose As (KK) Hose As (MM) Hose As Remove nut (A), washer (B), and clip (J) in order to remove the hoses. Retain these components for the reinstallation. See Illustration 15. Remove the hoses that were connected to the right pilot valve. Follow the instructions that are provided in Table 2. Note: Plug the ports as you remove the hoses in order to prevent dirt from entering the system. Table 2 Instructions for removing the hoses for the right side Pilot Valve See Illustration 15. Item Part Number Action KK Disconnect hose (KK) from the Connector Gp at Port 1B on the control valve. Do not remove the Connector Gp. See Illustration 16. Discard hose (KK). T Disconnect hose (T) from the Connector Gp at Port 2A on the control valve. Do not remove the Connector Gp. See Illustration 16. Retain hose (T). JJ Disconnect the hose (JJ) from the Connector Gp at Port 1A on the control valve. Do not remove the Connector Gp. See Illustration 16. Discard hose (JJ). MM Disconnect hose (MM) from the Adapter As on the return manifold. Do not remove the adapter. Remove clip (AA), bolt (BB), and washer (E). Install cap (19) on the Adapter As. See Illustration 17. Discard hose (MM). Discard clip (AA) and bolt (BB). Retain washer (E). U Disconnect hose (U) from the Connector Gp at Port 2B on the control valve. Do not remove the Connector Gp. See Illustration 16. Retain hose (U). N Disconnect hose (N) from tee (M) on the front port of the control valve. See Illustration 16. Retain hose (N).

21 Media Search - REHS Field Installation of the Joystick Conversion Page 21 of 54 FF Disconnect hose (FF) from tee (M) on the front port of the control valve. See Illustration 16. Reposition the Tee (M). See Illustration 18. Discard hose (FF). Illustration 16 g View of hose connections for control valve

22 Media Search - REHS Field Installation of the Joystick Conversion Page 22 of 54 Illustration 17 g Installation of cap (19) on the left port of the return manifold (19) 6V-9828 Cap As

23 Media Search - REHS Field Installation of the Joystick Conversion Page 23 of 54 Illustration 18 g Reposition tee (M) in the front port of the control valve. (A2) 30 ± 5 Installing the Components NOTICE Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.

24 Media Search - REHS Field Installation of the Joystick Conversion Page 24 of 54 The Manifold (Interlock) Assembly of the Components Illustration 19 g Installation of components on interlock manifold (22) (D) 8T-1158 Bolt (R) Solenoid Valve Gp (S) Flange (9) Connector Gp (16) Tee (17) Tee

25 Media Search - REHS Field Installation of the Joystick Conversion Page 25 of Install the following fittings on interlock manifold (22) : one Tee (16), two Connector As (9) and two Tee (17). See Illustration 19. Install the two solenoid valves (R) on the top of interlock manifold (22). Install the solenoid valves with the two flanges (S) and the two bolts (D). Tighten the bolts to a torque of 28 ± 7 N m (21 ± 5 lb ft). Installing the Interlock Manifold Illustration 20 g Installation of bracket for the Interlock Manifold (4) 8T-4121 Hard Washer (5) 8T-4133 Nut (7) 8T-6685 Bolt (22) Manifold (INTERLOCK) (24) Plate

26 Media Search - REHS Field Installation of the Joystick Conversion Page 26 of Assemble interlock manifold (22) to plate (24). Use two bolts (7), four hard washers (4) and two nuts (5). See Illustration 20. Illustration 21 g Installation of the interlock manifold (22) (4) 8T-4121 Hard Washer (5) 8T-4133 Nut (6) 8T-4195 Bolt (22) Manifold (INTERLOCK) (24) Plate (49) Bracket (UU) Plate As