Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion K Page 1 of 54 Special Instruction Field Installation of the 233-5720 Joystick Conversion Kit (DUAL CONTROL){1408, 5057, 5059, 5264, 5705} Media Number -REHS1805-04 Publication Date -28/08/2007 Date Updated -29/08/2007 Field Installation of the 233-5720 Joystick Conversion Kit (DUAL CONTROL){1408, 5057, 5059, 5264, 5705} SMCS - 1408; 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" i02708356 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 233-5720 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 233-5720 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.
Media Search - REHS1805 - Field Installation of the 233-5720 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 g01111714 Left Joystick Control Pattern ( 233-5736 Film )
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion K Page 3 of 54 Illustration 2 g01066253 Left Joystick Control Pattern ( 233-5734 Film ) Illustration 3 g01111717 Right Joystick Control Pattern ( 262-7669 Film )
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion K Page 4 of 54 Illustration 4 g01111722 Right Joystick Control Pattern ( 233-5735 Film ) Illustration 5 g01153309
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion K Page 5 of 54 Right Joystick Control Pattern ( 233-5737 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 233-5720 Joystick Conversion Kit (DUAL CONTROL) Configuration
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion K Page 6 of 54 Illustration 6 The configuration of the 233-5720 Joystick Conversion Kit (DUAL CONTROL) (WW) Pilot valves (XX) Hydraulic lines (YY) Interlock manifold (ZZ) Harness assemblies The installation of the 233-5720 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 233-5720 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 1. 2. 3. 4. 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.
Media Search - REHS1805 - Field Installation of the 233-5720 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.
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion K Page 8 of 54 Illustration 7 g01099187 View of the left joystick control (C) 8T-0269 Bolt (D) 8T-1158 Bolt (G) 8T-4205 Hard Washer (K) 148-8325 Connector As (P) 192-0836 Pressure Switch (BACKUP ALARM)
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion K Page 9 of 54 (R) 195-9700 Solenoid Valve Gp (S) 212-0061 Flange (NN) 150-4043 Connector As (RR) 110-8760 Strap (SS) 299-9116 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. 3. 4. 5. 6. 7. 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 148-8325 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).
Media Search - REHS1805 - Field Installation of the 233-5720 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) 148-8325 Connector As (L) 148-8369 Elbow As (Q) 193-8393 Hose As (V) 218-5770 Hose As (W) 218-5968 Bracket (CC) 148-8316 Connector As (GG) 193-8392 Hose As
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 11 of 54 (LL) 218-6864 Hose As (NN) 150-4043 Connector As (UU) 7K-1181 Cable Strap 8. 9. 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 218-5770 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 193-8393 Disconnect hose (Q) from the 148-8316 Connector As at Port X3 on hydrostatic pump 1. See Illustration 9. Do not remove the 148-8316 Connector As from Port X3. Install tee (20) in the 148-8316 Connector As. See Illustration 12. Retain hose (Q). GG 193-8392 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 193-8392 Disconnect hose (GG) from the 148-8369 Elbow Gp at Port X4 on hydrostatic pump 1. Do not remove the elbow from Port X4. See Illustration 9. Discard hose (GG). Q 193-8393 Disconnect hose (Q) from the 148-8423 Fitting Gp at Port Y on hydrostatic pump 1. Do not remove the 148-8423 Fitting Gp, the 164-5567 Fitting As, nor the 6V-0852 Dust Cap. See Illustration 9. Retain hose (Q).
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 12 of 54 LL 218-6864 Disconnect hose (LL) from the 148-8340 Connector As on the drain manifold. Do not remove the 148-8340 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 g01099920 View of hose connections for the hydrostatic pump
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 13 of 54 Illustration 10 g01066754 Removal of hose (LL) from the return manifold
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 14 of 54 Illustration 11 g01099540 Installation of fittings in Port X3 of hydrostatic pump 2 (12) 148-8351 Elbow Gp (14) 148-8369 Elbow As (20) 166-2033 Tee Gp
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 15 of 54 Illustration 12 g01099593 Installation of fitting in Port X3 of hydrostatic pump 1 (20) 166-2033 Tee Gp
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 16 of 54 Illustration 13 g01099598 Repositioning of elbow (L) in Port X4 of hydrostatic pump 2 (L) 148-8369 Elbow As (A1) 90 ± 5 10. Perform Step 10.a through Step 10.f in order to remove the right joystick control and mounting.
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 17 of 54 Illustration 14 g01099604 View of the right joystick control (C) 8T-0269 Bolt (G) 8T-4205 Hard Washer (D) 8T-1158 Bolt (K) 148-8325 Connector As (R) 195-9700 Solenoid Valve Gp
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 18 of 54 (S) 212-0061 Flange (EE) 179-7001 Oil Line Adapter (RR) 110-8760 Strap (TT) 299-9119 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. 12. 13. 14. 15. Remove bolt (C), solenoid valve (R), and flange (S) from the pilot valve. Retain these components for the reinstallation. Remove five 148-8325 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).
Media Search - REHS1805 - Field Installation of the 233-5720 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) 148-8325 Connector As (M) 148-8435 Tee (N) 190-7453 Hose As (T) 218-5571 Hose As (U) 218-5572 Hose As (AA) 6D-3479 Clip (BB) 8T-4191 Bolt
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 20 of 54 (EE) 179-7001 Oil Line Adapter (FF) 193-8313 Hose As (JJ) 218-5571 Hose As (KK) 218-5572 Hose As (MM) 218-6601 Hose As 16. 17. 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 218-5572 Disconnect hose (KK) from the 148-8325 Connector Gp at Port 1B on the control valve. Do not remove the 148-8325 Connector Gp. See Illustration 16. Discard hose (KK). T 218-5571 Disconnect hose (T) from the 148-8325 Connector Gp at Port 2A on the control valve. Do not remove the 148-8325 Connector Gp. See Illustration 16. Retain hose (T). JJ 218-5571 Disconnect the hose (JJ) from the 148-8325 Connector Gp at Port 1A on the control valve. Do not remove the 148-8325 Connector Gp. See Illustration 16. Discard hose (JJ). MM 218-6601 Disconnect hose (MM) from the 154-5232 Adapter As on the return manifold. Do not remove the adapter. Remove clip (AA), bolt (BB), and washer (E). Install cap (19) on the 154-5232 Adapter As. See Illustration 17. Discard hose (MM). Discard clip (AA) and bolt (BB). Retain washer (E). U 218-5572 Disconnect hose (U) from the 148-8325 Connector Gp at Port 2B on the control valve. Do not remove the 148-8325 Connector Gp. See Illustration 16. Retain hose (U). N 190-7453 Disconnect hose (N) from tee (M) on the front port of the control valve. See Illustration 16. Retain hose (N).
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 21 of 54 FF 193-8313 Disconnect hose (FF) from tee (M) on the front port of the control valve. See Illustration 16. Reposition the 148-8435 Tee (M). See Illustration 18. Discard hose (FF). Illustration 16 g01099954 View of hose connections for control valve
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 22 of 54 Illustration 17 g01066805 Installation of cap (19) on the left port of the return manifold (19) 6V-9828 Cap As
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 23 of 54 Illustration 18 g01064225 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.
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 24 of 54 The 232-4486 Manifold (Interlock) Assembly of the Components Illustration 19 g01100125 Installation of components on interlock manifold (22) (D) 8T-1158 Bolt (R) 195-9700 Solenoid Valve Gp (S) 212-0061 Flange (9) 148-8325 Connector Gp (16) 148-8435 Tee (17) 148-8439 Tee
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 25 of 54 1. 2. Install the following fittings on interlock manifold (22) : one 148-8435 Tee (16), two 148-8325 Connector As (9) and two 148-8439 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 g01321556 Installation of bracket for the Interlock Manifold (4) 8T-4121 Hard Washer (5) 8T-4133 Nut (7) 8T-6685 Bolt (22) 232-4486 Manifold (INTERLOCK) (24) 233-5721 Plate
Media Search - REHS1805 - Field Installation of the 233-5720 Joystick Conversion Page 26 of 54 1. Assemble interlock manifold (22) to plate (24). Use two bolts (7), four hard washers (4) and two nuts (5). See Illustration 20. Illustration 21 g01384205 Installation of the interlock manifold (22) (4) 8T-4121 Hard Washer (5) 8T-4133 Nut (6) 8T-4195 Bolt (22) 232-4486 Manifold (INTERLOCK) (24) 233-5721 Plate (49) 293-4075 Bracket (UU) 218-6363 Plate As