Installation Procedure for 259-5045 Combined Flow Wiring Gp {1408} Caterpillar

Introduction

This Special Instruction provides the information that is necessary to install the 259-5045 Combined Flow Wiring Gp on certain excavators.

Safety Section

Illustration 1	g00104545

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your AVSpare dealer.

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Check valves in the hydraulic system may allow pressure to exist in the hydraulic lines after the engine has been stopped. Pressure must be relieved prior to servicing the components of the hydraulic system. Failure to relieve pressure prior to servicing may result in personal injury.

Required Parts

Installation Procedure

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Illustration 2	g02138896

1. Locate the flow control valve inside of the pump compartment.

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Illustration 3	g02139405
View in pump compartment

2. Locate the chassis harness inside the right frame rail of the machine. Cut the strap securing the chassis harness. Route the harness through the wall of the pump compartment to the flow control valve.

3. Connect the chassis harness to the flow control valve solenoid at terminal "M737 WH", and "M739 YL".

4. Attach clip (8) on to the flow control valve. Use washer (15), and bolt (12). Secure the chassis harness to clip (8) with, and strap (1) .

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Illustration 4	g02139495
View in pump compartment

5. Locate the solenoid valve inside the pump compartment.

6. Make three terminal connections with wire harness (6) to the solenoid valve.

7. Fasten clip (7) on to solenoid valve support using washer (10) and bolt (13). Secure wire harness (6) to clip (7). Use strap (1) .

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Illustration 5	g02139508
View in pump compartment

8. Fasten the ground terminal "235 BK" to the existing bulkhead prior to routing harness through the opening.

9. Route wire harness (6) through the opening in the right-hand frame rail of the machine.

   Note: Two terminals "K872 OR", "200 BK" should not route through the frame rail. This portion of the wire harness will be installed last.

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Illustration 6	g02139780
View of main control valve

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Illustration 7	g02139522
Detail A

10. Route terminal "G973 OR", "235 BK" along the back side of the main control valve up to the pressure switch located on port "aL4". The pressure switch is located on the upper left-hand side of the main control valve.

11. Make the terminal connection to the pressure switch.

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Illustration 8	g02139798
View of engine room

12. Make the ground connection to the bulkhead in between the engine compartment and the main control valve compartment.

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Illustration 9	g02139813
View of engine room

13. Route wire harness with terminal connections "147 PU", "G973 OR", "K866 WH", "K871 WH" along the backside of the engine compartment, to the chassis harness. Make terminal connections to the chassis harness.

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Illustration 10	g02139843
View of battery room

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Illustration 11	g02139850
View of battery room

14. Make terminal connection to the cab harness.

15. Fasten clip (4) to terminal inside the battery compartment. Remove the bolt securing clip for the platform harness. Place clip (4) and the clip for the platform harness together. Fasten in place with the existing bolt.

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Illustration 12	g02139854

16. Route the remaining portion of the wire harness along the outside of the right-hand frame rail toward the front of the machine.

17. Route harness through the opening in the right-hand frame rail next to the foot of the boom.

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Illustration 13	g02139954
Valve - right hand

18. Make the terminal connection to the solenoid valve, located on the right-hand frame rail.

19. Fasten clip (9) onto the support below the solenoid valve. Use washer (10) and bolt (13). Secure the wire harness to clip (9). Use strap (1) .

20. Fasten the ground "200 BK" to the existing ground point located on the right-hand frame rail, next to the opening in the frame rail.

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Illustration 14	g02139974
Valve - left hand

21. Route the remaining portion of the wire harness across the boom foot, to the solenoid valve located on the left-hand side of the frame.

22. Make terminal connection to solenoid.

23. Remove the bolt securing hose clip to support below the solenoid valve. Place clip (3) onto the hose clip and secure to the frame with washer (10), and bolt (11). Secure wire harness to clip using strap (1) .

24. Mount clip (3) onto the support located on the backside of the boom foot with bolt (14). Secure the wire harness to clip (3), and strap (1) .

25. Secure wire harness in place as needed using straps (1), straps (2), or straps (5) .