TECNOTER N Series User manual

ILKF – ILKFB (PE)
ILKF – ILKFB (PE)
S
SAFETY AFETY VALVES VALVES RETROFIT RETROFIT KIT KIT FOR FOR FRONT FRONT LOADER LOADER AND AND TILT TILT
H
HYDRAULIC YDRAULIC ( (STANDARD STANDARD) ) AND AND ELECTRONIC ELECTRONIC CONTROL CONTROL (PE) (PE)
B
BASIC ASIC VERSION VERSION
SERIES
SERIES
N
N
HOST
HOST MACHINE MACHINE
CAT 938K
CAT 938K
Insta ation manua
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CAT 938K Page 1/22 Rev: 1.20_En –
01/02/2020

ATTENTION:
Some parts are supp ied a ready assemb ed and can be insta ed as “group”
More then one hose connected on a same port means the presence of an externa Tee.
Any kit connected to the main contro er needs the corresponding computer set up.
Refer to SIS for any specification
IMPORTANT NOTICE:
to prevent unauthorized use or distribution of caterpillar manuals and intellectual propert
rights, in accordance with the rules defined with Caterpillar Work Tool inc., this manual is
printed WITHOUT drawings.
WARNING:
Before using this manual, please access SIS and print the following documents:
Electric schematic
H draulic schematic
333-6538
347-8236
523-4260
333-6920
523-4245
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CAT 938K Page 2/22 Rev: 1.20_En –
01/02/2020

Index
INTRODUCTION................................................................................................................................4
Scope of the manua .........................................................................................................................4
How to read the manua ...................................................................................................................5
Preservation of the manua ..............................................................................................................6
Update of the manua .......................................................................................................................6
Addressees.......................................................................................................................................6
GENERAL INFORMATION...............................................................................................................7
Manufacturer identification.............................................................................................................7
INSTALLATION PROCEDURE.........................................................................................................8
Line gp Lift cy inder........................................................................................................................9
Testing and adjusting.................................................................................................................13
Line gp Ti t cy inder (SP version) .................................................................................................15
Testing and adjusting.................................................................................................................19
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CAT 938K Page 3/22 Rev: 1.20_En –
01/02/2020

INTRODUCTION
Scope of the manual
This instruction manua is part of the machine and it provides a the necessary information to:
•manipu ation of the machine, packed and unpacked in safety conditions
•correct assemb y of the machine
•thorough know edge of its operation and its imits;
According to the current regulations, the responsible of the departments where this s stem
will be assembled must read carefull the content of this instruction manual and make sure
that the emplo ees read it.
Time spent for this purpose will be rewarded b the correct functioning of the machine and b
its use in safet conditions.
This document assumes that the p ants where this system wi be set comp y with the current safety
regu ations and hygiene conditions.
Instructions, drawings and documentation contained in this manua are reserved and inte ectua
property of the manufacturer, and they cannot be fu y or partia y reproduced.
If the manufacturer made any change in this manua , the customer must verify that on y updated
versions of it wou d be present in site where the machine is used.
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CAT 938K Page 4/22 Rev: 1.20_En –
01/02/2020

How to read the manual
Manua is divided into autonomous chapters, and it is addressed to assemb ers with the necessary
ski s to operate on the machine in safety conditions.
The instruction manua is composed by a cover, a tab e of contents and a series of chapters
(sections).
PAGE NUMBERING
Compan Logo Product Name Model Serial no. Page no. Revision no.
TABLES NUMBERING
Every tab e is numbered progressive y
Numbering starts from “1” at every section.
Numbering is composed as fo ows:
ABBREVIATIONS
Sect. = Section
Ch. = Chapter
Par. = Paragraph
Pag. = Page
Fig. = Figure
Tab. = Tab e
UNIT OF MEASURE
Units from the Internationa System of Units (SI)
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CAT 938K Page 5/22 Rev: 1.20_En –
01/02/2020
LOGO NAME MODEL S/N and YEAR 5/36 REV. - DATE

Preservation of the manual
Instruction manua shou d be carefu y preserved and it has to accompany the machine in every
change of ownership. Preservation shou d be faci itated by a carefu hand ing, with c ean hands and
it shou dn't be put on dirty surfaces.
You don't have to e iminate, tear or change any part. Manua has to be fi ed in an environment
without humidity and heat and near the machine it refers to.
Manufacturer can supp y further copies of the instruction manua on demand of the User.
Update of the manual
Manufacturer has the right to modify and make improvements to the machine without
communicating it to the customers, and without updating the manua a ready in hands of the user.
Moreover, the manufactures has to send the updated manua for any agreed change of the machine
at the customer's site.
User is responsib e for changing the o d chapters, the cover and the tab e of contents with the new
ones in every owned copy.
Addressees
This manua addresses to the operator, the assemb er and the maintenance technicians.
OPERATOR: one or more peop e that assemb y or do the maintenance of a machine;
QUALIFIED PERSONNEL OR OPERATOR: peop e that attended specia ization courses and
that have experience in assemb y and maintenance of the machine.
Qualification of addressees
The machine is intended for industria and therefore professiona use, so its use is addressed to
qua ified technicians that:
•are of age;
•are physica y and psychica y apt to do technica y difficu t jobs;
•have been proper y instructed on use and maintenance of the machine;
•are judged by the emp oyer as suitab e to do the designed job;
•have the ski of assemb y and operating the specific type of equipment;
•have fami iarity with the specific regu ations of the matter.
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CAT 938K Page 6/22 Rev: 1.20_En –
01/02/2020

GENERAL INFORMATION
Manufacturer identification
Manufacturer
Tecnoter sr a socio unico
VAT: IT13072070157
Head office
P.zza E eonora Duse 3
20121 Mi ano
Ita y
Production site
Via Car o A berto da a Chiesa 6
20098 San Giu iano Mi anese (MI)
Ita y
After sales service / Spare parts
Via Car o A berto da a Chiesa 6
20098 San Giu iano Mi anese (MI)
Ita y
CONTACTS:
Tel: [phone] / .9339 /.9305
Fax: [phone]
[email protected]m
[email protected]m
www.tecnotergroup.com
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CAT 938K Page 7/22 Rev: 1.20_En –
01/02/2020

INSTALLATION PROCEDURE
TOP IMPORTANT
This system is not identica to the standard CAT system.
Any reference to CAT pict or documentation has to be considered as an indication on y.
Carefull follow this manual to install the s stem on the host machine
Attention:
Be sure to have understood the insta ation manua before the insta ation of the system.
Doub e check each hydrau ic insta ation before operate the system.
Attention:
In case of oca aws or restrictions were app icab e on the use of this upgrade kit, the
operator must strict y observe them.
IMPORTANT NOTICE
This s stem has been designed to fit the specific host machine onl and it is the result of
accurate engineering process. The presence of parts not identical to the expected one (e.g.
supports having different shape, bolts having different grade then expected, etc.) is
intentional.
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CAT 938K Page 8/22 Rev: 1.20_En –
01/02/2020

Line gp Lift cylinder
WARNING
A ways set the va ves before operate the machine.
Refer the paragraph Testing and adjusting for detai s
1. Disconnect the two ift cy inders 495-6000 and ocate them on a c ean working tab e
2. On the Rh cy inder, dismount the tube 346-5073 with hose 346-5078 and c amps. Be sure
to keep c amps, b ocks, p ates and strips for reuse
3. Dismount the corresponding parts from the Lh cy inder. Be sure to keep c amps, b ocks,
p ates and strips for reuse
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CAT 938K Page 9/22 Rev: 1.20_En –
01/02/2020
Print SIS pages
333-6538
347-8236
WARNING: illustration for reference onl .
Some parts have been replaced b Tecnoter parts
Strictl follow this manual

4. Execute the fo owing steps on both Rh and Lh ift cy inders:
4.1. rep ace the existing e bow 148-8357 with the provided e bow
4.2. Insta the tube 523_4251TEC (148-8357TEC in certain versions) on the e bow
4.3. Using the support 526-9202TEC, fit the safety va ve (port C2) to the tube
Note: use the va ve KF34D (0849250304400D) on the Rh cy inder and KF34S
(0849240344000D) on the Lh cy inder
4.4. Insta the tube 523-4257/8TEC on the port V2 of the va ve
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CAT 938K Page 10/22 Rev: 1.20_En –
01/02/2020
148-8357TEC
523-4251TEC
KF34D
KF34S
525-9202TEC523-4257TEC

4.5. Insta the provided e bows on the tube 523-457 and the ports T and Pi as shown
4.6. Fix the support 526-9202TEC using the provided c amp-hose
4.7. Using the hose 523-4259TEC, connect the tube 523-457 to the ine Gp Lift
4.8. Adjust the present c amp-hoses according to the new arrangement
4.9. Insta the provided hose guard on the origina hose connected to the rod port of the
cy inder (see the pict in previous page for reference)
4.10. Insta again the cy inder in the frame
WARNING
Doub e check the correct c earance between cy inder's components and frame before actuate the
cy inder itse f
5. Insta the Tees 148-8439TEC and the shutt e 387-1096 with Tee on the support PSTPSP
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CAT 938K Page 11/22 Rev: 1.20_En –
01/02/2020

6. Temporary disconnect the hose 350-7587 to the tube 508-4258, then remove the nut 6V-
9172 from the tube 508-4258 (ref. 24 SIS page 347-8236)
7. Insert the ho e of the support PSTPSP in the nipp e of the tube 508-4258 then fix it with the
nut 6V-9172 just removed
8. Reconnect the hose 350-7587 to the tube
9. Using the hoses 523-4235TEC, connect the side ports of Tee 148-8439TEC to the e bow on
the pi ot ports of the safety va ves
10. Insta the provided nipp e (148-8326TEC) on the port G of the va ve 565-0113 then, using
the hose 577-7715TEC, connect the port G to the one shutt e va ve side port
11. Using the hose 523-4237TEC, connect the ast shutt e va ve side port to the port V9 of the
main contro va ve (refer the hydrau ic schematic M0107766-01) trough the second nipp e
148-8326TEC
IMPORTANT NOTE: PE option (Aux ECM with PRV valves) shall be ordered and
added on machines without port V9
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CAT 938K Page 12/22 Rev: 1.20_En –
01/02/2020
Print SIS page
523-4260
WARNING: illustration for reference onl .
Some parts have been replaced b Tecnoter parts
Strictl follow this manual

12. Connect the two hoses F04F-F90B-FDOB-A1050 to the T ports of the safety va ves then
pu them ti the support PSTPSP
13. Connect the hoses to the side of the free Tee
14. Using the second hose 523-4237TEC, connect the centra port of the Tee to the return
manifo d 433-1417. The provided spare Tee EGIL-FDOB-MDOB-MDOB and e bow can
be uses on certain arrangements for an easier insta ation.
WARNING
Doub e check the correct c earance between hoses and frame before actuate the cy inder itse f
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CAT 938K Page 13/22 Rev: 1.20_En –
01/02/2020

Testing and adjusting
P ease note schematic and component position of the ift cy inders safety va ves
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CAT 938K Page 14/22 Rev: 1.20_En –
01/02/2020

IMPORTANT NOTICE
The Factor sealed “E” screw can be used for Emergenc spool opening and boom lowering,
in case of pilot pressure failure; once the emergenc boom lowering is completed, the “E”
screw must be restored to its original position and locked
Pilot ratio adjusting:
The va ve (1) – Pi ot – is preset at the va ue of 7,5 bar (109 PSI) cracking pressure.
This setting is the resu t of severe ab and on-the-fie d tests and it represents the idea va ue
to ensure the best operator experience.
In case of particu ar necessities, this setting can be changed by ski ed technicians to modify
the va ve sensibi ity.
Va ve (1) range: 7 – 20 bar (102 / 290 PSI)
Va ve (1) sensibi ity: approx 3.2 bar / turn (51 PSI)
Screw c ockwise to increase.
Overload setting:
The va ve inc udes an anti shock re ief (2) which senses C2 pressure and opens under
over oad or shock conditions in order to pi ot wide open the metering spoo and to a ow
cy inder pressure to be re ieved downstream through the main hose (V2) and through the
main contro va ve.
The cartridge (2) sha be adjusted during insta ation according to the host machine setting.
Va ve (2) range: 300 – 460 bar (approx 4350 / 6650 PSI)
Va ve (2) standard setting: 350 bar (approx 5000 PSI)
Va ve (2) sensibi ity: approx 228 bar / turn (approx 3300 PSI)
Screw c ockwise to increase.
WARNING
Alwa s set the valve (2) to the appropriate value before operate the host machine.
Safet valves supplied in the kit are pre set at the value of 350 bar!
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CAT 938K Page 15/22 Rev: 1.20_En –
01/02/2020

Line gp Tilt cylinder (SP version)
NOTE:
PE option (Aux ECM with PRV valves) shall be ordered for applications in EU market
15. Remove hoses and tube from the ti t cy inder
16. Keep hoses in a c ean compartment for reuse
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CAT 938K Page 16/22 Rev: 1.20_En –
01/02/2020
Print SIS page
333-6920

17. rep ace the e bow148-8356 with the provided 848-1356TEC
18. connect the tube 364-1545TEC to the e bow
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CAT 938K Page 17/22 Rev: 1.20_En –
01/02/2020
Print SIS page
523-4245
WARNING: illustration for reference onl .
Some parts have been replaced b Tecnoter parts
Strictl follow this manual

19. Using the provided c amp-hose, insta the support 523-4239TEC as in the fo owing
picture
20. Insta the safety va ve WCB17ISO on the support PSTVBL (523-4239TEC), then connect
the va ve (port C2) to the tube as shown
21. Using the provided e bow 148-8356TEC, reconnect the origina hose 393-0597 to the
safety va ve, port V2
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CAT 938K Page 18/22 Rev: 1.20_En –
01/02/2020
PSTVBL - 523-4239TEC
WCB17ISO
393-0597
C2
V2

22. Insta the provided Tee 148-8425TEC on the rod port of the cy inder
23. Using the hose 523-4248TEC (F04F-FDOB-FDOB-A350), connect the centra port of the
Tee to the pi ot port of the safety va ve
24. Connect the hose 393-0597TEC to the free port of the Tee
WARNING
Doub e check the correct c earance between cy inder's components and frame before actuate the
cy inder itse f
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CAT 938K Page 19/22 Rev: 1.20_En –
01/02/2020
148-8425TEC393-0597TEC 393-0597
364-1545TEC 523-4248TEC

Testing and adjusting
P ease note schematic and component position of the ift cy inders safety va ves
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CAT 938K Page 20/22 Rev: 1.20_En –
01/02/2020
Pi
C2
V2
2
2