COTTER KIT 8M7982 - Caterpillar

Assemble plug (5) into the bottom of quick-drop and brake valve (D).
Illustration 7 g06257616
(4) 148-8390 Elbow As
Remove the fittings from the former counterbalance valve and assemble the fittings into the new counterbalance valve. The former counterbalance valve may be discarded.Assemble new elbow assembly (4) into the new counterbalance as indicated in illustration 7.
Illustration 8 g06257861
(3) 8T-6685 Bolt
(7) 363-7497 Clip
(8) 520-3719 Counterbalance Valve
(9) 533-0927 Bracket As
Assemble new counterbalance valve (8) with the hardware indicated in Illustration 8.Note: Use the three 8T-4121 Hard Washers that were saved from Step 1. Use new hose clip (7) as illustrated.Reconnect the four counterweight cylinder hoses.
Illustration 9 g06257998
(E) Former bracket and hose
(G) Swap hoses inside this clamp
(11) 538-3965 Bracket
(12) 538-5171 Hose As
Disconnect the hose from the tee assembly at location (E). Replace the bracket that is holding the tee assembly at location (E). Use the same hardware to assemble new bracket (11).Reassemble the tee assembly into new bracket (11).Remove the hose between the top port of the counterbalance valve and the rear port of the counterweight control valve. Assemble new hose (12) using the same clipping points and hardware.Note: Swap the hoses at location (G) to improve the routing of the hoses.
Illustration 10 g06258288
(12) 538-5171 Hose As
Assemble the opposite end of the top hose from the new counterbalance valve (12) to the rear port of the counterweight control valve.
Illustration 11 g06258332
(1) 6V-1889 Clip
(6) 148-8449 Swivel Tee
(10) 538-3964 Hose As
Assemble swivel tee (6) onto the top of the tee assembly that was installed in Step 5.Assemble hose (10) between the elbow on the new counterbalance valve and new swivel tee (6) as indicated in Illustration 11.Reconnect the hose that was disconnected in Step 5 to the top of swivel tee (6).Use clip (1) and the existing hardware to secure the hose as indicated in Illustration 11.
Illustration 12 g06257206
When the assembly is complete, make sure the pressure relief valve on top of the new counterbalance valve is turned all the way clockwise.Note: Hand tighten only. No special tooling is required.
Start the engine and extend and retract the counterweight several times to remove air from the system.
Check the hydraulic oil level and add if required.Counterweight To Zero Energy State After Rework
Before beginning work on the hydraulic system, you must bring the counterweight to a zero energy state. The counterweight is not in a zero energy state when fully retracted or fully extended. Follow the procedure below to ensure that the counterweight will not unintentionally move while you are working.
Move the machine to a smooth horizontal location.
Place the steering control lever in the NEUTRAL position.
Engage the parking brake.
Illustration 13 g06219515
Illustration 14 g06257997
Verify that the counterweight retention components are removed from location (A) on the counterweight frame.
Extend the counterweight approximately 30.5 cm (12 inch).
Stop the engine.
Illustration 15 g06257206
Turn the pressure release valve counterclockwise to open the valve. The counterweight will relax to the zero energy state.Note: When normal operation of the counterweight is desired, close the pressure release valve by turning clockwise.
Turn the key to the ON position, but do not start the engine.
Verify that