Installation Procedure for the <NOBR>454-2353</NOBR> Lines Gp - Coupler on Certain Wheel Loaders {0679, 5057, 5133, 5491, 6129, 7050} Caterpillar


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Installation Procedure for the <NOBR>454-2353</NOBR> Lines Gp - Coupler on Certain Wheel Loaders {0679, 5057, 5133, 5491, 6129, 7050} [GEHS0742]
FRAME AND BODY
FRAME GP
1.1. Introduction
2.1. Safety Section
3.1. Welding Requirements
4.1. Required Parts
5.1. Installation Procedure
6.2. Mounting Brackets
7.2. Hydraulic Components
8.2. Electrical
9.1. Software Configuration
Wheel Loader
972M (S/N: A781-UP; L8E1-UP; LSJ1-UP; GGN1-UP; WGN1-UP; A8P1-UP; JPR1-UP; M8W1-UP)
972M Series XE (S/N: AN31-UP; L9S1-UP; M5S1-UP; EDW1-UP; R1Z1-UP)
Work Tool
QUICK COUPLER (S/N: Y7A1-UP; A8K1-UP)
Revision History:

Table 1
Revision  Summary of Changes 
05  Added Software Configuration Section. 

Introduction

This special instruction covers the installation procedure for 454-2353 Lines Gp - Coupler.

The coupler lines group consists of a switch in the cab, and a control valve and pressure lines which supply hydraulic pressure to the quick coupler. The switch has two positions that are used for coupling and uncoupling the work tool. Pressure for the operation of the quick coupler is supplied by the implement pump.

Safety Section


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.

Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.


------ WARNING! ------

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.

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.


------ WARNING! ------

Personal injury or death can result from improperly checking for a leak.

Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death.

If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.




Illustration 1g00104545

Prevent the machine from movement. Park the machine on a level surface.

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.

Welding Requirements

------ WARNING! ------

Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.

Welding can cause fumes, burn skin and produce ultraviolet rays.

Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.

Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.

American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125

See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor.

U.S. Department of Labor
Washington, D.C. 20210

Welding quality is critical to the success of the installation procedures. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds to a smooth radius.

All electrodes must be dried completely. The electrodes can be dried by heating the electrodes to 300°C (572°F). The electrodes must be dried for at least 30 minutes.

Do not weld in windy conditions. Do not weld when temperatures are below 16°C (60°F).

Penetration characteristics may vary greatly depending on the following conditions:

  • Electrode diameter

  • Shielding gas

  • Welding current

  • Plate thickness

The following items also affect the welds:

  • Geometry of welded joints

  • Surface conditions

  • Composition of the base metal and of the electrode

A root pass should be applied before each weld is finished.

Maintain a 3 mm (0.12 inch) minimum root opening on all cross welds and circle welds.

All welds to the stick must be welded in the direction from the rear of the stick toward the front of the stick.

For more welding information, consult the AVSpare Service Welding Guide, SEBD0512.

Required Parts

Table 2
454-2353 Lines Gp - Coupler Revision -04 
Item  Qty  Part No  Description 
(1)  6V-9829  Cap As 
(2)  112-1817  Ball Valve 
(3)  8Y-3795  Boss 
(4)  123-4750  Check Valve As 
(5)  148-8336  Connector As 
(6)  148-8351  Elbow As 
(7)  148-8353  Elbow As 
(8)  148-8367  Elbow As 
(9)  148-8378  Elbow As 
(10)  160-8708  Bracket As 
(11)  162-8264  Tee As 
(12)  324-3471  Bracket 
(13)  367-0391  Tube As 
(14)  367-0392  Tube As 
(15)  383-4355  Hose As 
(16)  416-4796  Control Valve and Mounting Gp 
(17)  418-3768  Bracket As 
(18)  418-3771  Tube As 
(19)  472-0175  Tube As 
(20)  423-9937  Hose As 
(21)  423-9938  Hose As 
(22)  423-9939  Hose As 
(23)  427-4963  Quick Coupler Switch Gp 
(23a)  424-4914  Rocker Switch 
(24)  096-6166  Hard Washer 
(25)  121-4405  Bolt 
(26)  150-4043  Connector As 
(27)  163-9662  Threaded Boss 
(28)  178-7023  Boss 
(29)  14  5P-9297  Clip 
(30)  6D-3479  Clip 
(31)  6V-8397  O-Ring Seal 
(32)  17  8T-4121  Hard Washer 
(33)  8T-4133  Nut 
(34)  8T-4136  Bolt 
(35)  8T-4137  Bolt 
(36)  8T-4172  Bolt 
(37)  8T-4192  Bolt 
(38)  8T-4223  Hard Washer 
(39)  8X-7415  Plate 
(40)  9C-4935  Plate 
(41)  9R-2613  Weld Boss 
(42)  9R-2821  Boss 
(43)  5P-7462  Clip 
(44)  5P-7463  Clip 
(45)  6V-0683  Grommet 


Illustration 2g03777178
454-2353 Coupler Lines Gp

Installation Procedure

Mounting Brackets



    Illustration 3g03716162
    (27) 163-9662 Threaded Boss
    (28) 178-7023 Boss
    (40) 9C-4935 Plate
    (41) 9R-2613 Weld Boss

  1. Weld the plates and bosses to the inside of the loader arm.


    Illustration 4g03716133
    (39) 8X-7415 Plate
    (42) 9R-2821 Boss

  2. Weld the plate and bosses to the frame.


    Illustration 5g03777182
    (3) 8Y-3795 Boss
    (41) 9R-3613 Tube As

  3. Weld the bosses to the frame.

Hydraulic Components



    Illustration 6g03716135
    Valve group (A)
    ( 4) 123-4750 Check Valve As
    (5) 148-8336 Connector As
    (7) 148-8353 Elbow As
    (8) 148-8367 Elbow As
    (16) 416-4796 Control Valve and Mounting Gp
    (32) 8T-4121 Hard Washer
    (36) 8T-4172 Bolt

  1. Assemble valve group (A).


    Illustration 7g03716584
    Valve group (B)
    ( 1) 6V-9829 Cap As
    (2) 112-1817 Ball Valve
    (5) 148-8336 Connector As
    (12) 324-3471 Bracket
    (24) 096-6166 Hard Washer
    (25) 121-4405 Bolt
    (32) 8T-4121 Hard Washer
    (34) 8T-4136 Bolt

  2. Assemble valve group (B).


    Illustration 8g03716138
    (10) 160-8708 Bracket As
    (13) 367-0391 Tube As
    (14) 367-0392 Tube As
    (15) 383-4355 Hose As
    (17) 418-3768 Bracket As
    (29) 5P-9297 Clip
    (31) 6V-8397 O-Ring Seal
    (32) 8T-4121 Hard Washer
    (34) 8T-4136 Bolt
    (35) 8T-4137 Bolt

  3. Install valve group (B).

  4. Install tube assemblies (14), and (15).

  5. Install hoses (15). Use seals (31).

  6. Secure the tubes.


    Illustration 9g03716122
    (17) 418-3768 Bracket As
    (18) 418-3771 Tube As
    (19) 472-0175 Tube As
    (29) 5P-9297 Clip
    (32) 8T-4121 Hard Washer
    (33) 8T-4133 Nut
    (34) 8T-4136 Bolt
    (35) 8T-4137 Bolt
    (37) 8T-4192 Bolt
    (38) 8T-4223 Hard Washer

  7. Install bracket (17), tubes (18) and (19). Use seals (31).

  8. Secure the tubes.


    Illustration 10g03777186
    (3) 8Y-3795 Boss
    (6) 148-8351 Elbow As
    (9) 148-8378 Elbow As
    (18) 418-3771 Tube As
    (19) 472-0175 Tube As
    (20) 423-9937 Hose As
    (21) 423-9938 Hose As
    (22) 423-9939 Hose As
    (30) 6D-3479 Clip
    (32) 8T-4121 Hard Washer
    (35) 8T-4137 Bolt
    (41) 9R-2613 Weld Boss
    (43) 5P-7462 Clip
    (44) 5P-7463 Clip
    (45) 6V-0683 Grommet

  9. Install valve group (A).

  10. Connect tubes (18) and (19).

  11. Install hoses (20), (21), and (22).


    Illustration 11g03716169
    (X) 344-7391 Pressure Sensor Gp
    (11) 162-8264 Tee As
    (21) 423-9938 Hose As
    (26) 150-4043 Connector As

  12. Remove the pressure sensor (X).

  13. Install connector (26) and tee (11) to the port where the pressure sensor was removed.

  14. Reinstall pressure sensor (X).

Electrical



    Illustration 12g03715095
    (23) 427-4963 Quick Coupler Switch Gp

  1. Install switch at position "86 Quick Coupler Switch (C-C15)".

  2. Connect to the existing plug.

Software Configuration

Note: This machine feature can be configured and must be activated with product software programming system or service tool.

  1. Use AVSpare Electronic Technician (Cat ET) and select the Implement Electronic Control Module (ECM).

  2. Select "Configuration" from the menu.

  3. Double click on the "Quick Coupler Installation Status" option on the "Configuration" screen.

  4. Verify the status is set to "Installed" and click "OK". The feature will be activated on the next power cycle.

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