Installation Procedure for the 457-4024 Lines Gp - Coupler on Certain Wheel Loaders {0679, 5057, 5133, 5491, 6129, 7050} Caterpillar

Installation Procedure for the 457-4024 Lines Gp - Coupler on Certain Wheel Loaders {0679, 5057, 5133, 5491, 6129, 7050} [GEHS0845]

FRAME AND BODY

FRAME GP

Installation Procedure for the 457-4024 Lines Gp - Coupler on Certain Wheel Loaders {0679, 5057, 5133, 5491, 6129, 7050}

1.1. Introduction

2.1. Safety Section

3.1. Welding Requirements

4.1. Required Parts

5.1. Installation Procedure

6.1. Hydraulic Components

7.1. Electrical Components

8.1. Software Configuration

Wheel Loader
980L (S/N: D8Z1-UP)
980M (S/N: MK21-UP; WW31-UP; MGD1-UP; XDJ1-UP; KRS1-UP; N8T1-UP)
Work Tool
QUICK COUPLER (S/N: Y7A1-UP; Y8B1-UP; A8K1-UP)

Revision History:

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Table 1
Revision	Summary of Changes
04	Added Software Configuration Section.
03	Graphics updated
02	Effectivity updated

Introduction

This special instruction covers the installation procedure for 457-4024 Coupler Lines Gp.

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

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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.

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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.

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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.

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Illustration 1	g00104545

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

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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

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Table 2
457-4024 Lines Gp - Coupler Revision -01
Item	Qty	Part No	Description
(1)	2	6V-9829	Cap As
(2)	2	112-1817	Ball Valve
(3)	1	123-4750	Check Valve As
(4)	8	148-8336	Connector As
(5)	2	148-8367	Elbow As
(6)	2	160-8708	Bracket As
(7)	1	162-8264	Tee As
(8)	1	324-3471	Bracket
(9)	1	378-5307	Block
(10)	1	489-3368	Quick Coupler Wiring Gp
(10a)	2	8T-4137	Bolt
(10b)	2	8T-4121	Hard Washer
(10c)	4	7K-1181	Cable Strap
(10d)	2	4P-7581	Clip
(10e)	1	489-3369	Quick Coupler Harness As
(10f)	1	206-2423	Saddle
(10g)	1	130-5300	Clip
(11)	2	389-4290	Hose As
(12)	1	416-4796	Control Valve and Mounting Gp
(13)	1	427-4963	Quick Coupler Switch Gp
(13a)	1	424-4914	Rocker Switch
(14)	1	433-6015	Hose As
(15)	2	433-6016	Hose As
(16)	1	433-6018	Hose As
(17)	2	433-6045	Hose As
(18)	1	433-6047	Tube As
(19)	1	433-6052	Tube As
(20)	1	433-6063	Hose As
(21)	1	500-0541	Tube As
(22)	1	500-0543	Tube As
(23)	2	067-2551	Clip
(24)	8	096-6166	Hard Washer
(25)	1	100-4336	Clip
(26)	8	121-4405	Bolt
(27)	2	133-6934	Spacer
(28)	1	150-4043	Connector As
(29)	1	198-4777	Hard Washer
(30)	1	500-0528	Bracket
(31)	4	2R-1866	Clamp
(32)	1	344-5675	Nut
(33)	2	5P-7462	Clip
(34)	2	5P-7463	Clip
(35)	10	5P-9297	Clip
(36)	2	5P-9299	Clip
(37)	2	6V-0683	Grommet
(38)	8	6V-8397	O-Ring Seal
(39)	6	7X-7729	Washer
(40)	1	8R-7783	Boss
(41)	19	8T-4121	Hard Washer
(42)	16	8T-4137	Bolt
(43)	1	8T-4139	Bolt
(44)	2	8T-4172	Bolt
(45)	2	8T-4185	Bolt
(46)	1	8T-4186	Bolt
(47)	3	8T-4195	Bolt
(48)	1	8T-4223	Hard Washer
(49)	2	9C-4935	Plate
(50)	10	9R-2613	Weld Boss
(51)	1	9R-2821	Boss
(52)	114 cm	7I-1024	Hose Guard
(53)	1	9C-7929	Block
(54)	1	294-4550	Weld Boss

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Illustration 2	g06297608
457-4024 Lines Gp - Coupler