Field Installation of the 224-9412 Quick Coupler Conversion Ar {6129} Caterpillar

Skid Steer Loader:

216 (S/N: 4NZ1-UP)

226 (S/N: 5FZ1-UP)

Introduction

Reference: Operation and Maintenance, SEBU7468, "216, 226, 228, 232, 236, 242, 246, 248, 252, and 262 Skid Steer Loaders"

Reference: Disassembly and Assembly, RENR2862, "216 and 226 Skid Steer Loaders"

This Special Instruction provides the information that is necessary for the installation of the 224-9412 Quick Coupler Conversion Ar .

Do not begin installation until you have read the information that is contained in this instruction. Also obtain the Operation and Maintenance Manual and the Disassembly and Assembly Manuals for instructions that are referenced herein.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

Required Parts

The required parts for field installation of the quick coupler conversion ar are provided in this section.

• See Table 1 for 224-9412 Quick Coupler Conversion Ar parts.

Table 1

Required Parts
Item	Quantity	Part Number	Description
1	10	8T-4121	Hard Washer
2	4	8T-4133	Nut
15	2	169-6156	Boss (2)
47	2	192-2640	Coupler Cylinder Gp
48	2	215-3957	Coupler Link Gp (1)
49	2	3B-4628	Cotter Pin
51	2	207-9785	Pin
52	2	195-6754	Spring Pin
53	4	8T-4196	Bolt
54	4	9T-7303	Spacer
55	2	5B-0651	Straight Fitting
56	2	5P-0372	Lock Pin
57	1	218-6334	Bracket
58	1	218-6335	Bracket
59	1	207-9754	Coupler Lines Gp (1)
60	1	212-6520	Quick Coupler Harness As (1)
66	2	8L-5188	Pin

( 2 )	Use on the (S/N: 4NZ1-3978) and the (S/N: 5FZ1-8203) machines
( 1 )	Nonserviceable

Table 2

215-3957 Coupler Link Gp Parts
Item	Quantity	Part Number	Description
61	1	8T-4123	Plated Washer
62	1	192-2637	Plate
63	1	192-2638	Bracket
64	1	192-2645	Spring
65	2	195-6754	Spring Pin

Table 3

212-6520 Coupler Wiring Group Parts
Item	Quantity	Part Number	Description
50	1	212-6521	Rocker Switch
46	1	212-6522	Coupler Harness Assembly

Table 4

207-9754 Coupler Lines Gp Parts
Item	Quantity	Part Number	Description
1	2	8T-4121	Hard Washer
2	1	8T-4133	Nut
3	2	8T-6870	Bolt
4	1	209-0640	Solenoid Valve and Mounting Gp
6	1	220-8089	Hose As
7	1	212-1336	Tee (1)
8	1	156-4282	Reducer As (1)
9	1	6V-8555	O-Ring Seal
10	1	148-8378	Elbow (1)
11	1	166-2033	Tee Gp (1)
12	1	220-8090	Tube As
13	4	148-8336	Connector (1)
16	2	220-8088	Hose As
17	1	5C-7261	Nut
18	2	5K-8451	Clip
19	1	9R-1004	Clip
20	1	9R-1005	Clip
22	6	8T-4224	Hard Washer
23	1	8T-4908	Bolt
24	4	2V-3216	Clip
25	1	220-8086	Tube As
26	1	220-8087	Tube As
27	4	6V-8397	O-Ring Seal
28	2	7H-7055	Clip
29	2	9M-8406	Clip
30	2	8T-4201	Locking Bolt
31	2	150-4034	Tee (1)
32	1	207-9737	Bracket
33	2	8T-4189	Bolt
35	4	148-8325	Connector Gp (1)
36	2	219-4335	Hose As
37	2	6V-9168	Nut
38	4	207-9756	Hose As
39	1	7G-2950	Clip
40	1	7G-2951	Clip
41	3	7X-7729	Washer
42	1	8T-4136	Bolt
43	1	212-6690	Guard
44	2	8T-4191	Bolt
45	1	124-2456	Film

Table 5

209-0640 Solenoid Valve and Mounting Gp Parts
Quantity	Part Number	Description
1	144-1644	Solenoid Valve Gp
1	185-2269	Manifold

Table 6

144-1644 Solenoid Valve Gp Parts
Quantity	Part Number	Description
1	6T-9244	Cartridge Assembly
1	126-5948	Seal Kit
1	144-1643	Solenoid Coil Group
1	157-2284	Special Locknut
1	160-5843	Washer
1	160-5844	Spring Washer

Table 7

148-8325 Connector Gp Parts
Quantity	Part Number	Description
1	3J-1907	O-Ring Seal
1	4J-5477	O-Ring Seal
1	6V-8641	Connector

Table 8

148-8336 Connector Parts
Quantity	Part Number	Description
1	3J-1907	O-Ring Seal
1	6V-8397	O-Ring Seal
1	6V-8636	Connector

Table 9

148-8378 Elbow Parts
Quantity	Part Number	Description
1	3J-1907	O-Ring Seal
1	6V-8397	O-Ring Seal
1	6V-8724	Elbow

Table 10

148-8446 Swivel Tee Parts
Quantity	Part Number	Description
1	6V-9838	Swivel Tee
2	7J-9108	O-Ring Seal

Table 11

150-4034 Tee Parts
Quantity	Part Number	Description
3	6V-8397	O-Ring Seal
1	8T-0379	Tee

Table 12

156-4282 Reducer As Parts
Quantity	Part Number	Description
1	6V-8397	O-Ring Seal
1	6V-8938	O-Ring Reducer

Table 13

166-2033 Tee Gp Parts
Quantity	Part Number	Description
1	4J-5477	O-Ring Seal
1	7X-2444	Swivel Tee

Preparing the Machine

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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.

1. Park the machine.

   Note: Refer to "Machine Parking" in the Operation and Maintenance Manual for your machine.

2. Release hydraulic system pressure.

   Note: Refer to "Release Procedure (Hydraulic System Pressure)" in the Disassembly and Assembly Manual for your machine.

Disassemble the Manual Coupler

Illustration 1	g00947829
The Quick Coupler Group (A) Handle Group (RH) (B) Handle Group (LH)

1. Perform Step 1.a through Step 1.d in order to remove mechanical lock group (A) from the quick coupler.
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   Illustration 2	g00947853
   Section A-A in Illustration 1 (A) Mechanical Lock Group (RH) (C) Locknut (D) Washer (E) Spring (F) Spacer (G) Bolt (H) Washer

   1. Remove locknut (C). See Illustration 2.

      Note: Use caution as you remove the nut. The spring tension will be released as you remove the nut.

   2. Remove washer (D), spring (E), and spacer (F) .

   3. Remove bolt (G) and two washers (H) .

   4. Withdraw Handle Group (A) from the quick coupler.

2. Repeat Step 1.a through Step 1.d in order to remove Handle Group (B) from the quick coupler.

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Illustration 3	g00947856
The mechanical lock group (RH) (A) Mechanical Lock Group (RH) (J) 166-2560 Spring Pin (K) 192-2642 Pin

3. Disconnect the 192-2642 Pin (K) from BOTH Handle and Pin Groups by removing the 166-2560 Spring Pin (J). See Illustration 3.

Installing the Cylinder Group

This section provides instruction for installing the coupler cylinder and link group on the existing 196-8870 Quick Coupler Gp .

1. Perform Step 1.a and Step 1.b in order to preassemble the link and lever group (RH) .
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   Illustration 4	g00983542
   The link and lever group (RH) (52) 195-6754 Spring Pin (47) 192-2640 Coupler Cylinder Gp (48) 215-3957 Coupler Cylinder and Link Gp (J) 166-2560 Spring Pin (K) 192-2642 Pin

   1. Assemble an existing 192-2642 Pin (K) to a 215-3957 Coupler Cylinder and Link Gp (48). Reuse a 166-2560 Spring Pin (J) in order to assemble these components. See Illustration 4.

   2. Assemble a 192-2640 Coupler Cylinder Gp (47) to the 215-3957 Coupler Cylinder and Link Gp (48). Use a 195-6754 Spring Pin (52) in order to assemble these components.

2. Repeat Step 1.a and Step 1.b in order to preassemble the link and lever group (LH). Use 215-3957 Coupler Cylinder and Link Gp

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Illustration 5	g00981177
(57) 218-6334 Bracket (LH) (58) 218-6335 Bracket (RH)

3. Install the 218-6334 Bracket (LH) (57) and the 218-6335 Bracket (RH) (58) on the quick coupler. Use the four 8T-4196 Bolts and the four 8T-4121 Hard Washers that are provided on the top plate of the quick coupler. See Illustration 5.

   Tighten bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 6	g00981141
(1) 8T-4121 Hard Washer (2) 8T-4133 Nut (53) 8T-4196 Bolt (55) 5B-0651 Straight Fitting

4. Secure the outside edge of EACH bracket to the quick coupler. Use two 8T-4196 Bolts (53), four 8T-4121 Hard Washers (1), and two 8T-4133 Nuts (2) to fasten each bracket. See Illustration 6.

   Tighten bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

5. Perform Step 5.a through Step 5.b in order to install the link and lever groups that were preassembled in Step 1.a.
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   Illustration 7	g00983539
   (56) 5P-0372 Lock Pin (51) 207-9785 Pin (49) 3B-4628 Cotter Pin (1) 8T-4121 Hard Washer (54) 9T-7303 Spacer (66) 8L-5188 Pin

   Note: Coat EACH pin bore with lubricant before inserting the pin.

   1. Attach the link to the quick coupler. Use a 207-9785 Pin (51), a 5P-0372 Lock Pin (56), and a 8T-4121 Hard Washer (1) in order to attach the link. See Illustration 7.

   2. Attach the head end of the cylinder to the quick coupler. Use a 8L-5188 Pin (50), two 9T-7303 Spacers (54), and a 3B-4628 Cotter Pin (49) in order to attach the cylinder. See Section A-A of Illustration 7.

Installation Instructions

Installing the Lines Group

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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 machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide"for tools and supplies to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations.

Note: For cleanliness, cap all hydraulic lines until the lines are installed.

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Illustration 8	g00986353
(A) 199-5373 Frame As (15) 169-6156 Boss (G) 929.8 mm (36.61 inch) (H) 904.4 mm (35.61 inch) (J) 144.0 mm (5.67 inch) (K) 93.2 mm (3.67 inch)

1. Locate the weld bosses (15) on the existing 199-5373 Frame As (A). On the (S/N: 4NZ1-3978) and the (S/N: 5FZ1-8203) machines, add weld bosses (15) to the top of the left side frame rail at the specified dimensions. See Illustration 8.

   Note: Follow the dimensions (G), (H), (J) and (K) in order to place the weld bosses. See Illustration 8.

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Illustration 9	g00948162

2. Install the 209-0640 Solenoid Valve and Mounting Gp (4) to the weld bosses. Use the two 8T-6870 Bolts (3) and the 8T-4224 Hard Washers (22) in order to secure the 209-0640 Solenoid Valve and Mounting Gp to the weld bosses.

   Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 10	g00866676
(B) 193-8311 Hose As (Existing)

3. Locate the existing 193-8311 Hose As (B) which is connected between the fan motor and the Gear Pump. See Illustration 10.

   Note: The 193-8311 Hose As is part of the 195-6790 Hydraulic Fan Lines Gp .

4. At the gear pump, disconnect hose assembly (B) .

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Illustration 11	g00944297
(6) 220-8089 Hose As (7) 212-1336 Tee (8) 156-4282 Reducer As (9) 6V-8555 Face Seal Nut (B) 193-8311 Hose As (Existing)

5. Install the 212-1336 Tee (7) to the gear pump. See Illustration 11.

6. Reconnect the 193-8311 Hose As (B) to tee (7) .

7. Install the 156-4282 Reducer As (8) and the 6V-8555 Face Seal Nut (9) to tee (7) .

8. Connect the end of the 220-8089 Hose As (6) with the 90° orifice coupling to reducer assembly (8) .

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Illustration 12	g00944337
(6) 220-8089 Hose As (10) 148-8378 Elbow Gp (B) 50° ± 5° Angle

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Illustration 13	g00944606
(6) 220-8089 Hose As (10) 148-8378 Elbow Gp

9. At the 209-0640 Solenoid Valve and Mounting Gp (4) that was installed in Step 2, install a 148-8378 Elbow Gp (10) to Port (P). See Illustration 12.

   Note: Align the elbow at an angle of 50° ± 5°, as shown.

10. Connect the end of the 220-8089 Hose As (6) with the straight orifice coupling to the elbow at Port (P) .

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Illustration 14	g00944583
(C) 142-9216 Hose As (Existing)

11. Locate the existing 142-9216 Hose As (C) which is installed between the implement control valve and the return manifold. See Illustration 14.

    Note: The 142-9216 Hose As (C) is part of the 193-0453 Pilot Lines .

12. At the return manifold, disconnect the 142-9216 Hose As (C) .

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Illustration 15	g00944585
(11) 166-2033 Tee Gp (12) 220-8090 Tube As (13) 148-8336 Connector Gp (C) 142-9216 Hose As (Existing)

13. Install the 166-2033 Tee Gp (11) to the return manifold. See Illustration 15.

14. Reconnect the 142-9216 Hose As (C) to tee (11), as shown.

15. Install the 148-8336 Connector Gp (13) to the remaining port of tee (11) .

16. Install the end of the 220-8090 Tube As (12) with the short 90° bend to connector (13) .

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Illustration 16	g00944623
(4) 209-0640 Solenoid Valve and Mounting Gp (13) 148-8336 Connector (16) 220-8088 Hose As (D) 90° ± 5° Angle (E) 30° ± 5° Angle

17. At the 209-0640 Solenoid Valve and Mounting Gp (4), install a 148-8336 Connector Gp (13) to Port (C1) and to Port (C2). See Illustration 16.

18. Connect a 220-8088 Hose As (16) to EACH of the two connectors (13).

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Illustration 17	g00985464
(4) 209-0640 Solenoid Valve and Mounting Gp (16) 220-8088 Hose As (17) 5C-7261 Nut (18A) 5K-8451 Clip (18B) 5K-8451 Clip (19) 9R-1004 Clip (20) 9R-1005 Clip (22) 8T-4224 Hard Washer (23) 8T-4908 Bolt

19. Route the two 220-8088 Hose As (16) along the left side wall. Feed the hose assemblies through the access hole in the left side wall of the engine compartment and up the left tower, as shown.

20. Route the hose through the 5K-8451 Clip (18A). Use existing hardware in order to install the 5K-8451 Clip (18A). Refer to Illustration 17.

21. Route the hose through the 5K-8451 Clip (18B). Use the 8T-4908 Bolt (23), the 8T-4224 Hard Washer (22), and the 5C-7261 Nut (17) in order to install the 9R-1004 Clip (19) and the 9R-1005 Clip (20) to the 5K-8451 Clip (18B) and to the adjacent tube assembly. Refer to Illustration 17.

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Illustration 18	g00944731
(16) 220-8088 Hose As (24) 2V-3216 Clip (25) 220-8086 Tube As (26) 220-8087 Tube As (27) 6V-8397 O-Ring Seal

22. Install two 6V-8397 O-Ring Seals (27) to the two 220-8088 Hose Assemblies (16).

23. Attach the 220-8086 Tube As (25) and the 220-8087 Tube As (26) to the 220-8088 Hose Assemblies (16). Position the two tube assemblies under the left lift arm, as shown. See Illustration 18.

    Note: Install the new tube assemblies parallel to any existing tube assemblies that are routed under the lift arm.

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Illustration 19	g00944771
Section A-A and Section B-B in Illustration 18 (24) 2V-3216 Clip (25) 220-8086 Tube As (26) 220-8087 Tube As

24. Attach the two 2V-3216 Clips (24) to the tube assemblies and use the existing 9X-2480 Bolt in order to fasten the clips to the lift arm. Refer to Illustration 19.

    Tighten the bolts to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

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Illustration 20	g00944793
(1) 8T-4121 Hard Washer (28) 7H-7055 Clip (29) 9M-8406 Clip (30) 8T-4201 Bolt

25. Fasten the two tubes to the threaded boss that is provided under the lift arm crossmember. Use a 8T-4121 Hard Washer (1) and a 8T-4201 Bolt (30) in order to fasten the two 7H-7055 Clips (28) to the lift arm. Refer to Illustration 20.

    Tighten the bolt to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

26. Connect the two 219-4335 Hose Assemblies (36) to the 220-8086 Tube As (25) and the 220-8087 Tube As (26) with two 6V-8397 O-Ring Seals (27). Refer to Illustration 20 and Illustration 21.

27. Use a 8T-4121 Hard Washer (1) and a 8T-4201 Bolt (30) in order to fasten the two 9M-8406 Clips (29) to the lift arm. Refer to Illustration 20.

    Tighten the bolt to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

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Illustration 21	g00986280
(2) 8T-4133 Nut (22) 8T-4224 Hard Washer (25) 220-8086 Tube As (26) 220-8087 Tube As (27) 6V-8397 O-Ring Seal (31) 150-4034 Tee (32) 207-9737 Bracket (33) 8T-4189 Bolt (35) 148-8325 Connector Gp (36) 219-4335 Hose As (37) 6V-9168 Nut (38) 207-9756 Hose As (39) 7G-2950 Clip (40) 7G-2951 Clip (41) 7X-7729 Washer (42) 8T-4136 Bolt (43) 212-6690 Guard (45) 124-2456 Film (N) 32° ± 5° Angle

28. Install the 207-9737 Bracket (32), two 8T-4189 Bolts (33) and two 8T-4224 Hard Washers (22).

29. Install the two 150-4034 Tee Assemblies (31). See Illustration 21.

30. Install the four 207-9756 Hose Assemblies (38) to the two 150-4034 Tee Assemblies (31). See Illustration 21.

31. Use the two 6V-9168 Nuts (37) in order to install the two 219-4335 Hose Assemblies (36) onto the two 150-4034 Tee Assemblies (31). See Illustration 21.

32. Use a 7G-2950 Clip (39), a 7G-2951 Clip (40), two 7X-7729 Washers (41), one 8T-4133 Nut (2) and one 8T-4136 Bolt (42) in order to attach the two 219-4335 Hose Assemblies (36) to the coupler. See Illustration 21.

    Note: Install clips (39) and (40) at angle (N) .

33. Use two 8T-4189 Bolts and two 8T-4224 Hard Washers in order to install the 212-6690 Guard (43). Place the 124-2456 Film (45) on the 212-6690 Guard (43). See Illustration 21.

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Illustration 22	g00983545
(35) 148-8325 Connector Assemblies (38) 207-9756 Hose Assemblies

34. Install four 148-8325 Connector assemblies (35) to the other end of the four 207-9756 Hose Assemblies (38). See Illustration 21 and Illustration 22.

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Illustration 23	g00944990
(E) 17° ± 5° Angle (F) 90° ± 5° Angle

35. Connect the four 207-9756 Hose Assemblies (38) to the cylinders.

    Note: Align the hose assemblies at the angles that are specified in Illustration 23.

Installing the Wiring Group

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Illustration 24	g00869642
Locate the unused position on the left hand control panel.

1. On the left hand control panel, remove the plug from the empty position that is indicated in Illustration 24.

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Illustration 25	g00981137
(43) 212-6521 Rocker Switch

2. Install the 212-6521 Rocker Switch (50) by inserting the rocker switch into the connector that is provided behind the control panel. See Illustration 25.

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Illustration 26	g00869647
Locate the unused 6-pin connector for the main cab harness.

3. Install the 212-6522 Quick Coupler Harness As (46) .

   Note: The harness assembly is installed between the connector on solenoid valve (4) and the spare 6-pin connector for the main cab harness. The spare 6-pin connector is located behind the cab on left side of the machine. See Illustration 26.

4. Use cable straps in order to secure harness (46) to existing wiring on the left side wall.

Operation of Work Tool Coupler Control

Illustration 27	g00869723

To disengage the coupler pins, pull red button (A) downward and press the TOP of rocker switch (B). When the rocker switch is in the UNLOCKED position, the coupler pins will be disengaged. See Illustration 27.

To engage the coupler pins, press the BOTTOM of rocker switch (B). The switch should be in the LOCKED position when you are not disengaging the quick coupler pins.

Note: If the coupler pins will not engage at low idle engine speed, repeat the procedure with the machine in high idle.