Field Installation of the 234-0777 Quick Coupler Conversion Ar {6129} Caterpillar

Multi Terrain Loader:

287 (S/N: CNY1-UP)

Introduction

Reference: Operation and Maintenance, SEBU7494, "247, 257, 267, 277, and 287 Multi Terrain Loaders"

Reference: Disassembly and Assembly, RENR4816, "267 and 277 Multi Terrain Loaders Machine Systems"

Reference: Disassembly and Assembly, RENR4814, "267 and 277 Multi Terrain Loaders Engine Supplement"

This Special Instruction provides the information that is necessary for the installation of the 234-0777 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 234-0777 Quick Coupler Conversion Ar are identified in Table 1.

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.

Installation Instructions

Installing the Cylinder Group

Illustration 1	g00867778
The 196-8870 Quick Coupler Gp (A) Mechanical Lock Group (RH) (B) Mechanical Lock Group (LH)

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

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Illustration 2	g00867779
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 mechanical lock group (A) from the quick coupler, as follows.

   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 mechanical lock group (A) from the quick coupler.

2. Repeat Step 1.a through Step 1.d in order to remove mechanical lock group (B) from the quick coupler.

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Illustration 3	g00867780
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 mechanical lock groups by removing the 166-2560 Spring Pin (J). See Illustration 3.

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Illustration 4	g00988888
The link and lever group (RH) (33) 192-2640 Coupler Cylinder Gp (34) 195-6754 Spring Pin (43) 215-3957 Coupler Link Gp (J) 166-2560 Spring Pin (K) 192-2642 Pin

4. Preassemble the link and lever group (RH), as follows.

   1. Assemble an existing 192-2642 Pin (K) to a 215-3957 Coupler Link Gp (43). Reuse a 166-2560 Spring Pin (J) in order to assemble these components. See Illustration 4.

   2. Assemble a 192-2640 Coupler Cylinder Gp (33) to the 215-3957 Coupler Link Gp (43). Use a 195-6754 Spring Pin (34) and assemble these components.

5. Repeat Step 4.a and Step 4.b in order to preassemble the link and lever group (LH) .

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Illustration 5	g00988867
(44) 218-6332 Bracket As (45) 218-6333 Bracket As

6. Install the 218-6332 Bracket As (44) and the 218-6333 Bracket (45) 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	g00988873
(14) 8T-4121 Hard Washer (15) 8T-4133 Nut (19) 8T-4196 Bolt

7. Secure the outside edge of EACH bracket to the quick coupler. Use two 8T-4196 Bolts (19), four 8T-4121 Hard Washers (14), and two 8T-4133 Nuts (15) and fasten each bracket. See Illustration 6.

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

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Illustration 7	g00988885
(1) 3B-4628 Cotter Pin (5) 5P-0372 Lock Pin (13) 8L-5188 Pin (14) 8T-4121 Hard Washer (26) 9T-7303 Spacer (38) 207-9785 Pin (K) 192-2642 Pin

8. Install the link and lever groups, as follows.

   1. Insert the 192-2642 Pin (K) into the pin bore on the quick coupler. See Illustration 7.

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

   2. Attach the link to the quick coupler. Use a 207-9785 Pin (38), a 5P-0372 Lock Pin (5), and a 8T-4121 Hard Washer (14) in order to attach the link.

   3. Attach the head end of the cylinder to the quick coupler. Use a 8L-5188 Pin (13), two 9T-7303 Spacers (26), and a 3B-4628 Cotter Pin (1) in order to attach the cylinder. See Section A-A of Illustration 7.

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Illustration 8	g00988878
(2) 5B-0651 Straight Fitting

9. Fill each pin bore with lubricant. See Illustration 8.

   Note: Install a new 5B-0651 Straight Fitting (2), as needed.

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Illustration 9	g00988884
(8) 6V-9168 Nut (12) 7X-7729 Washer (18) 8T-4191 Bolt (31) 150-4034 Tee (35) 207-9737 Bracket

10. Mount the 207-9737 Bracket (35) to the quick coupler. Use two 8T-4191 Bolts (18) and two 7X-7729 Washers (12) to mount the bracket. See Illustration 9.

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

    Note: Remove the two 7X-2621 Bolts and the two 8T-4121 Hard Washers that are provided on the quick coupler. Discard these components.

11. Install the two 150-4034 Tees (31) to bracket (35). Secure EACH tee with a 6V-9168 Nut (8) .

    Tighten the nuts to a torque of 34 ± 1 N·m (25 ± 1 lb ft).

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Illustration 10	g00988889
(28) 148-8325 Connector Gp (36) 207-9756 Hose As (A) 17° ± 5° Angle (B) 90° ± 5° Angle

12. Install a 148-8325 Connector Gp (28) on the two ports for EACH cylinder and install a 207-9756 Hose As (36) to each of the four connector groups (28). See Illustration 10.

    Align the hose assemblies at the angles that are shown in Illustration 10.

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Illustration 11	g00988887
(31) 150-4034 Tees (36) 207-9756 Hose As

13. Connect the free ends of the 207-9756 Hose As (36) to the two 150-4034 Tees (31). See Illustration 11.

Installing the Lines Group

Illustration 12	g00989032
Location diagram for the 234-0777 Quick Coupler Conversion Ar installation

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Illustration 13	g00989028
(14) 8T-4121 Hard Washer (15) 8T-4133 Nut (39) 209-0640 Solenoid Valve and Mounting Gp (Quick Coupler) (50) 8T-5005 Bolt (57) 207-9797 Plate

1. At Location (A) in Illustration 12, mount the 207-9797 Plate (57) .

   Mount the 207-9797 Plate (57) in tandem with the 208-1237 Solenoid Valve and Mounting Gp . See Illustration 13.

   Note: The 208-1237 Solenoid Valve and Mounting Gp is part of the 219-4317 Parking Brake Control Gp .

   Use the two existing 8T-3647 Bolts and the two existing 8T-4224 Hard Washers .

   Tighten the bolts to torque of 28 ± 7 N·m (21 ± 5 lb ft).

2. Install the 209-0640 Solenoid Valve and Mounting Gp (39) to plate (57). See Illustration 13.

   Use the two 8T-5005 Bolts (50), four 8T-4121 Hard Washers (14), and two 8T-4133 Nuts (15) .

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

3. At Location (B) in Illustration 12, disconnect the 193-8311 Hose As from the auxiliary gear pump.

   Note: This hose assembly is connected to the radiator cooling fan motor. This hose assembly is part of the 190-8116 Hydraulic Fan Lines Gp .

   Note: Do not remove the 148-8315 Connector Gp from the gear pump.

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Illustration 14	g00989030
(7) 6V-8555 Face Seal Nut (32) 156-4282 Reducer As (53) 207-9764 Hose As (58) 212-1336 Tee (A) 30° ± 5° (B) 120° ± 5°

4. Install the 212-1336 Tee (58) to the 148-8315 Connector Gp in the gear pump. See Illustration 14.

5. Reconnect the 193-8311 Hose As to the perpendicular port of tee (58). Align the hose at the angle that is shown in Illustration 14.

6. Install the 6V-8555 Face Seal Nut (7) in the parallel port of tee (58) and install the 156-4282 Reducer As (32) in the face seal nut.

7. Connect the end of the 207-9764 Hose As (53) with the 90° orifice coupling to reducer assembly (32). Align the hose at the angle that is shown in Illustration 14.

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Illustration 15	g00989036
(30) 148-8378 Elbow (39) 209-0640 Solenoid Valve and Mounting Gp (53) 207-9764 Hose As (C) 60° ± 5° Angle

8. At the 209-0640 Solenoid Valve and Mounting Gp (39), install a 148-8378 Elbow Gp (30) to Port (P) and connect the remaining end of the 207-9764 Hose As (53) to elbow (30). See Illustration 15.

   Align the elbow and the hose at the angle that is shown in Illustration 15.

9. At Location (C) in Illustration 12, disconnect the 142-9216 Hose As from the return manifold.

   Note: The 142-9216 Hose As is part of the 230-3714 Pilot Lines Gp .

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Illustration 16	g00992540
(29) 148-8336 Connector (39) 209-0640 Solenoid Valve and Mounting Gp (52) 166-2033 Tee Gp (59) 234-0773 Tube As

10. Install the 166-2033 Tee Gp (52) to the return manifold. See Illustration 16.

11. Reconnect the 142-9216 Hose As to the parallel port of tee (52) .

12. Install the 148-8336 Connector Gp (29) to the perpendicular port of tee (52) .

13. Install the end of the 234-0773 Tube As (59) with the short 90° bend to connector (29) .

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Illustration 17	g00992551
(30) 148-8378 Elbow (39) 209-0640 Solenoid Valve and Mounting Gp (59) 234-0773 Tube As

14. At the 209-0640 Solenoid Valve and Mounting Gp (39), install a 148-8378 Elbow (30) to Port (T) and connect the remaining end of the 234-0773 Tube As (59) to elbow (30). See Illustration 17.

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Illustration 18	g00989037
(29) 148-8336 Connector (39) 209-0640 Solenoid Valve and Mounting Gp (56) 207-9795 Hose As

15. At the 209-0640 Solenoid Valve and Mounting Gp (39), install a 148-8336 Connector Gp (29) in Port (C1) and in Port (C2). Connect a 207-9795 Hose As (56) to EACH connector (29). See Illustration 18.

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Illustration 19	g00989034
(3) 5C-7261 Nut (4) 5K-8451 Clip (22) 8T-4908 Bolt (24) 9R-1004 Clip (25) 9R-1005 Clip (47) 5P-4116 Hard Washer (56) 207-9795 Hose As

16. At Locations (D1) and (D2) in Illustration 12, secure the hose assemblies, as follows.

    1. Assemble a 9R-1004 Clip (24) and a 9R-1005 Clip (25). Position the clips around the existing tube assembly, as shown. See Illustration 19.

    2. Place a 5K-8451 Clip (4) around the two hose assemblies.

    3. Use a 8T-4908 Bolt (22), two 5P-4116 Hard Washers (47), and a 5C-7261 Nut (3) and fasten clip (4) to clips (24 and 25) .

       Tighten the bolt to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

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The lift arms must be raised partially in order to perform this procedure. Use a mobile crane or an overhead crane in order to support the lift arms during the performance of this procedure. Failure to follow this instruction could result in injury or death.

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Illustration 20	g00992736
(6) 6V-8397 O-Ring Seal (54) 207-9766 Tube As (55) 207-9767 Tube As (56) 207-9795 Hose As

17. Feed the hose assemblies (56) through the access hole in the left side wall of the engine compartment and up the left tower. See Illustration 20.

    To ensure correct engagement and disengagement of the coupler, maintain the routing of hoses (56), as follows.

    • The hose assembly that is connected to Port (C1) of solenoid valve (39) is routed through the left tower so that the hose exits to the FRONT of the "M" Pin. The hose is then routed with the LOWER hydraulic hose along the inside of the left lift arm.

    • The hose assembly that is connected to Port (C2) of solenoid valve (39) is routed through the left tower so that the hose exits to the REAR of the "M" Pin. The hose is then routed with the UPPER hydraulic hose along the inside of the left lift arm.

18. At Location (E1) in Illustration 12, secure EACH hose assembly (56) to the left tower, as follows.

    1. Raise the lift arms until Location (E1) in Illustration 12 is accessible. Use a mobile crane or use an overhead crane in order to support the lift arms while you perform this step.
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    Illustration 21	g00992741
    (14) 8T-4121 Hard Washer (15) 8T-4133 Nut (46) 2K-5232 Spacer (48) 6K-8178 Clip (50) 8T-5005 Bolt

    2. Place a 8T-4121 Hard Washer (14) on a 8T-5005 Bolt (50) and insert the bolt through the hole that is provided in the side plate of the left tower. See Illustration 21.

    3. Assemble a 2K-5232 Spacer (46) onto the bolt.

    4. Place a 6K-8178 Clip (48) around the hose assembly (56) .

    5. Position the clip (48) onto the bolt. Use a 8T-4121 Hard Washers (14) and a 8T-4133 Nut (15) and secure the clip.

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

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Illustration 22	g00992748
(48) 6K-8178 Clip (49) 7K-1181 Cable Strap (56) 207-9795 Hose As

19. At Location (E2) in Illustration 12, install 7K-1181 Cable Straps (49) in order to secure hose assemblies (56) to the existing hoses. See Illustration 22.

20. At Location (F) in Illustration 12, install two 6K-8178 Clips (48) in tandem with the existing clips in order to secure hose assemblies (56) to the left lift arm. See Illustration 22.

    Note: The clips (48) are installed between the lift arm and the existing clips. Position the clips so that the flat side of clips (48) is against the flat side of the existing clips. Use the existing 8T-4139 Bolts and the existing 8T-4223 Hard Washers to secure the clips.

    Tighten the bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

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Illustration 23	g00992779
(6) 6V-8397 O-Ring Seal (51) 119-6764 Clip (54) 207-9766 Tube As (55) 207-9767 Tube As (56) 207-9795 Hose As

21. Connect the 207-9766 Tube As (54) and the 207-9767 Tube As (55) to hose assemblies (56), as follows. See Illustration 23.
    • Hose (56) from Port (C1) of solenoid valve (39), which is the lower hose on the lift arm, connects to the 207-9767 Tube As (55) .

    • Hose (56) from Port (C2) of solenoid valve (39), which is the upper hose on the lift arm, connects to the 207-9766 Tube As (54) .

    Note: Install a 6V-8397 O-Ring Seal (6) in BOTH of these connections.

22. Secure the new tube assemblies at Location (G) and at Location (H) in Illustration 12.

    At each location, use two 119-6764 Clips (51) in order to fasten the clips to the lift arms. Use the 220-6381 Bolts and the 8T-4224 Hard Washers for the existing clamps. See Illustration 23.

    Tighten the bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

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Illustration 24	g00988877
(11) 7H-7055 Clip (14) 8T-4121 Hard Washer (20) 8T-4201 Locking Bolt (54) 207-9766 Tube As (55) 207-9767 Tube As

23. At Location (J) in Illustration 12, use two 7H-7055 Clips (11) in order to secure the tubes under the crossmember. Use a 8T-4201 Locking Bolt (20) and a 8T-4121 Hard Washer (14). See Illustration 24.

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

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Illustration 25	g00988875
(6) 6V-8397 O-Ring Seal (14) 8T-4121 Hard Washer (20) 8T-4201 Bolt (23) 9M-8406 Clip (31) 150-4034 Tee (37) 207-9758 Hose As (54) 207-9766 Tube As (55) 207-9767 Tube As

24. Install the two 207-9758 Hose As (37) between tees (31) and tube assemblies (54 and 55). Use a 6V-8397 O-Ring Seal (6) in the connections to the tube assemblies. See Illustration 25.

25. At Location (K) in Illustration 12, install two 9M-8406 Clips (23) in order to secure hose assemblies (37) under the crossmember. Use a 8T-4201 Bolt (20) and a 8T-4121 Hard Washer (14). See Section K-K in Illustration 25.

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

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Illustration 26	g00988876
(9) 7G-2950 Clip (10) 7G-2951 Clip (12) 7X-7729 Washer (16) 8T-4136 Bolt (37) 207-9758 Hose As (D) 20° ± 5° Angle

26. At Location (L) in Illustration 12, install a 7G-2950 Clip (9) and a 7G-2951 Clip (10) in order to secure hose assemblies (37) to the quick coupler. Use a 8T-4136 Bolt (16) and a 7X-7729 Washer (12). See Illustration 26.

    Tighten the bolt to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

    Note: Align the clip, as shown.

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Illustration 27	g00988881
(17) 8T-4189 Bolt (21) 8T-4224 Hard Washer (27) 124-2456 Film (42) 212-6690 Guard

27. Install the 212-6690 Guard (42). Use two 8T-4189 Bolts (17) and two 8T-4224 Hard Washers (21) in order to install the guard. See Illustration 27.

    Tighten the bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

28. Install the 124-2456 Film (27) on the guard, as shown.

Installing the Wiring Group

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Illustration 28	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 28.

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Illustration 29	g00988880
(40) 212-6521 Rocker Switch

2. Install the 212-6521 Rocker Switch (40) by inserting the rocker switch into the connector that is provided behind the control panel. See Illustration 29.

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Illustration 30	g00869647
Locate the unused 6-pin connector for the main cab harness.

3. Install the 212-6522 Quick Coupler Harness As (41) .

   Note: The harness assembly is installed between the connector on solenoid valve (39) 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 30.

4. Use cable straps in order to secure harness (41) to existing wiring on the left side wall.

Operation of Work Tool Coupler Control

Illustration 31	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 31.

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.