Procedure to Rework Hydraulic Lines and Third Valve Implement Lines on 447-6627 Quick Coupler Groups {5057} Caterpillar

Wheel Loader

980 XE (S/N: XE31-UP)

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: Y7A396-557)

Introduction

The special Instruction provides the procedure to re-routing the hydraulic lines for fusion coupler and implement valve lines on certain quick couplers.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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 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. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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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 by reading and understanding 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 instructions of the manufacturer and the safety practices of your employer. Do not touch live electrical parts. See “American National Standard Z49.1, Safety in Welding and Cutting” which is published by the American Welding Society. American Welding Society 8669 NW 36 Street #130 Miami, Florida 33166-6672 1-800-443-9353 See “OSHA Safety and Health Standards, 29 CFR 1910” which is available from the U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210 See applicable requirements for your local area.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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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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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

Required Parts

Installation Procedure

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Illustration 1	g06407205

1. Remove the coupler from the wheel loader and remove the existing hose assemblies, clamps, hardware, and hydraulic cylinder from coupler and save the parts.
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   Illustration 2	g06407221
   (A) Tapped boss

2. Remove the tapped boss (A) from rear box section and grind the surface smoothly.
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   Illustration 3	g06407279
   Some parts are hidden for clarity (B) Hinge plate holes (C) Hinge plates (D1) 80.0 ± 3.0 mm (3.14 ± 0.11 inch) (D2) 110.0 ± 3.0 mm (4.33 ± 0.11 inch)

3. Add two 70.0 mm (2.75 inch) diameter holes (B) to the center of hinge plate (C) in coupler frame, for plate holes dimensions refer to Illustration 3.
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   Illustration 4	g06407393
   Some parts are hidden for clarity (1) 566-2457 Boss (W1) 6.0 mm (0.23 inch) fillet weld

4. Locate and weld boss (1) at the center of hinge plate holes as shown in Illustration 4.
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   Illustration 5	g06407511
   Some parts are hidden for clarity (2) 163-9662 Threaded Boss (D) Coupler frame (D3) 194.0 ± 3.0 mm (7.63 ± 0.11 inch) (D4) 80 to 83 mm (3.14 to 3.26 inch) (W1) 6.0 mm (0.23 inch) fillet weld

5. Locate and weld threaded boss (2) on each end of coupler frame (D) for weld dimensions refer to Illustration 5.
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   Illustration 6	g06407753
   Some parts are hidden for clarity (E) Cylinders (F) Hoses from cylinder to cylinder (G) Wedge plates

6. Reassemble wedge plate (G), cylinders (E), and existing hoses (F) which routes from cylinder to cylinder. The parts saved in Step 1

   Note: Longer hose routes to cylinder port located closest to cylinder tube.

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   Illustration 7	g06407808
   Exploded view (3) 6W-2890 Dust Cap As (4) 8T-4194 Bolt (5) 8T-4223 Hard Washer (6) 8T-4244 Nut (7) 150-5430 Adapter As (8) 6W-2888 Fitting As (9) 2P-1293 Locknut (10) 447-3053 Plate (11) 6V-8990 Elbow (12) 6V-9746 O-Ring Seal (13) 567-7578 Hose As

7. Assemble plate (10) with two bolts (4), four washers (5) and two nuts (6) on main plate.

   Mount two adapters (7) on plate (10) with lock nut (9) and mount two fitting assemblies (8) mount with dust cap (3).

   Assemble two elbows (11) with O-ring (12) at the center of two hinge plates (C).

   Connect hose (13) from adapter (7) to elbow (11) as shown in Illustration 7.

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   Illustration 8	g06407934
   Some parts are hidden for clarity (E) Cylinder (Left side) (14) 575-9050 Hose As

8. Assemble two hose assemblies (14) to the adapters of left side cylinder (H) as shown in Illustration 8.

   Note: Hose that route to connector closest to cylinder tube will route to bottom connector on wheel loader lift arm.

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   Illustration 9	g06407947
   (11) 6V-8990 Elbow (15) 4J-0522 O-Ring Seal (16) 576-0027 Hose As

9. Assemble two hose assemblies (16) with O-rings (15) to two elbow assemblies (11).
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   Illustration 10	g06407961
   (5) 8T-4223 Hard Washer (17) 5P-7467 Clip (18) 5P-8112 Grommet (19) 5P-7466 Clip (21) 8T-4192 Bolt

10. Mount the hose assembly to the right side of the coupler frame with clip (17), grommet (18), clip (19), hard washer (5) and bolt (21).
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    Illustration 11	g06408002
    (14) 575-9050 Hose As (22) 7G-2950 Clip (23) 7G-2951 Clip

11. Secure hose assemblies (14) with clip (22) and clip (23) as shown in Illustration 11.
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    Illustration 12	g06408017
    (5) 8T-4223 Hard Washer (17) 5P-7467 Clip (18) 5P-8112 Grommet (19) 5P-7466 Clip (20) 8T-4139 Bolt

12. Assemble clip (17) on the plate and install the grommet (18) and cover with clip (19) and mount them with hard washer (5) and bolt (20) to left side of coupler frame.
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    Illustration 13	g06408052

13. Tighten all hardware, hose couplings and adapters before installing coupler on the machine.