Installation Instructions for 362-2996 Hydraulic Kit (Center Lock) for 308C CR Excavators{1408, 5079, 5479, 6129} Caterpillar

Excavator:

308C CR (S/N: KCX1-UP)

Work Tool:

Hydraulic Kit (S/N: HKD1-UP)

Introduction

This Special Instruction describes the installation procedure for the 362-2996 Hydraulic Kit . This kit is designed for use with the Center Lock Kit for 308C CR Excavators. If you need more information about the installation of the hydraulic kit on your machine, consult your Cat Dealer.

The 362-2996 Center Lock Kit can be installed on the following host machine:

• 308C CR Excavator

The kit consists of the following items: a switch in the operator compartment, a control valve and pressure lines that supply hydraulic pressure to the center lock. The switch that is used for the center lock has two positions. One position is used to lock the coupler, the other is to unlock the coupler. Pressure for the operation of the Center Lock Kit is supplied from the bucket curl circuit. Refer to the Operation and Maintenance Manual, SEBU7841 for the Center Lock Coupler for more information on the operation of the coupler.

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document. Do not order any parts until you understand the information that is contained in this document.

Illustrations and Parts List

Illustration 1	g02455680

Illustration 2	g02455679

Illustration 3	g02456467

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.

Prepare the metal for welding. Refer to ""Preparing the Metal for Welding" ". Further instructions for welding are stated within the installation.

Use LB-26 Electrodes (AWS E7016 or AWS E7018) or equivalent electrodes to weld the plates to the stick of the machine. Basic welding wire ESAB OK tubrod 15.00 with a 1.2 mm (0.05 inch) diameter can also be used. The basic welding wire must be the equivalent to AWS A5.20 E71T-5 with positive polarity. The welding wire must be protected with CO2 gas.

All electrodes must be completely dried. 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 Caterpillar Service Welding Guide, SEBD0512.

Preparing the Metal for Welding

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

All grease, paint, and foreign objects must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Remove foreign objects with a wire brush, a buffer, or a grinder. Shot blasting the appropriate areas will also remove foreign material.

Remove any oil or grease with a Caterpillar approved solvent.

Welding Instructions

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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

Note: Before you begin to weld to the host machine, ensure that the ground of the welder is located close to the item.

Weld Plates for the Stick

Note: The machine may already be equipped with mounting plates (6). Only weld the plates on the stick if required.

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Illustration 4	g02459285
(6) 7V-2882 Plates (F) 3 mm (0.12 inch) fillet weld

1. Position plates (6) on the stick. Refer to Table 2 and Illustration 4.
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   Table 2

   Dimension
   A	B	C	D	E
   570.0 mm (22.44 inch)	50.0 mm (1.97 inch)	1829.0 mm (72.01 inch)	1219.0 mm (47.99 inch)	60.0 mm (2.36 inch)

2. Weld plates (6) to the stick. Weld only the ends of the plates to the stick.

Weld Plate in Pump Compartment

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Illustration 5	g02455476
(A) 170 mm (6.7 inch) (B) 3 mm (0.12 inch) fillet weld (13) 214-8024 Plate

1. Position plate (13) on the support approximately 170 mm (6.7 inch) from the bottom.

2. Weld plate (13) to the support.

Installation Procedure for the Control Valve

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Illustration 6	g02498880
(13) 214-8024 Plate (14) 247-6295 Control Manifold Gp (19) 3J-1907 O-Ring Seal (20) 4J-5477 O-Ring Seal (21) 6V-8397 O-Ring Seal (22) 6V-8636 Connector (23) 6V-8641 Connector (26) 7X-0818 Bolt (28) 8T-4224 Hard Washer

1. Install seals (19) and (21) on three connectors (22). Install connectors (22) in ports (C1), (P), and (T) in control manifold (14) .

2. Install seals (19) and (20) on connector (23). Install connector (23) in port (C2) in control manifold (14) .

3. Install control manifold (14) on plate (13) with washers (28) and bolts (26). Install the manifold with the (P) and (T) ports facing up.

Installation Procedure for the Hydraulic Lines

1. For the installation of the hose assemblies on the stick of the host machine, Caterpillar recommends loosely routing the hose on the host machine in order to determine the proper length. From the nose of the stick, route each hose along the stick to the location of control manifold (14) in order to determine the measurement of each hose. After the proper length has been determined, remove the hose from the host machine and cut the hose to the proper length. If the hose and the permanent couplings have already been assembled prior to this step, wind the excess hose and store the excess hose in the compartment near the location of control manifold (14) .

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Illustration 7	g02459516
Detail C (1) 3V-0046 Plate (2) 4I-9521 Marker Band (3) 4I-9522 Marker Band (4) 6W-2464 Clamp (10) 186-3622 Hose As (11) 186-3623 Hose As (20) 4J-5477 O-Ring Seal (21) 6V-8397 O-Ring Seal (27) 8C-6561 Bolt

2. Install yellow marker bands (3) on each end of hose (10). Install red marker bands (2) on each end of hose (11) .

Note: Prior to connecting the hoses to the coupler lines install O-ring seal (21) in hose (10) and O-ring seal (20) in hose (11)

3. Route hose (10) and hose (11) along the boom and to the end of the stick.

Note: Position hose (11) in the left side of the clip. Position hose (10) in the right side of the clip.

4. Install clamps (4), plate (1), and bolt (27). Do not tighten the bolt.

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Illustration 8	g02459636
Detail D (C1) 186-3622 Hose As (C2) 186-3623 Hose As (1) 3V-0046 Plate (4) 6W-2464 Clamp (27) 8C-6561 Bolt

Note: Install hose (C2) in the top of the clip. Install hose (10) in the bottom of the clip.

5. Install clamps (4), plates (1), and bolts (6). Do not tighten the bolts.

6. Use cable straps (5) as required to fasten the hoses to the existing boom lines.

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Illustration 9	g02460484
Detail A (15) 352-3584 Hose As (16) 148-8444 Swivel Tee As (17) 152-3411 Elbow (18) 323-6157 Permanent Coupling As (21) 6V-8397 O-Ring Seal

7. Disconnect existing hose (A) for the bucket curl circuit from the boom lines.

8. Install tee (16) to the tube assembly.

9. Install O-Ring seal (21) in elbow (17). Install elbow (17) on tee (16) .

10. Reconnect existing hose (A) to tee (16) .

11. Route hose assembly (15) to the valve in the pump compartment to determine the length. Cut the hose to the appropriate length and install permanent coupling assembly (18) on the hose.

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Illustration 10	g02459497
(10) 186-3622 Hose As (11) 186-3623 Hose As (15) 352-3584 Hose As

12. Route hose assemblies (10), (11), and (15) from the boom to the pump compartment. Route the hoses through existing support (B) .

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Illustration 11	g02508400
(12) 196-2137 Hose As (19) 3J-1907 O-Ring Seal (21) 6V-8781 O-Ring Seal (24) 6V-8781 Tee (C) Existing drain line

13. Disconnect existing hose (C) from tank port. Remove the existing elbow.

14. Install O-Ring seals (21) and O-Ring seal (19) in tee (24). Install tee (24) in the port on the hydraulic tank.

15. Reconnect hose (C) to tee (24) .

16. Install hose (12) from the (T) port on the control valve to tee (24) .

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Illustration 12	g02460822
(10) 186-3622 Hose As (11) 186-3623 Hose As (15) 352-3584 Hose As

17. Connect hose assembly (10) to port (C1). Connect hose assembly (11) to port (C2) .

18. Connect hose assembly (15) to port (P) .

    Note: Use cable straps (5) where necessary to secure the hoses.

Installation Procedure for the Electrical Components

Use the cable straps (5) when the need is necessary to secure the additional wiring to existing components.

1. Locate switch wiring harness (9) and console wiring harness (8) .

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Illustration 13	g02463639
Preferred location of the switch for the C-Series Excavators

2. Loosen the console in order to expose the wires in the console. Duplicate the template in Illustration 14 in order to locate the holes. Fasten the template to the console in the appropriate location for your model in order to determine the position of switch (25) on the console. Do not damage any of the existing wires. Drill a 12 mm hole in the console. Drill a 3.0 mm hole for the second hole. Place switch (25) in plate (7). Install the plate and the switch into the hole in the console.

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Illustration 14	g00678430

3. Connect the wiring harness to the toggle switch. Connect the green wire to the terminal that is identified by the number three. Connect the yellow wire to the terminal that is identified by the number two.

Note: There is a wire that is 24 V at the ignition switch that is attached to the accessory terminal. There is a 112-H2-Purple wire at this terminal. The purple wire must be 24 V in order for the solenoid to operate properly.

4. Connect the yellow wire from the toggle switch to the 24 V purple wire that is attached to the ignition switch.

Note: Do not fasten wiring harnesses to the hydraulic hoses when you are routing the wiring harnesses.

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Illustration 15	g02463661

5. Connect the green wire to the valve. In order to ground the wiring harness, connect the black wire to the lower mounting bolt of the valve. There is a ring terminal that is installed on the black wire.

Check the System

1. Purge the hydraulic system of air. Refer to the Testing and Adjusting manual for the host machine for the appropriate information.

2. After the electrical system and the hydraulic system are connected, check the system for proper operation. Refer to the Operation and Maintenance Manual, SEBU7841 for more information.

Schematics

Illustration 16	g02465176
(1) Bucket Cylinder (2) Coupler Cylinder (3) Check Valve (4) Solenoid Valve (5) Tee (6) Pilot Valve (Boom/Bucket) (7) Bucket Control Valve (8) Pilot Pump (9) Main Pump

Illustration 17	g00679442
Electrical Schematic (1) Switch (2) Solenoid (3) Diode (4) Alarm

Template

Illustration 18	g01366798
Template (Switch)