Procedure to Install 432-6064 Quick Coupler Lines Gp on Certain Backhoe Loaders {5057, 6129} Caterpillar

Backhoe Loader

416F (S/N: KSF1-UP; LWT1-UP)

416F2 (S/N: LYA1-UP; LBF1-UP)

420F (S/N: LTG1-UP; SKR1-UP)

420F2 (S/N: LBS1-UP)

420F2 ST (S/N: LYB1-UP)

430F (S/N: RDF1-UP; LDY1-UP)

430F2 ST (S/N: LYD1-UP)

Work Tool

QUICK COUPLER (S/N: Y7A1-UP; Y8B1-UP; A8K1-UP)

Introduction

This Special Instruction contains the procedure for installing Quick Coupler Lines Gp on certain Backhoe Loaders.

Safety

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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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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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 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.

Required Parts

Location of Components

Illustration 1	g03327907
View of the left side (3) 354-4126 Hose As (4) 373-2353 Hose As (5) 418-9060 Plate (6) 418-9065 Plate (8) 418-9072 Hose As (9) 418-9073 Hose As (10) 418-9074 Hose As (11) 432-6026 Coupler Valve and Mounting Gp (12) 432-6148 Quick Coupler Wiring Gp

Illustration 2	g03327908
View of the right side (3) 354-4126 Hose As (4) 373-2353 Hose As (5) 418-9060 Plate (6) 418-9065 Plate (8) 418-9072 Hose As (9) 418-9073 Hose As (10) 418-9074 Hose As (11) 432-6026 Coupler Valve and Mounting Gp (12) 432-6148 Quick Coupler Wiring Gp

Procedure to Install Quick Coupler Lines Gp

Locations of Plates to be Welded

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. Refer to Caterpillar Service Welding Guide, SEBD0512.

Note: After welding, allow all areas to cool to room temperature. After the areas have cooled, paint the area with primer. After the primer has dried, coat the area with 4C-4200 Yellow Paint.

Illustration 3	g03327977
Weld locations of the plates (23) and (6) ( A-A) Section view (A) 100 ± 5 mm (4 ± 0.2 inch) (B) 617 ± 5 mm (24.3 ± 0.2 inch) (C) 25 ± 5 mm (1 ± 0.2 inch) (D) 181 ± 5 mm (7 ± 0.2 inch) (E) 25 ± 5 mm (1 ± 0.2 inch) (W1) IE0099S (6) 418-9065 Plate (23) 7V-2882 Plate As

Note: Locate plate (6) in line with the existing tapped boss on the lift arm.

Illustration 4	g03328034
Section A-A view Three locations (F) 8 ± 3 mm (0.3 ± 0.1 inch) (W1) IE0099S

Illustration 5	g03328092
Location of plate (5) ( G) 150 ± 5 mm (6 ± 0.2 inch) (H) 50 ± 5 mm (2 ± 0.2 inch) (W1) IE0099S (5) 418-9060 Plate

Procedure to Install the Coupler Valve Group and Lines

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Illustration 6	g03328190
Coupler valve group (5) 418-9060 Plate (11) 432-6026 Coupler Valve and Mounting Gp (17) 148-8407 Plug As (25) 8T-4121 Hard Washer (26) 8T-4137 Bolt (27) 8T-4178 Bolt

1. Install valve group (11) onto plate (5) using two bolts (27) and two washers (25). Install plug assembly (17) into port (ST) on valve group (11).

   Note: Use bolt (26) to retain the existing hose clamp from the differential lock group.

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   Illustration 7	g03424007
   Installation of hose assembly (1) 7K-1181 Cable Strap (4) 373-2353 Hose As (18) 148-8423 Tee As (20) 150-3033 Elbow As

2. Install hose assembly (4) to coupler valve group (11) at port (LS) using elbow assembly (20). Route hose assembly (4) and connect to the signal lines group using tee assembly (18). Secure hose assembly (4) to the auxiliary hydraulic lines using cable strap (1).
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   Illustration 8	g03328204
   Installation of hose assemblies Hose assembly (4) not shown for clarity (8) 418-9072 Hose As (9) 418-9073 Hose As (11) 432-6026 Coupler Valve and Mounting Gp (13) 148-8325 Connector As (15) 148-8368 Elbow As

3. On coupler valve group (11). Install hose assembly (9) to port (RET) using connector assembly (13). Install hose assembly (8) to port (EXT) using elbow assembly (15).
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   Illustration 9	g03328259
   Routing of hoses (B-B) Section view (C-C) Section view (8) 418-9072 Hose As (9) 418-9073 Hose As

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   Illustration 10	g03328318
   Section B-B (6) 418-9065 Plate (8) 418-9072 Hose As (9) 418-9073 Hose As (16) 148-8384 Elbow As (21) 2P-1279 Locknut

4. Route hose assemblies (8) and (9) and connect to plate (6) using elbow assembly (16) and locknut (21).
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   Illustration 11	g03328493
   Section C-C (7) 418-9067 Plate As (25) 8T-4121 Hard Washer (28) 8T-4195 Bolt

5. Install plate assembly (7) using washer (25) and bolt (28).
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   Illustration 12	g03328503
   Strap and clamp locations (D-D) Section view (E-E) Section view (1) 7K-1181 Cable Strap (2) 086-9286 Clamp (22) 3V-0046 Plate (24) 8C-6561 Bolt (29) 8T-6869 Bolt

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   Illustration 13	g03328555
   Section D-D (2) 086-9286 Clamp (22) 3V-0046 Plate (23) 7V-2882 Plate As (24) 8C-6561 Bolt

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   Illustration 14	g03328610
   Section E-E (2) 086-9286 Clamp (22) 3V-0046 Plate (29) 8T-6869 Bolt

6. Secure Hose assemblies (8) and (9) to plate assemblies (23) and (7) using the following hardware.

   • Eight cable straps (1)

   • Twelve clamps (2)

   • Six plates (22)

   • Five bolts (24)

   • One bolt (29)

   Note: In section E-E remove existing bolt from the hose clamp. Secure the new hose assemblies in place using two clamps (2), plate (22), and bolt (29).

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   Illustration 15	g03424008
   Installation of hose assembly (10) 418-9074 Hose As (11) 432-6026 Coupler Valve and Mounting Gp (14) 148-8367 Elbow As (15) 148-8368 Elbow As (19) 148-8434 Tee As

7. Install hose assembly (10) to coupler valve group (11) at port (T) using elbow assembly (15). Route hose assembly (10) and connect to the filter group using elbow assembly (14) and tee assembly (19).

   Note: If the machine is not equipped with ride control lines group, connect hose assembly (10) to elbow assembly (14) and do not use tee assembly (19). If the machine is equipped with ride control lines group, disconnect existing hose. Connect tee assembly (19) then attach existing hose assembly.

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   Illustration 16	g03424009
   Installation of hose assembly (1) 7K-1181 Cable Strap (3) 354-4126 Hose As (11) 432-6026 Coupler Valve and Mounting Gp (15) 148-8368 Elbow As (18) 148-8423 Tee As

8. Install hose assembly (3) to coupler valve group (11) at port (P) using elbow assembly (15).

9. Route hose assembly (3) and connect to the pressure port on the pump group using tee assembly (18). Secure hose assembly (3) to the auxiliary hydraulic lines group using cable strap (1).

Components of the Quick Coupler Wiring Group

Location of Components

Illustration 17	g06069653
Location of wiring group components (31) 218-4935 Arc Suppressor (32) 225-6303 Rocker Switch (33) 232-1792 Horn (34) 422-3856 Harness As (35) 122-4401 Terminal

Procedure to Install the Quick Coupler Wiring Group

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Illustration 18	g03329041
Console (A) View of Console (B) View with the top front console removed

1. Remove the top front console to gain access to route the harness assembly (34).
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   Illustration 19	g03329092
   Routing of harness (34) 422-3856 Harness As

2. Route the harness assembly (34) down though the console and under the cab floor pan.

   Note: The cab floor pan may be removed for ease of access.

3. Connect the harness connector (A-C1) to the coupler valve group (11)
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   Illustration 20	g06069671
   Inside view of console (31) 218-4935 Arc Suppressor (32) 225-6303 Rocker Switch (33) 232-1792 Horn (34) 422-3856 Harness As (35) 122-4401 Terminal

4. Install one arc suppressor (31) to each connector (A-C2 and A-C3).

5. Disconnect existing harness from the transmission lock switch. Remove wires from connectors wire positions 2and 7 and remove terminal ends.

6. Connect wire from position 2 of the existing connector and the yellow wire (308-A7) of harness assembly (34) with terminal (35).

7. Connect wire from position 7 of the existing connector and the black wire (202-A8) of harness assembly (34) with terminal (35).

8. Connect existing harness into transmission lock switch.

9. Remove blank cover from the console and install rocker switch (32). Connect harness assembly (34) to rocker switch (32).

10. Connect horn (33) to harness assembly (34) (wires 202-BL and 780-PU) and secure with cable straps (30).

11. Secure harness assembly (34) with cable straps (30).