Procedure to Install 315-6307, 315-6310 Coupler Lines Groups on Certain Wheel Loaders{5057, 5147, 5734, 6129, 7332} Caterpillar

Wheel Loader:

938G Series II (S/N: RTB1081-UP; CRD1176-UP)

Introduction

This special instruction covers the installation procedure for 315-6307 315-6310 Coupler Lines Groups on 938G Series II Wheel loader.

If the machine has an existing coupler lines group that had been installed by the factory or installed in the field. This kit will convert the existing lines so 310-9392 Quick Coupler Gp can be installed.

Do not perform any of the procedures until you have read the information in this publication.

Safety Section

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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 sudden work tool movement. Sudden movement of the work tool can cause injury to persons near the work tool. To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool.

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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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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

Required Parts

Note: Refer to individual installation instructions per segment for a detailed list of parts.

Welding Requirements

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 according to the next section. Refer to the illustrations in this special instruction for welding symbols and specifications.

All electrodes must be 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.

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.

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 Caterpillar 4C-4200 Yellow Paint .

Installation Procedure

Illustration 1	g00104545

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or controls before you service or repair the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.

Procedure to Install 315-6307 Coupler Lines Group

Illustration 2	g03519859
Weld locations (A1) Remove these tapped blocks from the left-hand lift arm. (A2) Remove this boss (N5) IE0099S (A) 260 ± 5 mm (10.24 ± 0.2 inch) (B) 378 ± 5 mm (14.88 ± 0.2 inch) (C) 373 ± 5 mm (14.69 ± 0.2 inch) (D) 128 ± 5 mm (5.04 ± 0.2 inch) (E) 67 ± 5 mm (2.64 ± 0.2 inch) (F) 44 ± 5 mm (1.73 ± 0.2 inch) (G) 140 ± 3 mm (5.51 ± 0.12 inch) (H) 140 ± 3 mm (5.51 ± 0.12 inch) (J) 139 ± 2 mm (5.47 ± 0.08 inch) (K) 70 ± 3 mm (2.76 ± 0.12 inch) (L) 520 ± 3 mm (20.47 ± 0.12 inch) (2) 163-9662 Threaded Boss (12) 9C-4935 Plate (13) 9R-2613 Weld Boss

1. Weld bosses (2), (13) and plate (12) into place.

   Note: If necessary, use the existing bracket to correctly space plate (12) .

   Note: If necessary, remove tapped blocks from the left lift arm.

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Illustration 3	g03520108
Left side lift arm

Note: Create enough clips for three sets.

2. Loosely assemble and then attach clips (8) and clips (9). Bolt the three sets of clips to weld bosses (13) by using washer (10) and bolt (11) .

3. Mount the existing manual valve groups and the bracket to plates (12) .

4. Use O-ring (3) and O-ring (5) per elbow, attach one elbow (6) on the rear end of the manual valve group.

5. Use O-ring (3) and O-ring (4) per elbow, attach one elbow (7) on the front end of the manual valve group.

6. Attach hose (1) per elbow (6) .

7. Route the two hoses (1) through the clips that were built in Step 2 and tighten the clips to the appropriate torque.

8. Attach the opposite ends of hose (1) to the tube assembly at point (A). Refer to Illustration 3.

Installation Procedure of 315-6310 Coupler Lines Group

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Illustration 4	g03520318
Weld locations (A1) Remove these tapped blocks on the left-hand lift arm (N5) IE0099S (A) 259 ± 5 mm (10.2 ± 0.2 inch) (B) 381 ± 5 mm (15 ± 0.2 inch) (C) 542 ± 5 mm (21.34 ± 0.2 inch) (D) 146 ± 5 mm (5.75 ± 0.2 inch) (E) 107 ± 5 mm (4.21 ± 0.2 inch) (F) 117 ± 5 mm (4.61 ± 0.2 inch) (G) 50 ± 3 mm (1.97 ± 0.12 inch) (H) 50 ± 3 mm (1.97 ± 0.12 inch) (J) 139 ± 2 mm (5.47 ± 0.08 inch) (K) 120 ± 3 mm (4.72 ± 0.12 inch) (L) 70 ± 3 mm (2.76 ± 0.12 inch) (M) 520 ± 3 mm (20.47 ± 0.12 inch) (N) 850 ± 3 mm (33.46 ± 0.12 inch) (2) 163-9662 Threaded Boss (10) 9C-4935 Plate (11) 9R-2613 Weld Boss

1. Weld bosses (2), (11) and plates (10) to the left lift arm.

   Note: If necessary, use the existing bracket to correctly space plate (10) .

   Note: If necessary, remove tapped blocks (A1) from the left lift arm.

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Illustration 5	g03520399
Left lift arm

Note: Create enough clips for four sets.

2. Loosely assemble and then attach clips (6) and clips (7). Bolt the four sets of clips to weld bosses (11) using washer (8) and bolt (9) .

3. Mount the existing manual valve groups and the bracket to plates (10) .

4. Use O-ring (3) and (4) per elbow, attach one elbow (5) per valve on the front end of the manual valve group.

5. Attach hose (1) per manual valve group.

6. Route the two hoses (1) through the clips that were built in Step 2 and tighten the clips to the appropriate torque.

7. Attach the opposite ends of hoses (1) to the tube assembly at point (A). Refer to Illustration 5.