Installation of the 315-6302 Third Valve Rework Kit {5051} Caterpillar

Wheel Loader:

966H (S/N: A6D1-UP)

972H (S/N: A7D1-UP)

Introduction

This special instruction covers the installation procedure for 315-6302 Third Valve Rework Kit on the 966HWheel loaderand the 972HWheel loader with a high lift linkage.

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 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.

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 to the controls before you service the equipment or before you repair the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.

Installation Procedure of 315-6302 Third Valve Rework Kit

Note: Refer to Table 1 for a complete listing of parts for the installation of 315-6302 Third Valve Rework Kit .

Illustration 2	g03562159
(A) Point (B) Point

1. Remove existing hard lines and hose assemblies to point (A) .

2. Position the tapped blocks and weld the tapped 104-5671 Blocks that are supplied in the kit. The blocks are located in the view of the right-hand side. Position the tapped blocks and weld the tapped blocks onto both the right hand and left-hand lift arms.

3. Remove the tapped blocks and remove the guard plates on each lift arm. The tapped blocks and guard plates are located in Section "A-A".

4. Reinstall the existing hard lines with the existing clamps and hardware.

5. Install the new hose assembly 315-6298 Hose As from point (A) to point (B) with the existing hardware.

6. Tighten all fittings and hardware to the desired specification.