Installation Instructions for 368-6422, 368-6423, 368-6424 Coupler Lines Gp for 966K and 972K Wheel Loaders {0679, 1408, 5057, 5133, 6129} Caterpillar

Wheel Loader

966K (S/N: TFS1-UP)

972K (S/N: Z4W1-UP)

Work Tool

QUICK COUPLER (S/N: Y7A1-UP)

Introduction

This Special Instruction covers the installation procedure for the 368-6422 Coupler Lines Gp, 368-6423 Coupler Lines Gp, and the 368-6424 Coupler Lines Gp on 966K and 972K Wheel Loaders.

Note: 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 completely. 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 4C-4200 Yellow Paint.

Installation Procedure

Illustration 1	g00104545

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

Installation Procedure for the 368-6422 Coupler Lines Gp (Standard Lift) 966K

Illustration 2	g02695904

Illustration 3	g02677697
Inside view of Left Loader Arm (A) 276 ± 3 mm (10.9± 0.12 inch) (B) 623 ± 3 mm (24.5 ± 0.12 inch) (C) 682 ± 3 mm (26.8 ± 0.12 inch) (D) 100 ± 3 mm (3.9 ± 0.12 inch) (E) 154 ± 3 mm (6.1 ± 0.12 inch) (F) 143 ± 2 mm (5.6 ± 0.07 inch) (G) 28 ± 3 mm (1.10 ± 0.12 inch) (H) 72 ± 3 mm (2.8 ± 0.12 inch) (J) 756 ± 3 mm (29.8 ± 0.12 inch) (K) 1084 ± 3 mm (42.7 ± 0.12 inch) (L) 501 ± 3 mm (19.7 ± 0.12 inch)

1. Weld three bosses (3) to the inside of left lift arm.

2. Weld one boss (1) to the inside of left lift arm.

3. Weld two plates (2) to the inside of left lift arm.

4. Install the 315-5966 Coupler Lines Gp.

5. Install the 315-5977 Coupler Lines Gp.

6. Install the 313-9763 Quick Coupler Wiring Gp.

Installation Procedures for 368-6423 Lines Gp-Coupler (Standard Lift) 972K

Illustration 4	g03775620

Illustration 5	g03775516
Left Inner Lift Arm (A) 287 ± 3 mm (11.3 ± 0.12 inch) (B) 497 ± 3 mm (19.6 ± 0.12 inch) (C) 101 ± 3 mm (4.0 ± 0.12 inch) (D) 522 ± 3 mm (20.6 ± 0.12 inch) (E) 57 ± 3 mm (2.2 ± 0.12 inch) (F) 330 ± 3 mm (13 ± 0.12 inch) (G) 130 ± 3 mm (5.1 ± 0.12 inch) (H) 423 ± 3 mm (16.7 ± 0.12 inch) (I) 47 ± 3 mm (1.9 ± 0.12 inch) (J) 213 ± 3 mm (8.41 ± 0.12inch) (K) 143 ± 3 mm (5.6 ± 0.12 inch) (L) 754 ± 3 mm (29.7 ± 0.12 inch)

1. Weld one boss (4) to the inside of left lift arm.

2. Weld two plates (5) to the inside of left lift arm

3. Weld four bosses (6) to the inside of left lift arm

4. Install the 315-5966 Coupler Lines Gp.

5. Install the 315-5967 Coupler Lines Gp.

6. Install the 313-9763 Quick Coupler Wiring Gp.

Installation Procedure for 368-6424 Coupler Lines Gp (High Lift) 966K, 972K

Illustration 6	g02706357

1. Install the 315-5966 Coupler Lines Gp.

2. Install the 315-5968 Coupler Lines Gp .

3. Install the 313-9763 Quick Coupler Wiring Gp.

Installation Procedure for the 315-5966 Coupler Lines Group

Illustration 7	g02676836
315-5966 Coupler Lines Gp

Illustration 8	g02689039
(3) 235-3582 Elbow As (6) 321-8473 Control Valve and Mounting Gp (12) 148-8318 Connector As (13) 148-8336 Connector As (14) 148-8367 Elbow As (22) 148-8383 Elbow As (24) 271-7649 Bolt (31) 8T-4121 Hard Washer

1. Install connector assembly (13) in port "UL".

2. Install connector assembly (12) in port "L". Install elbow assembly (14) on connector (12).

3. Install elbow assembly (22) in port "T".

4. Install elbow assembly (3) in port "P".

5. Mount control valve (6) to the frame with two hard washers (31) and two bolts (24).

   Note: Mount the control valve inside the front frame on left side with the "T" port facing up. Refer to Illustration 8

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   Illustration 9	g02686356
   (6) 321-8473 Control Valve and Mounting Gp (10) 347-6406 Hose As (19) 364-0001 Hose As (25) 302-3908 Spacer (27) 4D-7733 Clip (29) 6V-8397 O-Ring Seal (31) 8T-4121 Hard Washer (35) 8T-4185 Bolt

6. Connect hose assembly (10) to adaptor (13) in port "UL" on the control valve.

7. Connect hose assembly (19) to elbow (14) leading to port "L" on the control valve.

8. Mount clip (27) to the left side frame using spacer (25), hard washer (31), and bolt (35).

9. Route both hose assemblies, (10) and (19) through clip (27) and tighten the bolt securing the clip to specifications.

10. Connect hose assembly (5) to elbow (22) in port "T" on control valve (6).
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    Illustration 10	g02690916
    Main control valve (5) 316-8346 Hose As (16) 148-8435 Tee As (B) Existing hose

11. Disconnect existing tank drain line (B) from the elbow. Remove and discard the elbow.

12. Install tee assembly (16) in the port where the elbow was removed.

13. Reattach the existing tank drain line (B) to tee (16).

14. Install the 90 degree end of hose assembly (5) onto tee (16). Connect the other end of hose assembly (5) to elbow (22) on control valve (6) (port "T").
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    Illustration 11	g02684716
    Close up of Detail A, Illustration 7 (11) 351-5738 Bracket As (17) 363-9999 Tube As (18) 364-0000 Tube As (28) 5P-9297 Clip (29) 6V-8397 O-Ring Seal (31) 8T-4121 Hard Washer (32) 8T-4133 Nut

15. Attach tube assembly (17) and tube assembly (18) to the stud on the underside of bracket assembly (11) using the following parts: two clips (28), hard washer (31) and nut (32).

16. Attach tubes (17) and (18) to the inner face of bracket (11) using the following parts: two clips (28), bolt (36), washer (31) and nut (32).
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    Illustration 12	g02684917
    Rear view of Front Frame (11) 351-5738 Bracket As (17) 363-9999 Tube As (18) 364-0000 Tube As (28) 5P-9297 Clip (29) 6V-8397 O-Ring Seal (31) 8T-4121 Hard Washer (32) 8T-4133 Nut (33) 8T-4136 Bolt (34) 8T-4137 Bolt

17. Use two bolts (33) and two hard washers (31) to fasten the following parts to the boss on the rear of the front frame assembly: bracket assembly (11), tube assemblies (17) and (18). Refer to Illustration 12

18. Route the tubes down the rear of the front frame assembly.

    Note: Tube assembly (18) will route toward the "L" port of the control valve. Tube assembly (17) will route toward the "UL" port of control valve.

19. Attach the tube assemblies down the back of the front frame assembly, at the first boss, use the following parts: two clips (28), hard washer (31) and nut (32).

20. Route the tubes through the clips and loosely secure nut (32).

21. Secure the tubes to the next boss using the following parts: two clips (28), hard washer (31) and bolt (34). Refer to Illustration 12

    Note: Check the clearance of both tubes in opening of the front frame. The clearance is to ensure that the tubes do not contact the frame opening.

22. Connect tube (17) and O-ring seal (29) to hose (19) from Step 7.

23. Connect tube (18) and O-ring seal (29) to hose (10) from Step 6.
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    Illustration 13	g02694097
    Rear of Machine , Towards the Engine side (4) 287-7298 Elbow As (7) 346-8503 Hose As (8) 346-8504 Hose As (9) 346-8532 Hose As (15) 148-8377 Elbow As (26) 369-8284 Hard Washer (30) 6V-9168 Nut (31) 8T-4121 Hard Washer (32) 8T-4133 Nut (33) 8T-4136 Bolt (37) 8M-2773 Clip

24. Connect hose assembly (8) to elbow (3) in port "P" on control valve (6).Route the hose through the front frame cutout towards the rear frame of the machine.

25. Use elbow assembly (15) and nut (30), connect hose assembly (9) to hose assembly (8).

26. Attach to hose assembly (9) and the existing hose above (not shown) the following parts: two clips (37), bolt (33), hard washer (31) and nut (32)

27. Install elbow assembly (4) through the rear frame of the machine with hard washer (26) and nut (30).

    Note: Be sure the body of elbow (4) is on the inside of the rear frame. The washer (26) and nut (30) secure the elbow on the outside of frame. Refer to Illustration 13.

28. Connect hose (9) to elbow (4).

29. Connect hose assembly (7) to elbow (4) on the inner bulkhead of the rear frame. Refer to Illustration 13.
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    Illustration 14	g02696036
    346-8503 Hose As with clip and bracket attached (2) 192-5017 Bracket As (23) 245-8842 Clip (31) 8T-4121 Hard Washer (34) 8T-4137 Bolt

30. Route hose (7) from elbow (4) to the right side of the machine.

31. Assemble the following parts: bracket assembly (2), clip (23), hard washer (31) and bolt (34).

32. Attach clip (23) and bracket assembly (2) loosely onto hose (7).

33. Route hose (7) towards control valve by the brake accumulators.
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    Illustration 15	g02709949

34. Remove existing hose assembly (A) from the service brake control group port "A2" and discard. Remove the connector assembly from the port and discard.

35. Install tee (16) in port "A2".

36. Install hose assembly (20) at tee (16) and the port where hose (A) was removed.

37. Connect hose (7) to tee (16).

38. Attach clip (23) to the frame. Tighten all hose and fitting connections.

Installation Procedure for the 315-5977 Coupler Lines Gp (Standard Lift) 966k

Illustration 16	g02680178
Placement of 315-5977 Coupler Lines Gp

Illustration 17	g03547616
(A) 9C-4935 Plate (1) 112-1817 Manual Valve Gp (3) 324-3471 Bracket (6) 148-8336 Connector As (7) 096-6166 Hard Washer (10) 6V-9829 Cap (11) 8T-0285 Screw (12) 8T-4121 Hard Washer (13) 8T-4137 Bolt

1. Mount two manual valves (1) to bracket (3) with eight screws (11) and eight hard washers (7).

2. Attach four connector assemblies (6) to manual valve (1).

3. Install two caps (10) to the two forward facing ends of the adapter assemblies. Refer to illustration 16 for orientation of the valves and caps to the bracket as

4. Install bracket (3) with the valve group to the left inner load arm. Use four bolts (13) and four hard washers (12) to mount bracket (3) to the plates.

   Note: The plates were welded to the lift arm in the previous step. Refer to "Installation Procedure for the 368-6422 Coupler Lines Gp" and to Illustration 3 callout (2) 9C-4935 Plate

5. Tighten all bolts and connections to the required specifications.

6. Attach two clips (8), bolt (13), and hard washer (12) to the three bosses on the left inner load arm.

   Note: Do not tighten the three bolts at this time.

7. Connect tube assembly (5) and O-ring seal (9) to connector assembly (6) (route A) on manual valve (1).

8. Repeat this step for tube assembly (2) and O-ring seal (9) (route B).

9. Route the tubes through the clips installed in Step 6 towards the back of the machine. Refer to Illustration 16 for correct positioning.

10. Connect two hose assemblies (4) to the previously installed tubes (5) and (2) and route the hoses toward the rear of the machine. The two hose assemblies (4) will attach to the 315-5966 Coupler Lines Gp.

    Note: Tube assembly (5) routes from the "L" port of the 321-8473 Control Valve and Mounting Gp to the head end of cylinder group (A). Tube assembly (2) routes from the "UL" port of the valve group to the rod end of cylinder group (B).

Installation Procedure for the 315-5967 Coupler Lines Gp

Illustration 18	g03547620
Component location for 315-5967 coupler lines gp.

Note: Callout (A) from "L" of the Valve Gp to the Head End Cylinder Gp

Note: Callout (B) from "UL" of the Valve Gp to the Rod End of the Cylinder Gp

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Illustration 19	g03547622

1. Mount two manual valves (1) to bracket (2) with eight screws (11) and eight hard washers (7).

2. Attach four connector assemblies (6) to manual valve (1).

3. Install two caps (10) to the forward facing ends of adapter assemblies (6).

4. Use four hard washers (12) and four bolts (13) to mount bracket (2) and valve group (1). Mount the parts to the front two plates on the forward location on the inner load arm.

5. On each of the four 9R-2613 Weld Bosses that were installed on the left inner load arm attach the following parts: two clips (8), bolt (13) and hard washer (12).

   Note: Do not tighten the four bolts at this time.

6. Connect tube assembly (5) and O-ring seal (9) to adapter assembly (6) (route A) on the valve group (1).

7. Repeat this step for tube assembly (3) and O-ring seal (9) (route B).

8. Route the tubes through the clips installed in Step 5 towards the back of the machine. Refer to Illustration 18 for correct positioning

9. Connect two hose assemblies (4) to tubes (5) and (3). Route the hoses towards the rear of the machine. The two hose assemblies (4) will attach to the 315-5966 Coupler Lines Gp.

   Note: Tube assembly (5) routes from port "L" of the 321-8473 Control Valve and Mounting Gp to the head end of cylinder group (A). Tube assembly (3) routes from port "UL" of the valve group to the rod end of cylinder group (B).

10. Tighten all bolts and connections.

Installation Procedure for 315-5968 Coupler Lines Gp (High Lift) 966K and 972K

Illustration 20	g02704478
Left Inner lift arm

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Illustration 21	g03547636

1. Mount two manual valves (1) to bracket (2) with eight screws (11) and eight hard washers (7).

2. Install bracket (2) with valve group (1) to the left inner load arm with four bolts (13) and four hard washers (12). Install parts on the two mounting plates positioned on the forward portion of the lift arm. Refer to Illustration 20.

3. Attach four connector assemblies (6) to manual valve (1).

4. Install two caps (10) to the two forward facing ends of the adapter assemblies (6). Refer to illustration 20

5. Attach two clips (8), bolt (13), and hard washer (12) to the three bosses positioned along the inner left load arm. Refer to Illustration 20 for placement.

   Note: Do not tighten the three bolts at this time.

6. Connect tube assembly (5) and O-ring seal (9) to adapter (6) (route A) on manual valve (1).

7. Repeat this step for tube assembly (2) (route B) and O-ring seal (9).

8. Route the tube through the clips installed in Step 5 towards the back of the machine. Refer to Illustration 20 for correct positioning.

9. Connect two hose assemblies (4) to tubes (5) and (3).

10. Route hoses (4) toward the rear of the machine. The two hose assemblies (4) will attach to the 315-5966 Coupler Lines Gp.

    Note: Tube assembly (5) routes from port "L" of the 321-8473 Control Valve and Mounting Gp to the head end of cylinder group (A). Tube assembly (2) routes from port "UL" of the valve group to the rod end of cylinder group (B).

Installation Procedure for the 313-9763 Quick Coupler Wiring Group

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Illustration 22	g02697163
Inner View of Non-Engine frame side (1) 7K-1181 Cable Strap (2) 326-8813 Quick Coupler Harness As (3) 130-5300 Clip (4) 8T-4121 Hard Washer (5) 8T-4133 Nut

1. Connect harness assembly (2) to the front frame harness at (B). Use clip (3), hard washer (4), and nut (5) to secure end (B) of the harness to the frame.

2. Connect harness assembly (2) to solenoid connection (A) on the 321-8473 Control Valve and Mounting Gp.

3. Attach the harness to the front frame assembly with cable straps (1) as necessary. Refer to Illustration 22.