Installation Procedure of the Coupler Lines Gp for Certain 950K and 962K Wheel Loaders{1408, 5057, 5133, 6129} Caterpillar

Wheel Loader:

950K (S/N: R4A1-UP; J5M1-UP; FER1-UP)

962K (S/N: T6A1-UP; FLL1-UP; X4T1-UP)

Work Tool:

QUICK COUPLER (S/N: Y7A1-UP)

Introduction

This special instruction covers the installation procedure for 368-0684 Coupler Lines Gp (950K Standard Lift), 368-0686 Coupler Lines Gp (962K Standard Lift), and 368-0687 Coupler Lines Gp (950K, 962K High Lift) on the 950K Wheel loader and the 962K Wheel loader.

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

Illustration 1	g00104545

Attach a "Do Not Operate" 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 Cat dealer.

Safety Section

Show/hide table

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.

Show/hide table

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.

Show/hide table

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.

Show/hide table

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

Required Parts

Refer to the following individual installation procedures per segment for a detailed list of parts.

• Installation Procedure of the 368-0684 Coupler Lines Gp (Standard Lift) for the 950K Wheel Loader

• Installation Procedure of the 368-0686 Coupler Lines Gp (Standard Lift) 962K Wheel Loader

• Installation Procedure of the 368-0687 Coupler Lines Gp (High Lift) for 950K and 962K Wheel Loaders

• Installation Procedure of the 325-3195 Quick Coupler Wiring Gp for 950K and 962K Wheel Loaders

• Installation Procedure of the 346-9929 Coupler Lines Group (Front-Standard Lift) for 950K Wheel Loader

• Installation Procedure of the 420-5322 Coupler Lines Group (Rear) for 950K and 962K Wheel Loaders

• Installation Procedure of the 346-9931 Coupler Lines Group (Front-Standard Lift) for 962K Wheel Loader

• Installation Procedure of the 346-9932 Coupler Lines Group (Front-High Lift) for 950K and 962K Wheel Loaders

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

Show/hide table

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 Cat 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 of the 368-0684 Coupler Lines Gp (Standard Lift) for the 950K Wheel Loader

Illustration 2	g02691697

Show/hide table



Illustration 3	g02474599
Inside View of Left Loader Arm (1) 9R-2821 Boss (2) 9R-2640 Boss (3) 9C-4935 Plate (4) 131-8684 Plate (A) 184 ± 3 mm (7.24 ± 0.12 inch) (B) 19 ± 3 mm (0.75 ± 0.12 inch) (C) 78 ± 3 mm (3.1 ± 0.12 inch) (D) 57 ± 3 mm (2.24 ± 0.121 inch) (E) 70 ± 2 mm (2.76 ± 0.08 inch) (F) 67 ± 2 mm (2.64 ± 0.08 inch) (G) 631 ± 3 mm (24.8 ± 0.12 inch) (H) 432 ± 3 mm (17 ± 0.12 inch) (J) 47° (K) 68 ± 3 mm (2.68 ± 0.12 inch) (L) 290 ± 3 mm (11.4 ± 0.12 inch) (M) 402 ± 3 mm (15.8 ± 0.12 inch) (N) 327 ± 3 mm (12.9 ± 0.12 inch) (P) 594 ± 3 mm (23.4 ± 0.12 inch) (R) 7 ± 3 mm (0.276 ± 0.12 inch) (S) 0 ± 2 mm (0.0 ± 0.08 inch) (T) 143 ± 2 mm (5.6 ± 0.08 inch) (U) 79 ± 3 mm (3.1 ± 0.12 inch)

1. Weld four bosses (1) to the inside of the LH lift arm.

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

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

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

5. Install the 420-5322 Coupler Lines Gp .

6. Install the 346-9929 Coupler Lines Gp .

7. Install the 325-3195 Quick Coupler Wiring Gp

Installation Procedure of the 368-0686 Coupler Lines Gp (Standard Lift) 962K Wheel Loader

Illustration 4	g02475704

Show/hide table



Illustration 5	g02473879
Inside View of Loader Arm (A) 335 ± 3 mm (13.2 ± 0.12 inch) (B) 174 ± 3 mm (6.9 ± 0.12 inch) (C) 314 ± 3 mm (12.4 ± 0.12 inch) (D) 437 ± 3 mm (17.2 ± 0.12 inch) (E) 496 ± 3 mm (19.5 ± 0.12 inch) (F) 323 ± 3 mm (12.7 ± 0.12 inch) (G) 115 ± 2 mm (4.53 ± 0.08 inch) (H) 117 ± 2 mm (4.61 ± 0.08 inch) (J) 625 ± 3 mm (24.6 ± 0.12 inch) (K) 46° (L) 265 ± 3 mm (10.4 ± 0.12 inch) (M) 417 ± 3 mm (16.4 ± 0.12 inch) (N) 548 ± 3 mm (21.6 ± 0.12 inch) (P) 496 ± 3 mm (19.5 ± 0.12 inch) (R) 143 ± 2 mm (5.61 ± 0.08 inch) (S) 0 ± 2 mm (0.0 ± 0.08 inch) (T) 246 ± 3 mm (9.69 ± 0.12 inch) (U) 427 ± 3 mm (16.81 ± 0.12 inch)

1. Weld four 9R-2821 Threaded Bosses (1) that are supplied in the kit onto the inside of both LH lift arms.

2. Weld one 9R-2640 Threaded Boss (2) that is supplied in the kit onto the inside of both LH lift arms.

3. Weld two 9C-4935 Plates (3) that are supplied in the kit onto the inside of both LH lift arms.

4. Weld one 131-8684 Plate (4) that is supplied in the kit onto the inside of both LH lift arms.

5. Install the 420-5322 Coupler Lines Gp .

6. Install the 346-9931 Coupler Lines Gp .

7. Install the 325-3195 Quick Coupler Wiring Gp

Installation Procedure of the 368-0687 Coupler Lines Gp (High Lift) for 950K and 962K Wheel Loaders

Illustration 6	g02475751

1. Install the 420-5322 Coupler Lines Gp .

2. Install the 346-9932 Coupler Lines Gp (High Lift) .

3. Install the 325-3195 Quick Coupler Wiring Gp

Installation Procedure of the 325-3195 Quick Coupler Wiring Gp for 950K and 962K Wheel Loaders

Show/hide table



Illustration 7	g02693736
Location of 325-3195 Quick Coupler Wiring Gp

Show/hide table



Illustration 8	g02475776
325-3195 Quick Coupler Wiring Gp (C) Chassis harness (D) 321-8473 Control Valve and Mounting Gp (1) 7K-1181 Cable Strap (2) 354-0919 Work Tool Harness As (3) 130-5300 Clip (4) 8T-4121 Hard Washer (5) 8T-4137 Bolt

1. Install clip (3) to the frame with washer (4) and bolt (5) .

2. Connect work tool harness (2) from control valve (D) to chassis harness (C). Install harness (2) on clip (3) .

3. Install cable straps (1) on harness (2) as required.

Installation Procedure of the 346-9929 Coupler Lines Group (Front-Standard Lift) for 950K Wheel Loader

Illustration 9	g02475219

Show/hide table



Illustration 10	g02574576
(1) 112-1817 Manual Valve Gp (2) 324-3471 Bracket (6) 357-4366 Connector As (7) 096-6166 Hard Washer (9) 6V-9829 Cap As (12) 8T-0285 Screw

1. Install valves (1) on bracket (2) with washers (7) and bolts (12) .

2. Install four connectors (6) in valves (1) .

Show/hide table



Illustration 11	g02575880
(1) 112-1817 Manual Valve Gp (2) 324-3471 Bracket (3) 355-3697 Tube As (4) 355-3698 Tube As (8) 6V-8397 O-Ring Seal (10) 7X-7729 Washer (11) 8B-6127 Clip (13) 8T-4121 Hard Washer (14) 8T-4137 Bolt

3. Install the assembled valve (1) and bracket (2) on the inside of the left loader arm with washers (13) and bolts (14) .

Note: Verify that the O-ring seals are installed in the connectors on the valve.

4. Install tube assembly (3) to top valve (1). Install tube assembly (4) to bottom valve (1) .

5. Install clips (11), washers (10), and bolts (14) on the tube assemblies at five locations.

Show/hide table



Illustration 12	g02595747
(5) 372-5280 Hose As

6. Connect hoses (5) to the tube assemblies.

Installation Procedure of the 420-5322 Coupler Lines Group (Rear) for 950K and 962K Wheel Loaders

Illustration 13	g03200616
Right side view of frame

1. Install connector (9) in port (UL). Install elbow (11) on connector (9). Refer to view of area (D) .

2. Install connector (8) in port (L). Install elbow (11) on connector (8) .

3. Install connector (8) in port (T) .

4. Install connector (24) in port (P) .

Note: Mount the control valve with port (T) facing up.

5. Mount control valve (3) on the frame with washers (29) and bolts (33) .

6. Install bracket (7) on the frame with washers (29) and bolts (31) .

7. Connect tube assembly (5) to the elbow on port (UL). Connect tube assembly (6) to the elbow on port (L). Do not tighten the tube assemblies at this time.

8. Install clips (28) on tube assemblies (5) and (6). Install spacer (25), washer (29) and bolt (27) in clips (28) .

9. Install clips (28) on tube assemblies (5) and (6). Install washer (29) and bolt (32) in clips (28) .

10. Install clips (28) on tube assemblies (5) and (6). Install washer (29) and nut (30) in clips (28). Refer to view of area (C) .

11. Tighten the tube assembly fittings on the elbows. Tighten the bolts for the clips. Tighten nut (30) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

12. Install elbow (12) and nut (27) in the bulkhead. Refer to view of area (A) .

13. Disconnect existing hose (A) from port (A2) .

14. Install tee (13) in port (A2) .

15. Route hose (16) from tee (13) to elbow (12) .

16. Install bracket (2) on the frame with washer (29) and bolt (32) .

17. Install clip (37) on hose (16). Install washer (23) between clip (37) and bracket (2). Install washer (29) and bolt (36) in clip (37) .

18. Reconnect existing hose (A) to tee (13) .

19. Tighten all hose and fitting connections. Tighten the bolts for clip (37) .

20. Install union assembly (22) and nut (27) in the bulkhead. Refer to view of area (B) .

21. Install hose assembly (4) from elbow (12) to union (22) .

22. Disconnect existing tank line (B) from the control valve and remove the elbow.

23. Install tee (13) in the control valve.

24. Install hose (17) from port (T) of control valve (3) to tee (13) .

25. Reconnect existing tank line (B) to tee (13) .

26. Install plate (18) onto frame with bolts (35). Refer to view of area (E) .

27. Connect clip (20) and clip (21) together and slide onto each end of accumulator (1) .

28. Install washer (29) and bolt (36) in clips (20) and (21) to mount accumulator (1) to bracket (18) .

29. Install tee (14) onto union (22) .

30. Install elbow (10) onto accumulator (1) .

31. Connect hose (19) to elbow (10) and tee (14) .

Charging the Accumulator (Nitrogen Gas Charge)

1. Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures" for the required tooling, and the testing and charging procedure.

   Note: Do not attempt to charge the accumulator until all pressure has been removed from the pilot manifold accumulator.

2. Refer Table 8 for the correct charge pressure.
   Show/hide table

   Table 8

   Accumulator Precharge Pressure/Temperature Relationship for the 6900 kPa (1000 psi) Service Brake Accumulators
   Temperature	Pressure
   −7°C (20°F)	6250 kPa (907 psi)
   −1°C (30°F)	6380 kPa (926 psi)
   4°C (40°F)	6510 kPa (945 psi)
   10°C (50°F)	6640 kPa (964 psi)
   16°C (60°F)	6770 kPa (983 psi)
   21°C (70°F)	6900 kPa (1000 psi)
   27°C (80°F)	7030 kPa (1020 psi)
   32°C (90°F)	7160 kPa (1039 psi)
   38°C (100°F)	7290 kPa (1058 psi)
   43°C (110°F)	7420 kPa (1077 psi)
   49°C (120°F)	7550 kPa (1096 psi)

Installation Procedure of the 346-9931 Coupler Lines Group (Front-Standard Lift) for 962K Wheel Loader

Illustration 14	g02605096

Show/hide table



Illustration 15	g02574576
(1) 112-1817 Manual Valve Gp (2) 324-3471 Bracket (6) 357-4366 Connector As (7) 096-6166 Hard Washer (9) 6V-9829 Cap As (12) 8T-0285 Screw

1. Install valves (1) on bracket (2) with washers (7) and bolts (12) .

2. Install four connectors (6) in valves (1) .

Show/hide table



Illustration 16	g02605296
(1) 112-1817 Manual Valve Gp (2) 324-3471 Bracket (3) 355-3697 Tube As (4) 355-3698 Tube As (8) 6V-8397 O-Ring Seal (10) 7X-7729 Washer (11) 8B-6127 Clip (13) 8T-4121 Hard Washer (14) 8T-4137 Bolt

Show/hide table



Illustration 17	g02605339
(3) 355-3697 Tube As (4) 355-3698 Tube As (8) 6V-8397 O-Ring Seal (10) 7X-7729 Washer (11) 8B-6127 Clip (14) 8T-4137 Bolt

3. Install the assembled valve (1) and bracket (2) on the inside of the left loader arm with washers (13) and bolts (14) .

Note: Verify that the O-ring seals are installed in the connectors on the valve.

4. Install tube assembly (3) to top valve (1). Install tube assembly (4) to bottom valve (1) .

5. Install clips (11), washers (10), and bolts (14) on the tube assemblies at five locations.

Show/hide table



Illustration 18	g02595747
(5) 372-5280 Hose As

6. Connect hoses (5) to the tube assemblies.

Installation Procedure of the 346-9932 Coupler Lines Group (Front-High Lift) for 950K and 962K Wheel Loaders

Illustration 19	g02691318

Show/hide table



Illustration 20	g02574576
(1) 112-1817 Manual Valve Gp (2) 324-3471 Bracket (6) 357-4366 Connector As (7) 096-6166 Hard Washer (9) 6V-9829 Cap As (12) 8T-0285 Screw

1. Install valves (1) on bracket (2) with washers (7) and bolts (12) .

2. Install four connectors (6) in valves (1) .

Show/hide table



Illustration 21	g02691538
(1) 112-1817 Manual Valve Gp (2) 324-3471 Bracket (3) 355-3697 Tube As (4) 355-3698 Tube As (8) 6V-8397 O-Ring Seal (10) 7X-7729 Washer (11) 8B-6127 Clip (13) 8T-4121 Hard Washer (14) 8T-4137 Bolt

3. Install assembled valve (1) and bracket (2) on the inside of the left loader arm with washers (13) and bolts (14) .

Note: Verify that the O-ring seals are installed in the connectors on the valve.

4. Install tube assembly (3) to top valve (1). Install tube assembly (4) to bottom valve (1) .

5. Install clips (11), washers (10), and bolts (14) on the tube assemblies at five locations.

Show/hide table



Illustration 22	g02691541
(5) 372-5280 Hose As

6. Connect hoses (5) to the tube assemblies.