Installation Procedure for 368-8120 Hydraulic Ar for 963D Track-Type Loaders{1408, 5057, 5133, 6129} Caterpillar

Track-Type Loader:

963D (S/N: LCS1-UP)

Work Tool:

Quick Coupler (S/N: Y7A1-UP)

Introduction

The Special Instruction, REHS5665 is for the installation of the 368-8120 Hydraulic Ar (2 Valve) for 963D Track-Type Loaders. If you need more information about the installation, consult your Cat dealer.

Do not perform any procedure that is outlined in this publication. Do not order any parts until you understand the information that is contained in this document.

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

1. Install the 363-1280 Coupler Lines Gp

2. Install the 363-1287 Chassis Wiring Gp

3. Install the 363-1285 Cab Wiring Gp

Installation Procedure for the 363-1280 Coupler Lines Gp

Illustration 2	g02625596

Illustration 3	g02720029

Show/hide table



Illustration 4	g02625625
View of inside of right loader arm (5) 112-1817 Manual Valve Gp (9) 230-7058 Bracket (11) 342-0564 Tube As (12) 342-0566 Tube As (15) 342-0583 Bracket As (31) 096-6166 Hard Washer (32) 121-4405 Bolt (33) 140-6329 Spacer (34) 148-8336 Connector As (35) 148-8353 Elbow As (46) 6V-2383 Clip (48) 6V-8397 O-Ring Seal (50) 6V-9829 Cap (53) 8T-4121 Hard Washer (56) 8T-4137 Bolt (59) 8T-4192 Bolt (60) 8T-4223 Hard Washer (62) 8T-4910 Bolt (63) 8T-7971 Hard Washer

1. Install two valves (5) on bracket (9) with washers (31) and bolts (32) .

2. Install two connector assemblies (34) and two elbow assemblies (35). Install two caps (50) on the elbow assemblies (35) .

   Note: Verify that the O-ring seals are installed in the connector assemblies and elbow assemblies.

3. Install assembled valve (5) and bracket (9) on the inside of the right loader arm with washers (53) and bolts (56) .

   Note: Verify that the O-ring seals are installed in the connector assemblies on the valves.

4. Install tube assemblies (11) and (12) to assembled valves (5) .

5. Install the first clip (46) with washer (60), washer (63), and bolt (59) .

6. Install the next two clips (46) with washers (60) and bolts (59) .

7. Install the bracket (15) with spacers (33), washers (60), and bolts (62) .

Show/hide table



Illustration 5	g02625889
View looking down on inside of right loader arm (11) 342-0564 Tube As (13) 342-0571 Hose As (14) 342-0572 Hose As (20) 363-1263 Bracket (22) 363-1265 Hose As (23) 363-1266 Hose As (38) 148-8377 Elbow Gp (46) 6V-2383 Clip (47) 6V-8367 Lockwasher (48) 6V-8397 O-Ring Seal (49) 6V-9168 Nut (57) 8T-4183 Bolt (60) 8T-4223 Hard Washer

8. Install one elbow group (38) on the end of each hose (13 & 14) .

   Note: Verify that the O-ring seals are installed in the elbow group.

9. Connect hose (13) to tube assembly (11) .

10. Connect hose (14) to tube assembly (12) .

    Note: Be sure that O-ring seals (48) are used to connect the tube to the hose.

Show/hide table



Illustration 6	g02626029
Bracket view from above (13) 342-0571 Hose As (14) 342-0572 Hose As (20) 363-1263 Bracket (22) 363-1265 Hose As (23) 363-1266 Hose As (38) 148-8377 Elbow Gp (47) 6V-8367 Lockwasher (48) 6V-8397 O-Ring Seal (49) 6V-9168 Nut (57) 8T-4183 Bolt (60) 8T-4223 Hard Washer

11. Install bracket (20) with washers (60) and bolts (57) .

12. Connect elbows (38) to bracket (20) with lockwashers (47) and nuts (49) .

13. Connect hoses (22 & 23) to the two elbows (38) .

Show/hide table



Illustration 7	g02626121
Baffle view from front of machine (A) Existing clips on frame (B) Opening in baffle (8) 223-1395 Bracket As (13) 342-0571 Hose As (14) 342-0572 Hose As (20) 363-1263 Bracket (21) 363-1264 Baffle (22) 363-1265 Hose As (23) 363-1266 Hose As (43) 206-5017 Spacer (45) 5K-5338 Clip (53) 8T-4121 Hard Washer (58) 8T-4186 Bolt

14. Attach the baffle (21) to the frame with the two existing clips (A) and hardware.

15. Insert hoses (22 & 23) through the opening (B) in the baffle (21) .

Show/hide table



Illustration 8	g02630522
View above control valve (C) Existing Control Valve (8) 223-1395 Bracket As (21) 363-1264 Baffle (22) 363-1265 Hose As (23) 363-1266 Hose As (27) 363-1271 Hose As (28) 363-1272 Hose As (29) 363-1273 Hose As (36) 148-8361 Elbow As (42) 205-3692 Elbow As (43) 206-5017 Spacer (45) 5K-5338 Clip (53) 8T-4121 Hard Washer (54) 8T-4133 Nut (55) 8T-4136 Bolt (58) 8T-4186 Bolt

Note: Refer to Illustration 7 for a different view of this work.

16. Attach the hoses (22 & 23) to the clips (45) .

17. Install clips (45) to the frame with hardware.

18. Attach bracket (8) to clip (45) and the frame.

Show/hide table



Illustration 9	g02633402
Overview of valves and pumps looking from right side to center of machine (C) Existing control valve (D) Existing implement pump (E) Existing hystat pump (3) 7K-1181 Cable Strap (7) 206-2423 Saddle (10) 281-5898 Tee As (16) 342-0585 Control Valve Gp (17) 342-0587 Bracket As (18) 349-1178 Pressure Sensor Gp (19) 352-2735 Control Manifold Gp (21) 363-1264 Baffle (22) 363-1265 Hose As (23) 363-1266 Hose As (25) 363-1268 Bracket As (26) 363-1269 Hose As (28) 363-1272 Hose As (29) 363-1273 Hose As (30) 363-1274 Tube As (37) 148-8367 Elbow As (45) 5K-5338 Clip (54) 8T-4133 Nut (55) 8T-4136 Bolt (56) 8T-4137 Bolt

Show/hide table



Illustration 10	g02633517
Overview of valves and pumps looking from left side to center of machine (C) Existing control valve (D) Existing implement pump (E) Existing hystat pump (3) 7K-1181 Cable Strap (5) 112-1817 Manual Valve Gp (7) 206-2423 Saddle (16) 342-0585 Control Valve Gp (20) 363-1263 Bracket (21) 363-1264 Baffle (22) 363-1265 Hose As (23) 363-1266 Hose As (24) 363-1267 Tube As (26) 363-1269 Hose As (27) 363-1271 Hose As (29) 363-1273 Hose As (30) 363-1274 Tube As (36) 148-8361 Elbow As (42) 205-3692 Elbow As

Show/hide table



Illustration 11	g02627024
View of valves from above (2) 5I-4376 Fitting (4) 8I-3633 Adapter As (5) 112-1817 Manual Valve Gp (16) 342-0585 Control Valve Gp (17) 342-0587 Bracket As (18) 349-1178 Pressure Sensor Gp (19) 352-2735 Control Manifold Gp (22) 363-1265 Hose As (23) 363-1266 Hose As (24) 363-1267 Tube As (25) 363-1268 Bracket As (27) 363-1271 Hose As (28) 363-1272 Hose As (29) 363-1273 Hose As (31) 096-6166 Hard Washer (32) 121-4405 Bolt (37) 148-8367 Elbow As (39) 148-8435 Tee As (40) 198-4775 Hard Washer (41) 198-4776 Hard Washer (44) 3J-1907 O-Ring Seal (45) 5K-5338 Clip (51) 7X-2535 Bolt (52) 7X-7888 Bolt (56) 8T-4137 Bolt (61) 8T-4908 Bolt

Show/hide table



Illustration 12	g02626780
View of valves from below (2) 5I-4376 Fitting (4) 8I-3633 Adapter As (6) 187-2137 Elbow (16) 342-0585 Control Valve Gp (17) 342-0587 Bracket As (19) 352-2735 Control Manifold Gp (22) 363-1265 Hose As (23) 363-1266 Hose As (25) 363-1268 Bracket As (26) 363-1269 Hose As (27) 363-1271 Hose As (28) 363-1272 Hose As (29) 363-1273 Hose As (30) 363-1274 Tube As (36) 148-8361 Elbow As (37) 148-8367 Elbow As (40) 198-4775 Hard Washer (41) 198-4776 Hard Washer (42) 205-3692 Elbow As (44) 3J-1907 O-Ring Seal (45) 5K-5338 Clip (52) 7X-7888 Bolt (56) 8T-4137 Bolt (61) 8T-4908 Bolt

Note: Refer to Illustration 11 and Illustration 12 for the following steps.

19. Install one adapter assembly (4) into each port of control valve (16) .

20. Install two elbows (37) to adapter assembly (4) on control valve (16) .

21. Install fitting (2) to control valve (16) .

22. Install pressure sensor (18) into fitting (2) .

23. Mount control valve (16) to bracket (25) with three bolts (52) and washers (40) .

24. Install elbow (6) and O-ring (44) to control manifold (19) .

25. Install tee assembly (39) to control manifold (19) .

    Note: Verify that the O-ring seals are installed in the tee assembly.

26. Mount control manifold (19) to bracket (25) with two washers (40) and two bolts (51) .

27. Install one connecter assembly (4) into each port of manual valve (5) .

28. Mount manual valve (5) to bracket (25) with four washers (31) and four bolts (32) .

29. Mount bracket (25) with assembled valves (5,16,19) to the existing pump with four washers (41) and four bolts (61) .

Show/hide table



Illustration 13	g02628461
Left side view of valves (3) 7K-1181 Cable Strap (5) 112-1817 Manual Valve Gp (7) 206-2423 Saddle (10) 281-5898 Tee As (16) 342-0585 Control Valve Gp (17) 342-0587 Bracket As (19) 352-2735 Control Manifold Gp (24) 363-1267 Tube As (25) 363-1268 Bracket As (26) 363-1269 Hose As (27) 363-1271 Hose As (28) 363-1272 Hose As (29) 363-1273 Hose As (30) 363-1274 Tube As (36) 148-8361 Elbow As (42) 205-3692 Elbow As (45) 5K-5338 Clip (48) 6V-8397 O-Ring Seal (56) 8T-4137 Bolt

Show/hide table



Illustration 14	g02628878
View from front left side of valves (3) 7K-1181 Cable Strap (5) 112-1817 Manual Valve Gp (6) 187-2137 Elbow (7) 206-2423 Saddle (10) 281-5898 Tee As (16) 342-0585 Control Valve Gp (17) 342-0587 Bracket As (18) 349-1178 Pressure Sensor Gp (19) 352-2735 Control Manifold Gp (24) 363-1267 Tube As (25) 363-1268 Bracket As (26) 363-1269 Hose As (27) 363-1271 Hose As (28) 363-1272 Hose As (29) 363-1273 Hose As (30) 363-1274 Tube As (36) 148-8361 Elbow As (39) 148-8435 Tee As (42) 205-3692 Elbow As (45) 5K-5338 Clip (56) 8T-4137 Bolt

Note: 3S-2093 Cable Strap - Use as required.

Note: Refer to Illustration 13 and Illustration 14 for the following steps.

30. Install tube assembly (24) to valve (5) and control valve (16) .

31. Install tube assembly (30) to valve (5) and tee assembly (39) .

32. Attach tee assembly (10) to the elbow end of hose (26) .

33. Attach hose (26) to control manifold (19) .

34. Attach elbow assembly (42) to the end of hose (27) .

35. Attach hose (27) to control valve (16) .

36. Attach elbow assembly (36) to hose (28) .

37. Attach hose (28) to elbow (6) with O-ring (48) .

38. Attach elbow assembly (42) to hose (29) .

39. Attach hose (29) to tee assembly (39) .

Show/hide table



Illustration 15	g02631679
View from left side of the valves and pumps (C) Existing control valve (D) Existing implement pump (E) Existing hystat pump (3) 7K-1181 Cable Strap (7) 206-2423 Saddle (16) 342-0585 Control Valve Gp (22) 363-1265 Hose As (23) 363-1266 Hose As (24) 363-1267 Tube As (26) 363-1269 Hose As (27) 363-1271 Hose As (28) 363-1272 Hose As (29) 363-1273 Hose As (30) 363-1274 Tube As (36) 148-8361 Elbow As (42) 205-3692 Elbow As

Show/hide table



Illustration 16	g02632799
View from right side of the valves and pump (C) Existing control valve (E) Existing hystat pump (3) 7K-1181 Cable Strap (6) 187-2137 Elbow (7) 206-2423 Saddle (10) 281-5898 Tee As (16) 342-0585 Control Valve Gp (17) 342-0587 Bracket As (18) 349-1178 Pressure Sensor Gp (19) 352-2735 Control Manifold Gp (22) 363-1265 Hose As (23) 363-1266 Hose As (25) 363-1268 Bracket As (26) 363-1269 Hose As (28) 363-1272 Hose As (29) 363-1273 Hose As (30) 363-1274 Tube As (37) 148-8367 Elbow As (45) 5K-5338 Clip (56) 8T-4137 Bolt

Note: Refer to Illustration 15 and Illustration 16 for the following steps.

40. Make final connection for hose (27) with elbow assembly (42) to existing control valve (C) as illustrated above.

41. Make final connection for hose (26) with tee assembly (10) to existing control valve (C) as illustrated above. Connect the existing return hose assembly to the bull end of the tee.

42. Make final connection for hose (28) with elbow assembly (36) to existing control valve (C) as illustrated above.

43. Make final connection for hose (29) with elbow assembly (42) to existing control valve (C) as illustrated above.

44. Attach clip (45) with bolt (56) to hoses (27 & 29).

45. Attach bracket (17) to clip (45) and bolt to bracket on frame.

46. Attach cable strap (3) and saddle (7) to hose (26) and bolt to frame.

Note: After completing the installation, pressurize the hydraulic system and check all connections for leaks.

Installation Procedure for 363-1287 Chassis Wiring Gp

Show/hide table



Illustration 17	g02626009
(1) 7K-1181 Cable Strap (3) 363-1278 Solenoid Harness As

Show/hide table



Illustration 18	g02625828
(1) 7K-1181 Cable Strap (3) 363-1278 Solenoid Harness As (6) 4P-8134 Clip

1. Remove necessary panels to gain access under the cab.

2. Route solenoid harness from under the right side cover assembly to the control valve using cable straps (1) as necessary and clip (6). Refer to Illustration 18.

Show/hide table



Illustration 19	g02626008
(1) 7K-1181 Cable Strap (2) 256-1028 Bracket As (4) 156-6175 Clip (5) 4P-7581 Clip (7) 5P-9299 Clip (8) 8J-1256 Clip (9) 8T-4121 Hard Washer (10) 8T-4136 Bolt (A) Pressure sensor connector (B) Control valve hoses (C) Connector

3. Install cable straps (1) as needed and route the solenoid harness (3) under the control valve hoses (B) .

4. Install clip (5) then install clip (7) using bolt (10) and hard washer (9) .

5. Install clip (8) then route the harness to the control valve and plug connector (C) into the control valve. Plug connector (A) in to the pressure sensor.

6. Reinstall all panels removed for access from step 1.

Installation Procedure for 363-1285 Cab Wiring Gp

Show/hide table



Illustration 20	g02637037
(3) 7K-1181 Cable Strap (4) 132-1829 Alarm Gp (5) 155-0576 Isolation Mount (6) 292-4189 Electronic Control Module (11) 4P-7581 Clip (14) 7X-0579 Hard Washer (15) 8T-4224 Hard Washer (16) 8T-6912 Bolt (D) 160-7689 Connector Plug As

1. Remove seat and any necessary panels to gain access to ECM (5). Remove the existing ECM and old wire harness. Then install the new ECM (5). Bolt in place by using bolt (16), washer (14), washer (15), and isolation mount (5). Install clips (11) and cable strap (3) according to Illustration 20.

2. Plug in connector (D) to the new ECM, and tighten the nut to a torque of 6 ± 1 N·m (53 ± 9 lb in). Route new cab wiring harness along the path of the original cab wiring harness, using cable straps (3) according to the illustrations.

3. Connect the alarm group (4) and other connectors to clip (11) using cable strap (3) on the top left corner of the ECM.

Show/hide table



Illustration 21	g02637181
(1) 3E-5239 Relay As (3) 7K-1181 Cable Strap (7) 363-1277 Operator Controls Harness As (8) 364-6028 Rocker Switch (9) 364-6029 Lamp (10) 369-1344 Bracket (12) 5C-2890 Nut (13) 5C-9553 Bolt (17) 9X-8256 Washer

4. Route new harness to under the right side cover. Bolt relay assembly (1) to bracket (10), using bolt (13), washer (17), and nut (12) .

5. Continue to route the harness under the top right side cover assembly. Install connector to rocker switch (8) and lamp (9). Then finish routing the harness according to illustrations, using cable straps (3) as necessary.

6. Reinstall any panels removed for installation process.

Software Requirements

1. Verify that machine control software is either 365-1268 Machine Software Gp or 386-4200 SFWR GP-A3000 . If not, download this software file from SIS and then upload the software file to the machine ECM. When "Coupler" appears in the configuration, the software should be "Enabled".

2. Download the 372-6777 SFWR GP-A3012 software file from SIS and upload this software file to the implement ECM. This action will enable the coupler to function properly.