Installation Procedure for the 423-5844 Conversion Kit {5057, 5147, 5734, 6129, 7332} Caterpillar

Wheel Loader:

950G Series II (S/N: AXR1-276; AXX1-717)

962G Series II (S/N: AXS1-371; AXY1-300)

Work Tool:

QUICK COUPLER (S/N: Y7A1-UP; Y8B1-UP; A8K1-UP)

Introduction

This special instruction covers the installation procedure for 423-5844 Conversion Kit revision - 00.

The coupler conversion kit consists of a switch in the cab, and pressure lines which supply hydraulic pressure to the quick coupler. The switch has two positions that are used for coupling and uncoupling the work tool. Pressure for the operation of the quick coupler is supplied by the brake system accumulator.

Safety Section

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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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.

Welding Requirements

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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.

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.

All welds to the stick must be welded in the direction from the rear of the stick toward the front of the stick.

For more welding information, consult the Caterpillar Service Welding Guide, SEBD0512.

Required Parts

Illustration 1	g03268396
423-5844 Lines Gp - Coupler

Illustration 2	g03268456
Assembled valves (A)

Installation Procedure For the Hydraulic Components

Illustration 3	g00104545

Prevent the machine from movement. Park the machine on a level surface.

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. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.

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Illustration 4	g03269817
Keep these hydraulic lines.

1. Keep the hydraulic lines shown in the above illustration.

2. Remove the hydraulic lines that run down the lift arm.

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Illustration 5	g03268397
Remove these components

3. Remove the bosses (B), and guard (C) from the lift arm.

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Illustration 6	g03269856
Weld Information (A) 1000 mm (39.37 inch) (B) 300 mm (11.81 inch) (C) 50 mm (1.97 inch) Three Places. (D) 40 mm (1.57 inch) (E) 1104 mm (43.46 inch) (F) 838 mm (33.0 inch) (G) 749 mm (29.49 inch) (H) 483 mm (19.02 inch) (J) 156 mm (6.14 inch) (K) 140 mm (5.51 inch) (L) 139 mm (5.47 inch) (M) 245 mm (9.65 inch)

4. Locate and weld components (10), (18), and (19) onto the lift arm.

5. Paint the welded areas.

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Illustration 7	g03268398
Installed View (N) From "C2" port of the manifold group to the rod end of the coupler cylinder. (P) From "C1" port of the manifold group to the head end of the coupler cylinder. (5) 423-8526 Hose As (12) 7G-2950 Clip (13) 7G-2951 Clip (16) 8T-4192 Bolt (17) 8T-4223 Hard Washer

6. Install valve group (A) .

7. Install and secure hoses (5) .

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Illustration 8	g03269858
Installed View (5) 423-8526 Hose As

8. Attach hoses (5) to the existing hydraulic lines.

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Illustration 9	g03270405
Switch Location in Cab

9. Replace the existing coupler switch with switch (3) .

10. Cycle the lift arm control group and coupler through a full range of motion. Adjust clamps as necessary.

Operation of the Coupler

1. Turn on the battery disconnect switch.

2. Start the engine.

3. Activate the toggle switch to the disengage position in order to retract the coupler pins for bucket removal.

4. An alarm should sound indicating the pins are retracted.

5. Visually check the coupler. The pins must be retracted.

6. Activate the toggle switch to the engage position in order to extend the coupler pins for bucket installation.

   Note: If the coupler reacts opposite of the description above, the hoses at ports "C1" and "C2" of the control manifold must be reversed.

7. Cycle the coupler system four times in order to purge air from the system.