- Wheel Loader
- 966L (S/N: FSL1-UP; FRS1-UP)
- Work Tool
- QUICK COUPLER (S/N: PA21-UP; Y7A1-UP; Y8B1-UP; A8K1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
The coupler lines group consists of a switch in the cab, and a control valve 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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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
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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. |
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| Illustration 1 | 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.
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 Society2501 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 LaborWashington, 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
Do not weld in windy conditions. Do not weld when temperatures are below
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
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
| 526-5028 Lines Gp - Coupler (- 00) | |||
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| Item | Qty | Part No | Description |
| (1) | 2 | Cap As | |
| (2) | 2 | Ball Valve | |
| (3) | 1 | Check Valve As | |
| (4) | 6 | Connector As | |
| (5) | 1 | Elbow As | |
| (6) | 2 | Elbow As | |
| (7) | 3 | Elbow As | |
| (8) | 1 | Elbow As | |
| (9) | 1 | Bracket As | |
| (10) | 1 | Bracket | |
| (11) | 2 | Nut | |
| (12) | 1 | Tube As | |
| (13) | 1 | Tube As | |
| (14) | 2 | Hose As | |
| (15) | 1 | Cover Plate and Mounting | |
| (16) | 1 | Bracket As | |
| (17) | 1 | Tube As | |
| (18) | 1 | Hose As | |
| (19) | 1 | Hose As | |
| (20) | 1 | Quick Coupler Switch Gp | |
| (20a) | 1 | Rocker Switch | |
| (21) | 1 | Hose As | |
| (22) | 1 | Tube As | |
| (23) | 8 | Hard Washer | |
| (24) | 8 | Bolt | |
| (25) | 1 | Threaded Boss | |
| (26) | 1 | Boss | |
| (27) | 1 | Clip | |
| (28) | 1 | Clip | |
| (29) | 14 | Clip | |
| (30) | 1 | Clip | |
| (31) | 1 | Grommet | |
| (32) | 4 | O-Ring Seal | |
| (33) | 17 | Hard Washer | |
| (34) | 8 | Bolt | |
| (35) | 5 | Bolt | |
| (36) | 2 | Bolt | |
| (37) | 2 | Bolt | |
| (38) | 2 | Hard Washer | |
| (39) | 1 | Plate | |
| (40) | 1 | Boss | |
| (41) | 2 | Plate | |
| (42) | 3 | Weld Boss | |
| (43) | 2 | Boss | |
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| Illustration 2 | g06167943 |
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Overview of the | |
Installation Procedure
- Weld bosses and plates to the left-hand loader arm.
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Illustration 4 g06168388 (39) 8X-7415 Plate
(43)9R-2821 Boss - Weld bosses and plates as shown.
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Illustration 5 g06170570 (15) 416-4796 Coupler Valve and Mounting Gp
(40)8Y-3795 Boss
(42)9R-2613 Weld Boss - Weld bosses and install the coupler valve group inside the left-hand machine frame.
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Illustration 6 g06168873 (3) 123-4750 Check Valve As
(4)148-8336 Connector As
(5)148-8351 Elbow As
(6)148-8353 Elbow As
(7)148-8367 Elbow As
(8)148-8378 Elbow As
(15)416-4796 Coupler Valve and Mounting Gp
(17)418-3771 Tube As
(18)423-9937 Hose As
(19)423-9939 Hose As
(21)457-3114 Hose As
(22)472-0175 Tube As
(30)6D-3479 Clip
(33)8T-4121 Hard Washer
(35)8T-4137 Bolt
(36)8T-4172 Bolt - Install coupler valve, connectors, hoses and tubes on the inside of the left-hand machine frame.
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Illustration 7 g06169269 (B) 500-3640 Control Valve and Mounting Gp (2V STD-No Ride Control)
(7)148-8367 Elbow As
(21)457-3114 Hose As
(27)5P-7462 Clip
(28)5P-7463 Clip
(31)6V-0683 Grommet
(33)8T-4121 Hard Washer
(34)8T-4136 Bolt
(42)9R-2613 Weld Boss - Route hose (21) over to control valve group (B) as shown.
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Illustration 8 g06169313 (11) 344-5675 Nut
(14a)383-4355 Hose As
(14b)383-4355 Hose As
(16)418-3768 Bracket As
(17)418-3771 Tube As
(22)472-0175 Tube As
(29)5P-9297 Clip
(33)8T-4121 Hard Washer
(34)8T-4136 Bolt
(35)8T-4137 Bolt
(38)8T-4223 Hard Washer
(37)8T-4192 Bolt - Install and route tubes, brackets and hoses as shown.
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Illustration 9 g06169382 (9) 160-8708 Bracket As
(12)367-0372 Tube As
(13)367-0373 Tube As
(14a)383-4355 Hose As
(14b)383-4355 Hose As
(29)5P-9297 Clip
(33)8T-4121 Hard Washer
(34)8T-4136 Bolt
(35)8T-4137 Bolt
(37)8T-4192 Bolt - Route hoses and tubes down the inside of the left-hand loader arm.
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Illustration 10 g06169383 Area A.
(1a)6V-9829 Cap, **From "C2" of Manifold Gp to Rod End of Coupler Cylinder
(1b)6V-9829 Cap, **From "C1" of Manifold Gp to Head End of Coupler Cylinder.
(2)112-1817 Ball Valve
(4)148-8336 Connector As
(10)324-3471 Bracket
(12)367-0372 Tube As
(13)367-0373 Tube As
(23)096-6166 Hard Washer
(24)121-4405 Bolt
(25)163-9662 Threaded Boss
(29)5P-9297 Clip
(33)8T-4121 Hard Washer
(34)8T-4136 Bolt
(35)8T-4137 Bolt - Install pre-assembled ball valves and bracket, then route tubes as shown.
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Illustration 11 g06170038 Right-hand switch panel in the cab.
(20)427-4963 Quick Coupler Switch Gp - Install the coupler switch in the right-hand panel in the cab.
- Unless specified, tighten all hardware and fittings to standard torque.
- Check for leaks.
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| Illustration 3 | g06167953 |
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View of the right-hand side of the left-hand lift arm. (25) (26) (41) (42) | |
