Installation Procedure of the 371-1699 Hydraulic Kit (Center Lock) for Certain 321D LCR Excavators{6129} Caterpillar

Excavator:

321D (S/N: MPG1-UP)

Work Tool:

Hydraulic Kit (S/N: HKD1-UP)

Introduction

This hydraulic kit contains the components that are required for installing a CWTS designed center-lock pin-grabber coupler on a 321D LCR Excavator.

The machine cannot have any other auxiliary hydraulics already installed and the machine must have a quick coupler group.

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 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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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.

Reference Section

ReferenceSystems Operation, KENR5774, "321D LCR Excavator Hydraulic System "

ReferenceTesting and Adjusting, KENR5775, "321D LCR Excavator Hydraulic System "

ReferenceSchematic, KENR5837, "321D LCR Hydraulic System - Attachment - Center Lock Quick Coupler"

ReferenceDisassembly and Assembly, KENR6012, "321D LCR Excavator Machine Systems "

ReferenceSystems Operation, RENR7389, "321D LCR Excavators Tool Control System "

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.

Be sure that all electrodes are 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

For more welding information, consult the General Welding Procedures, REHS1841.

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.

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 Cat 4C-4200 Yellow Paint .

Required Parts

Required Tools

Machine Preparation

1. Clear all personnel from the machine and from the area around the machine.

2. Start the engine.

3. Set the engine speed dial at "10".

4. Place the hydraulic activation control lever in the LOCKED position.

5. Position the machine on level ground. Check the visibility and adjust the mirrors for the best vision close to the machine.

6. Fully retract the stick cylinder rod.

7. Fully extend the bucket cylinder and place the bucket flat on the ground.

8. Stop the engine.

9. Release the hydraulic system pressure. Refer to the Operation and Maintenance Manual, "System Pressure Release".

10. Place the hydraulic activation control lever in the UNLOCKED position.

11. Turn the engine start switch to the OFF position.

12. Attach tooling (F) onto the hydraulic tank. Attach an air supply hose onto the assembly. Apply 276 to 414 kPa (40 to 60 psi). This procedure will pull a vacuum on the hydraulic system.

Installation Procedures

267-7773 Cab Wiring Gp

The 267-7773 Cab Wiring Gp connects to the main cab harness.

Parts Consist

Installation Procedure

Illustration 1	g03377380
Top View of Control Panel in Right Side of Cab (1) 259-7180 Cover (2) 267-7965 Bracket As (3) 275-7190 Toggle Switch Gp (4) 9X-2042 Screw

1. Install bracket assembly (2) onto the control panel with two screws (4). Refer to View A-A of Illustration 1.

2. Install toggle switch (3) as shown.

3. Connect harness from toggle switch (3) to the cab harness.

4. Install cover (1) onto toggle switch (3) .

275-7017 Quick Coupler Wiring Gp

The 275-7017 Quick Coupler Wiring Gp connects to the chassis harness and to the quick coupler solenoid.

Parts Consist

Installation Procedure

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Illustration 2	g03377505
Top View (1) 7K-1181 Cable Strap (2) 116-0118 Clip (3) 283-3043 Solenoid Harness As

1. Route the harness as shown in Illustration 2, making sure that the harness does not interfere with the following: sharp metal edges, hydraulic lines and fuel lines.

   Note: Stack the terminals with changing the angle. Do not pile up tip of barrel.

2. Install clip (2) onto the plug connector of solenoid harness assembly (3) .

3. Tie up harness with cable strap (1) and cut off surplus strap to 3 mm (0.12 inch) or less.

282-5705 Film Gp

The 282-5705 Film Gp contains the instruction film for properly operating the quick coupler and warning films.

Parts Consist

Installation Procedure

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Illustration 3	g03377465
Right Side View of Cab (1) 268-4531 Film (Coupler Operation) (Instructions) (2) 269-0120 Film (Warning) (Safe Distance) (3) 269-0121 Film (Warning) (Safe Distance) (4) 268-4530 Film (Warning) (Safe Distance) (5) 268-8872 Film (Warning) (Safe Distance)

1. Install firms inside the cab on the glass of the right window.

337-1268 Front Lines Gp

The lines from the 337-1268 Front Lines Gp connect to the lines from 343-8342 Hydraulic Lines Kit .

Parts Consist

Installation Procedure

1. Install the components of 337-1268 Front Lines Gp . Refer to Illustrations 4 and 5

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Illustration 4	g02947259
Front View (2) 4I-0797 Hose As (5) 4I-9525 Marker Band (6) 7K-1181 Cable Strap (7) 9X-6582 Nut (12) 333-7200 Hose As (13) 337-1269 Tube As (14) 337-1295 Hose As (15) 337-1317 Flange (17) 148-8336 Connector As (19) 148-8378 Elbow As (20) 148-8419 Reducer As (22) 199-1286 Bolt (23) 4J-5267 O-Ring Seal (24) 6V-9746 O-Ring Seal

2. Assemble hose assembly (12) so that orange marker band (5) is hidden under the rubber clamp.

3. Assemble two hose assemblies (10) so that red marker band (3) and yellow marker band (4) are hidden under the rubber clamp.

4. Tightens nuts (7) to a torque of 76 ± 4 N·m (56 ± 3 lb ft).

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Illustration 5	g02947727
Auxiliary Views (C1) Shown with Heavy Lift and Quick Coupler (C2) Shown only with Quick Coupler (1) 3S-2093 Cable Strap (3) 4I-9521 Marker Band (4) 4I-9522 Marker Band (8) 267-4051 Connector As (9) 292-7317 Support As (10) 314-8249 Hose As (11) 328-2035 Solenoid Valve and Manifold Gp (16) 148-8325 Connector As (18) 148-8374 Elbow As (19) 148-8378 Elbow As (21) 148-8433 Tee As (22) 199-1286 Bolt (25) 8T-4121 Hard Washer (26) 8T-4185 Bolt (27) 8T-4192 Bolt (28) 8T-4223 Hard Washer

5. Tie up hoses to the boom cylinder lines group lines with cable strap (1). Remove all sharp corners from cable strap.

6. Tie up hoses to the front control group lines with cable strap (1). Remove all sharp corners from cable strap.

7. Tee assembly (21) is required for machines that are equipped with heavy lift.

343-8342 Hydraulic Lines Kit

The lines from the 343-8342 Hydraulic Lines Kit connect to the lines from the 337-1268 Front Lines Gp and the lines from the quick coupler.

Parts Consist

Installation Procedure

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Illustration 6	g02929636
Right Side View and Top View of Machine (View A-A) Refer to Illustration 7. (1) 4I-9521 Marker Band (Red) (2) 4I-9522 Marker Band (Yellow) (3) 4V-0611 Clamp (Double) (4) 4V-0612 Plate (5) 4V-0969 Plate As (6) 7K-1181 Cable Strap (7) 196-9994 Union Gp (8) 343-8343 Hose As (9) 344-6276 Hose As (10) 323-6157 Permanent Coupling As (11) 164-5570 Union As

1. Attach one red marker band (1) to each end of left hose (8) .

2. Attach one yellow marker band (2) to each end of right hose (8) .

3. By using one coupling (10), one Union (11), and one Union (7), attach the hose (8) to the hose on the boom.

4. By using one coupling (10), one union (11), and one union (7), attach the hose (8) to the hose on the boom.

5. Use the cable strap (6) in order to secure both hoses (8) to the existing hydraulic lines.

6. By using one union (11), attach the previously installed hoses (8) to hoses (9) .

7. Attach one red marker band (1) to each end of hose (9) .

8. Attach one red marker band (2) to each end of another hose (9) .

9. Use the remaining cable straps (6) in order to secure hoses (9).

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Illustration 7	g02938318
View A-A (W1) Apply 1 mm (0.04 inch) Fillet weld to the sides of plates (5). (N1) No weld on both sides of plates (5). (A) 380 ± 5 mm (14.9 ± 0.2 inch) (B) 590 mm (23.2 inch) (C) 7.5 mm (0.3 inch) (D) 665 mm (26.2inch) (E) 147.5 mm (5.8 inch) (5) 4V-0969 Plate As (9) 344-6276 Hose As

10. Weld four plates (5) to the stick. Refer to Illustration 7 for dimensions.

11. Route the two hoses (9) over the stick and secure both hoses using eight clamps (3), four plates (4), and four bolts (12) .

12. Attach one union (7) to the hose (9) that has the red marker band (1) .

13. Attach one union (11) to the hose (9) that has the yellow marker band (2) .

Testing Procedure

1. Remove tooling (F) from the hydraulic tank after the installation procedure is complete.

2. Test the operation of the hydraulic center lock.

3. Inspect the fittings for hydraulic leaks.