Usage:
Introduction
This Special Instruction provides the necessary guidelines for installation of the Caterpillar Quick Coupler Universal Control Kit on all brands and models hydraulic excavators.
After the assembly is complete, prepare the machine for service as instructed in the machine's Operation and Maintenance Manual.
Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information provided herein.
Do not rush the job. Take your time and most important, take it safely.
If there is anything you do not understand, ask your employer or the Caterpillar dealer.
Reference: Service Manual, Parts Manual and Operation and Maintenance Manual.
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Do not attempt to install the Quick Coupler until you have read and understand the installation instructions. Improper procedures could result in injury or death. |
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NOTE: Do not let any dirt get into the hydraulic system during assembly. Keep the oil in the hydraulic system at the correct level to prevent pump cavitation.
Kit description
The kit consists of:
- - a set of hydraulic hoses and stems.
- - hydraulic solenoid valves (2×) for control of coupler operation.
- - electric switch (1×) to actuate the valves and the warning signal.
- - connectors and seals.
- - hydraulic solenoid valves (2×) for control of coupler operation.
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All components supplied in the kit are designed to operate safely with a maximum working pressure of 32000 kPa. (4640 psi) |
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Connections to the original hydraulic components of the machine such as hydraulic pump, safety valve or main valve vary from one machine to another. Adapters will be needed to connect the kit components to the various existing components.
NOTE: To provide maximum versatility, the stems are not fitted to the hoses. This allows adjustment of the hose length during installation. Once the correct length has been determined, the stems will have to be crimped to the hose.
List of components
NOTE: When a hoist is used to lift any part or assembly, stand clear of the area. Always make sure the hoist has the correct capacity.
Hydraulic circuit installation
NOTE: Before you start the installation of the coupler circuit you must drain the hydraulic tank, or use any system you may have to prevent oil spillage in the work area. This is both for your own safety and comfort but it will also help to reduce pollution.
The Quick Coupler requires oil supply with a minimum operating pressure of 12000 kPa. (120 bars/1740 psi) and requires a flow of 20 Lpm. (5 Gpm)
It is recommended to use one of the main pump pressure test ports as the source of oil supply to the coupler circuit.
If available, an auxiliary pump may also be used if it can withstand the required flow and pressure.
Oil supply connection (Fig. 1)
1. Install 7X2459 Tee (item 1) with an appropriate adapter in the pump port.
2. Remove 9S4191 Plug (item 55) and install the connector for your test equipment.
Control valve installation Fig. (2)
3. Install the 7Y5005 Control Valve (item 3) in any convenient place between the pump compartment and boom foot. Use the 113-7183 Plate Assembly (item 6) and the appropriate bolts, seals and washers.
Boom lines installation (Fig. 6, page 4)
4. Weld three 7Y4090 Plates (item 28) at the best suitable places with regard to existing tubing.
6. Install four 6V8994 Bulkhead fittings (it 26) and four 6V9168 Bulkhead nuts (it 27) with eight 6V8397 Seals (it 2) and eight 3J1907 Seals (it 9) on the brackets (it 25 & 30).
7. Make two hoses CP8 (Fig. 3)
8. Connect the two hoses CP8 to the bulkhead fittings (it 26).
9. Strap the center part of the hoses along the existing hoses with fifteen 7K1141 Straps (it 31).
10. Make hoses CP6 and CP 7 (See Figure 4)
11. Connect the hoses CP6 and CP 7 to the boom lines and to the 7Y5005 Valve group (it 3). (Fig. 5)
Coupler lines installation.
12. Make two hoses CP11. (Fig. 8)
NOTE: The coupler cylinder has two oil line connecting ports. The one in the center of the cylinder is the pressure port. The one on the tube running along the cylinder is the drain port.
13. Install 114-0235 Bracket (it. 37) on the stick in such a way that, once hoses CP 11 are installed, they will bend smoothly when the bucket cylinder is fully extended. (Fig. 7 & 9)
14. Connect two hoses CP 11 to the coupler hydraulic cylinder making sure that they are not twisted. Do not tighten the pressure port connector yet. (Fig. 9)
NOTE: One some machines there is a risk that the power link hits or squeezes the CP11 hoses against the top plate of the stick. Once the installation is completed, the stick cylinder must be carefully retracted. In case of interference, manufacture two, 40 mm high, stops from St52 (50E) steel. Weld them in such a position that they prevent the linkage to hit the hoses.
Stick lines installation (Fig.7, page 4)
15. Make and install two hoses CP9. (Fig. 10)
16. Install 7Y4090 Plates (it 28) in such a way that the hoses CP 9 will run alongside the existing bucket cylinder lines. You may consider to strap them together. (Detail B, fig. 7)
17. Make and install two hoses CP 10 (Fig. 11)
18. Weld 6C8895 Bosses (it.33) on the stick at the most convenient places. (Detail C, fig. 7)
19. Make hose CP5. (Fig. 12)
20. Install hose CP5 between tank and 7Y5005 Valve group (it 3)(Fig. 13)
21. Make hose CP4. (Fig. 14)
22. Install hose CP4 between 7Y5005 Valve group and the Tee previously installed on the main pump. (Fig. 15 & Fig. 13)
NOTE: Most hydraulic excavators are equipped with open center valves. When this type of valve is not being used to control a machine function, the oil will flow through the center and back to the tank.
In this case the Quick Coupler will not respond when the Coupler Valve is actuated unless a machine function is operated simultaneously. Using the swing with the lock pin or brake applied is the preferred method.
The following additional hudraulic circuit can be installed to provide a pressure build-up system that will alleviate the above problem and eliminate the need to operate a machine function. The necessary parts are provided in the kit.
Pressure build-up circuit
1. Select a stem on the main control valve that is used for a flow control function (two speed valve, combined flow valve, etc.). Refer tot the Service Manual or ask the hydraulics specialist.
2. Locate the pilot pump or the safety valve.
3. Install two Tee fittings on the safety valve (or pilot pump) (Fig. 16)
4. Install the 4I6158 Valve Group (it 11) using 109-3534 Bracket (it. 12). A location close to the safety valve is recommended. Install three 6V8724 Elbow fittings on the 4I6158 Valve Gp. (Fig. 17)
5. Make hoses CP1 and CP2. (Fig. 18)
6. Install hose CP2 between line pressure port of the safety valve (or pilot pump) and the inlet port (P) of the 4I6158 Valve. (it 11) Re-install the original line pressure hose on the Tee with a suitable adapter. (Fig. 19)
7. Install 8J6875 Valve (it17) on the pilot port of the valve stem selected in step 1. Reconnect the original pilot hose. (Fig. 20)
8. Make hose CP3. (Fig.21)
9. Install hose CP3 between the output port (A) of the 4I6158 Valve (it 11) and the second port on the 8J6875 Valve (it 17). (Fig.22)
Hydraulic System Schematic
10. Install hose CP1 between the tank port (T) of the 4I6158 Valve (it 11) and the tank port of the safety valve. Re-install the original tank hose on the Tee. (fig 23)
Electrical circuit
The kit contains only two electrical parts, a switch and a horn. Because of the many different cab configurations the wires have not been included in the kit.
All wires are 16 Gage (1.2 mm2). Refer to Figure 15 for the schematic.
1. Install the switch in such a location that it can not be inadvertently actuated. The recommended location is on the right hand side of the cab about as far back as the seat backrest.
2. Drill a 26 mm hole in the selected location. If the installation requires a fixation bracket, make sure that it is not possible for the switch contacts to touch any machine part.
3. Install the horn in a convenient location.
4. Use red wire to connect the + horn terminal to any wire that is connected to the battery positive.
5. Connect the + terminal of each valve solenoid (part of items 3 and 11 of the hydraulic kit) to the same battery positive wire, using red wire.
6. Using white wire, connect the "-" terminal of the horn to terminal B of the switch.
7. Using orange wire, connect the "-" terminal of both solenoids to terminal R of the switch.
8. Using black wire, connect terminal AC of the switch to any wire that is connected to the battery negative terminal or to a ground bus.
Electric system schematic
Start-up
1. Verify all electrical and hydraulic connections. They must be tightened correctly. Leave the pressure connector to the Quick Coupler hydraulic cylinder loose.
2. Refill the hydraulic system of the machine and close the tank. Follow the instructions in the machine's Operating and Maintenance manual.
3. Start the engine and move the general safety lever or switch into the "WORKING" position. Consult the machine's Operating Manual for the correct procedures.
4. Turn the Quick Coupler switch to it's first position. The horn / beeper must sound. If it does not, check the electrical connections and polarities.
5. Turn the switch further into it's second position and check that oil starts to leak out of the loose connection to the pressure port on the hydraulic cylinder. If after two minutes oil has not arrived at the pressure port connector, do the following:
a) Actuate slowly one of the machine functions (boom up or stick out). If you now have oil flow, go directly to point " e ".
b) Check if the electro valve stems are not sticking by pushing the button in the center of the solenoid with a screwdriver.
c) Check the electrical connections between the switch, the valves and the battery wires.
d) Loosen the drain port connector of the cylinder to make sure there is no hose inversion in the piping. If oil bleeds abundantly from the drain port, switch the hoses CP6 and CP7 connected to the " A " and " T " ports on the coupler control valve (it.3)
e) If the pressure build-up circuit is installed, check if the oil arrives, through hose CP3, at the double check valve (it. 17).
f) Verify following connections to the small solenoid valve (it. 11):
Port " T " to drain.
Port " P " to the pilot valve output port.
Port " A " to double check valve (it. 17).
g) Refer to the machine's Operation and Maintenance Guide and the Service Manual, check for any possibility that could cause interference with the coupler control circuit.
6. Let air bleed completely out of the line and tighten the connector.
7. Check that the cylinder rod goes out and pushes the locking wedge. If it does not, go back to point 5 and do the checks again.
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Improper installation of implements could result in injury or death. Do not attempt to install an attachment on the Quick Coupler if you are not familiar with the attachment installation procedures. Read and understand the procedures listed in the Cat Quick Coupler Operation and Maintenance Guide. |
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NOTE: It is good practice to keep a record of any modification and repair work carried out on your machine. Use the sheet on the next page to make a record of the parts that were installed and file it in the Machine History Folder.
