Installation of the 519-9196 Lines Gp - Coupler on Certain Backhoe Loaders {5057, 5133, 6129} Caterpillar

Backhoe Loader

416F2 (S/N: HWB1-UP)

420F2 ST (S/N: HWC1-UP)

430F2 ST (S/N: HWE1-UP)

Work Tool

QUICK COUPLER (S/N: ARJ1-UP; 7WW1-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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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	g06129575
Overview of the 519-9196 Lines Gp - Coupler

Note: * Item not shown in this media

Installation Procedure

Mounting Plate Weld Locations

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Illustration 2	g06129634
(B) 130 ± 3 mm (5 ± 1 inch) (C) 25 ± 5 mm (1 ± 1 inch) (D) 625 ± 5 mm (25 ± 1 inch) (E) 1260 ± 5 mm (50 ± 1 inch) (18) 418-9065 Plate (29) 7V-2882 Plate As

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Illustration 3	g06129668
(F) 180 ± 5 mm (7 ± 1 inch) (G) 92 ± 3 mm (4 ± 1/10 inch) (H) 25 ± 5 mm (1 ± 1 inch) (18) 418-9065 Plate, (**See Note) ( 29) 7V-2882 Plate As

1. Locate and mark the positions for the plates.

2. Remove the paint from the areas to be welded.

3. Remove any grease or debris.

4. Weld plates (18) and (29) as shown.

   Note: **Install plate (18) in line with existing tapped boss on lift arm.

5. Apply primer, then paint to all of the welded areas.

Hydraulic Components Installation

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Illustration 4	g06129703
Close up of area A (3) 8T-6466 Bolt (6) 8T-4121 Hard Washer (7) 8T-4178 Bolt (11) 148-8325 Connector As (13) 148-8368 Elbow As (14) 148-8407 Plug As (20) 418-9152 Coupler Valve and Mounting Gp (24) 520-8198 Mounting Plate, (***See Note) ( 27) 104-4980 Elbow As

1. Assemble coupler valve group as shown.
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   Illustration 5	g06129727
   (3) 8T-6466 Bolt (20) 418-9152 Coupler Valve and Mounting Gp (24) 520-8198 Mounting Plate, (***See Note)

2. Attach assembled valve group an mounting plate to the inside of the right-hand frame rail as shown.

   Note: *** If machine is equipped with "Ride Control Lines Gp", remove the existing bolts, install mounting plate (24), and re-attach with longer bolts provided in this kit.

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   Illustration 6	g06129733
   (12) 148-8367 Elbow As (15) 148-8423 Tee As (16) 148-8434 Tee As (17) 396-6935 Hose As (22) 441-2045 Hose As (23) 463-6898 Hose As

3. Install elbow and tee assemblies as shown.

4. Install and route hose (23) from port "LS" on the coupler valve to the "Load Sense" port on the pump.

5. Connect and route hose (22) from port "P" on the coupler valve to the "Pressure" port on the pump.

6. Install and route hose (17) from port "T" on the coupler valve to the port on the filter group as shown.
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   Illustration 7	g06129735
   (2) 8T-4195 Bolt (5) 8C-6561 Bolt (6) 8T-4121 Hard Washer (8) 8T-6869 Bolt (9) 086-9286 Clamp (10) 102-8703 Cover Plate (19) 418-9067 Plate As (25) 520-8220 Hose As (26) 520-8221 Hose As

7. Connect and route hoses (25) and (26) as shown.
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   Illustration 8	g06130118
   (2) 8T-4195 Bolt (5) 8C-6561 Bolt (6) 8T-4121 Hard Washer (8) 8T-6869 Bolt (9) 086-9286 Clamp (10) 102-8703 Cover Plate (19) 418-9067 Plate As (25) 520-8220 Hose As (26) 520-8221 Hose As (29) 7V-2882 Plate As

8. Install and route hoses (25), and (26) down the left-hand loader arm as shown.
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   Illustration 9	g06130134
   (4) 2P-1279 Locknut (5) 8C-6561 Bolt (9) 086-9286 Clamp (10) 102-8703 Cover Plate (18) 418-9065 Plate As (25) 520-8220 Hose As (26) 520-8221 Hose As (28) 148-8384 Elbow As (29) 7V-2882 Plate As

9. Finish routing hoses (25), and (26) to plate (18), then connect them to elbows (28) as shown.

10. Unless specified, tighten all fittings and hardware to standard torque.
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    Illustration 10	g00687600

11. Check for leaks.