Installation Procedure for the <NOBR>492-2301</NOBR> Front Lines Gp On Certain Hydraulic Excavators {5057} Caterpillar


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Installation Procedure for the <NOBR>492-2301</NOBR> Front Lines Gp On Certain Hydraulic Excavators {5057} [M0066926]
HYDRAULIC SYSTEM
LINES GP-FRONT
Installation Procedure for the <NOBR>492-2301</NOBR> Front Lines Gp On Certain Hydraulic Excavators {5057}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Installation Procedure
Excavator
390F (S/N: MGF1-UP; HSM1-UP)
Work Tool
HYDRAULIC KIT (S/N: HKF1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

------ WARNING! ------

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.


------ WARNING! ------

Personal injury or death can result from sudden work tool movement.

Sudden movement of the work tool can cause injury to persons near the work tool.

To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool.


------ WARNING! ------

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 attachments have been lowered, 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.


------ WARNING! ------

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.



NOTICE

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, PERJ1017, "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.




Illustration 1g00104545

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 before you service the equipment . These warning tags (Special Instruction, SEHS7332) are available from your AVSpare dealer.

Required Parts

Table 1
Parts List for 492-2301 Front Lines Gp (- 02) 
Item  Qty  Part No.  Part Name 
(1)  505-7037  Plate 
(2)  4I-9521  Marker Band (Red) 
(3)  4I-9522  Marker Band (Yellow) 
(4)  7K-1181  Cable Strap 
(5)  123-4750  Check Valve As 
(6)  168-1968  Tee As 
(7)  241-6215  Elbow As 
(8)  328-2035  Solenoid Valve and Manifold Gp 
(9)  337-1327  Boss 
(10)  383-9405  Support As 
(11)  439-9078  Support As 
(12)  454-0504  Check Valve Gp 
(13)  457-9869  Spacer 
(14)  464-8577  Hose As 
(15)  492-2295  Hose As 
(16)  492-2296  Hose As 
(17)  492-2297  Hose As 
(18)  492-2298  Hose As 
(19)  492-2299  Hose As 
(20)  492-2300  Hose As 
(21)  141-6348  Bolt 
(22)  148-8310  Adapter As 
(23)  148-8336  Connector As 
(24)  148-8353  Elbow As 
(25)  148-8378  Elbow As 
(26)  148-8407  Plug As 
(27)  150-3036  Elbow As 
(28)  164-5546  Tee As 
(29)  164-5567  Quick Disconnect Coupler As 
(30)  164-9869  Connector As 
(31)  3J-1907  O-Ring Seal 
(32)  5P-7464  Clip 
(33)  5P-7465  Clip 
(34)  6V-0852  Dust Cap 
(35)  6V-1249  Grommet 
(36)  8T-7547  Bolt 
(37)  6V-8076  Elbow 
(38)  13  8T-4121  Hard Washer 
(39)  8T-4136  Bolt 
(40)  8T-4195  Bolt 
(41)  8T-4196  Bolt 
(42)  8T-4198  Bolt 
(43)  8T-4224  Hard Washer 


Illustration 2g06023015
492-2301 Front Lines Gp

Installation Procedure



    Illustration 3g06449404
    Close up of Area (A), left-hand side.
    (1) 505-7037 Plate
    (8a) 328-2035 Solenoid Valve and Manifold Gp
    (8b) 328-2035 Solenoid Valve and Manifold Gp
    (12) 454-0504 Check Valve Gp
    (13) 457-9869 Spacer
    (14) 464-8577 Hose As
    (17) 492-2297 Hose As
    (18) 492-2298 Hose As
    (22) 148-8310 Adapter As
    (23) 148-8336 Connector As, NOTE: Install bracket and solenoid valves to the machine before installing this connector due to clearance issues with bolt (36).
    (24) 148-8353 Elbow As
    (25) 148-8378 Elbow As
    (26) 148-8407 Plug As
    (27) 150-3036 Elbow As
    (36) 8T-7547 Bolt
    (37) 6V-8076 Elbow
    (38) 8T-4121 Hard Washer
    (39) 8T-4136 Bolt
    (42) 8T-4198 Bolt
    (43) 8T-4224 Hard Washer


    Illustration 4g06449407
    Close up of Area (A), right-hand side.
    (1) 505-7037 Plate
    (8a) 328-2035 Solenoid Valve and Manifold Gp
    (8b) 328-2035 Solenoid Valve and Manifold Gp
    (12) 454-0504 Check Valve Gp
    (13) 457-9869 Spacer
    (14) 464-8577 Hose As
    (17) 492-2297 Hose As
    (18) 492-2298 Hose As
    (22) 148-8310 Adapter As
    (23) 148-8336 Connector As
    (24) 148-8353 Elbow As
    (25) 148-8378 Elbow As
    (26) 148-8407 Plug As
    (27) 150-3036 Elbow As
    (30) 164-9869 Connector As, NOTE: Install bracket and solenoid valves to the machine before installing this connector due to clearance issues with bolt (36).
    (36) 8T-7547 Bolt
    (37) 6V-8076 Elbow
    (38) 8T-4121 Hard Washer
    (39) 8T-4136 Bolt
    (40) 8T-4195 Bolt
    (42) 8T-4198 Bolt
    (43) 8T-4224 Hard Washer


    Illustration 5g06449408
    Close up of Area (A) connecting hose routing, left-hand side.
    (8a) 328-2035 Solenoid Valve and Manifold Gp
    (8b) 328-2035 Solenoid Valve and Manifold Gp
    (14) 464-8577 Hose As
    (17) 492-2297 Hose As
    (18) 492-2298 Hose As


    Illustration 6g06450756
    Close up of Area (A) connecting hose routing, right-hand side.
    (8a) 328-2035 Solenoid Valve and Manifold Gp
    (8b) 328-2035 Solenoid Valve and Manifold Gp
    (14) 464-8577 Hose As
    (17) 492-2297 Hose As
    (18) 492-2298 Hose As

  1. Assembly the control valves onto the plate as shown.


    Illustration 7g06450789
    (1) 505-7037 Plate
    (2) 4I-9521 Marker Band (Red)
    (3) 4I-9522 Marker Band (Yellow)
    (4) 7K-1181 Cable Strap
    (8a) 328-2035 Solenoid Valve and Manifold Gp
    (8b) 328-2035 Solenoid Valve and Manifold Gp
    (10) 383-9405 Support As
    (12) 454-0504 Check Valve Gp
    (15) 492-2295 Hose As
    (16) 492-2296 Hose As
    (19) 492-2299 Hose As
    (20) 492-2300 Hose As
    (32) 5P-7464 Clip
    (33) 5P-7465 Clip
    (35) 6V-1249 Grommet
    (36) 8T-7547 Bolt
    (38) 8T-4121 Hard Washer
    (39) 8T-4136 Bolt
    (40) 8T-4195 Bolt
    (43) 8T-4224 Hard Washer

  2. Install valve assembly (A) onto the frame.

  3. Connect hose (19) to port "P" of solenoid valve (8a).

    Note: On the check valve side, tighten hose (19) to a torque of 40 ± 4 N·m (30± 3 lb ft).

  4. Connect hose (15) to port "T" on solenoid valve (8a), and hose (16) to port "T" solenoid valve (8b).


    Illustration 8g06450820
    Right-hand frame rail removed in the graphic for part location purposes only.
    (B) "LOCK"
    (C) "UNLOCK"
    (2) 4I-9521 Marker Band (Red)
    (3) 4I-9522 Marker Band (Yellow)
    (12) 454-0504 Check Valve Gp
    (20) 492-2300 Hose As

  5. Connect the red hose (20) to port "P1" of check valve (12).

    Note: Oil flow goes to the cab side line (No. 1) when switch is in "Locking Position". Alternate routing: hoses must be reversed according to the type of quick coupler installed.

  6. Connect the yellow hose (20) to port "S1" of check valve (12).

    Note: Oil flow goes to the cab side line (No. 1) when switch is in "Locking Position". Alternate routing: hoses must be reversed according to the type of quick coupler installed.



    Illustration 9g06450826
    View from under the main control valve on the left-hand side.
    (4) 7K-1181 Cable Strap
    (6) 168-1968 Tee As
    (15) 492-2295 Hose As
    (16) 492-2296 Hose As
    (25) 148-8378 Elbow As

  7. Route hoses (15), and (16) under the main control valve and connect to the main drain line as shown.


    Illustration 10g06450940
    (10) 383-9405 Support As
    (11) 439-9078 Support As
    (19) 492-2299 Hose As
    (32) 5P-7464 Clip
    (33) 5P-7465 Clip
    (35) 6V-1249 Grommet
    (38) 8T-4121 Hard Washer
    (39) 8T-4136 Bolt
    (40) 8T-4195 Bolt

  8. Route hose (19) to the main pump as shown.

    Note: On the check valve side, tighten hose (19) to a torque of 40 ± 4 N·m (30± 3 lb ft).



    Illustration 11g06450948
    (5) 123-4750 Check Valve As, 34 ± 4 N·m (25 ± 3 lb ft)
    (19) 492-2299 Hose As
    (28) 164-5546 Tee As
    (29) 164-5567 Quick Disconnect Coupler As
    (34) 6V-0852 Dust Cap

  9. Connect hose (19) to the test port of the manifold block on the main pump that is closest to the engine.

    Note: On the check valve side, tighten hose (19) to a torque of 40 ± 4 N·m (30± 3 lb ft).

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


    Illustration 12g00687600

  11. Check for leaks.

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