Replacement Procedure for the Return Hose Assemblies on Certain 308E2 Excavators {5057, 5068} Caterpillar


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Replacement Procedure for the Return Hose Assemblies on Certain 308E2 Excavators {5057, 5068} [M0067128]
HYDRAULIC SYSTEM
FILTER GP
Replacement Procedure for the Return Hose Assemblies on Certain 308E2 Excavators {5057, 5068}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Replacement Procedure
5.2. Machine Preparation
6.2. Removal Procedure
7.2. Installation Procedure
Mini Hydraulic Excavator
308E2 CR (S/N: FJX1-UP)

Introduction

This special instruction includes the replacement procedure for the return hose assemblies on certain 308E2 Excavators. The replacement procedure for the return hose assemblies will improve resistance to kinking, improve fatigue characteristics, and reduce back pressure.

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

Safety Section

Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by AVSpare is safe.

Make sure that the product will not be damaged, made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

------ 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! ------

Accidental engine starting can cause injury or death to personnel working on the equipment.

To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system.

Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.


------ 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 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.



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, 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.


Required Parts

Table 1
Required Parts 
Item  Qty  New Part Number  Description  Former Part Number 
(1)  483-7473  Hose As  393-8268 
(2)  483-7474  Hose As  393-8254 
(3)  483-7475  Hose As  393-8255 
(4)  7X-7958  Hose Clamp  2S-3440 
(5)  5K-9090  O-Ring Seal  5K-9090 
(6)  6V-9847  Swivel Tee  6V-9840 
(7)  311-1362  Vacuum Gauge Gp   

Table 2
Hose Assembly Torque Specifications 
Item  Part Number  Clamp Torque  Hose Fitting Torque 
(1)  483-7473 Hose As  15 ± 2 N·m (11 ± 1.5 lb ft)(1)  90 ± 9 N·m (66.4 ± 6.6 lb ft) 
(2)  483-7474 Hose As  15 ± 2 N·m (11 ± 1.5 lb ft)(2)  90 ± 9 N·m (66.4 ± 6.6 lb ft) 
(3)  483-7475 Hose As  15 ± 2 N·m (11 ± 1.5 lb ft)(3)  90 ± 9 N·m (66.4 ± 6.6 lb ft) 
(1) Lower oil cooler clamp
(2) Upper oil cooler clamp
(3) Hydraulic tank clamp

Replacement Procedure

Machine Preparation

  1. Park machine on level ground with the implements lowered into the service position.

  2. Turn the engine switch and the battery isolator switch to the OFF position.

  3. Attach 311-1362 Vacuum Cap (7) onto the hydraulic tank. Attach an air supply hose onto the assembly. Apply 345 ± 69 kPa (50 ± 10 psi). This procedure will pull a vacuum on the hydraulic system.

Removal Procedure



    Illustration 1g06026384
    Hose assembly locations
    (8) 7D-7233 Clip
    (A) Oil cooler
    (B) Filter base
    (C) Hydraulic tank
    (D) 2S-3440 Hose Clamps
    (E) 6V-9840 Swivel Tee
    (F) 393-8268 Hose As
    (G) 393-8254 Hose As
    (H) 393-8255 Hose As

  1. Loosen the hose fittings and clamps (D) on filter base (B), oil cooler (A), and hydraulic tank (C).

  2. Remove clip (8) from hose assembly (H). Refer to Illustration 1 for the clip location.

    Note: Save the clip and hardware for the new hose assembly install.

  3. Remove the three return hose assemblies (F), (G), and (H) from oil cooler (A), filter base (B), and hydraulic tank (C). Refer to Illustration 1 for hose assembly locations.

  4. Remove swivel tee (E) from hydraulic filter base (B).

  5. Remove and discard the existing 5K-9090 O-Ring Seals at filter base (B) locations.

    Note: The hose assemblies and tee assembly can be discarded. The hose assemblies and tee assembly are not required for the new hose assembly install.

Installation Procedure



    Illustration 2g06024810
    New hose assemblies
    (1) 483-7473 Hose As
    (2) 483-7474 Hose As
    (3) 483-7475 Hose As
    (4) 7X-7958 Hose Clamp
    (6) 6V-9847 Swivel Tee
    (8) 7D-7233 Clip
    (A) Oil cooler
    (B) Filter base
    (C) Hydraulic tank


    Illustration 3g06024860
    Rear view of new hose assemblies
    (1) 483-7473 Hose As
    (2) 483-7474 Hose As
    (3) 483-7475 Hose As
    (4) 7X-7958 Hose Clamp
    (5) 5K-9090 O-Ring Seal
    (6) 6V-9847 Adapter Tee
    (A) Oil cooler
    (B) Filter base
    (C) Hydraulic tank

  1. Install a new o-ring seal (5) in hydraulic filter base (B) and connect adapter tee (6). Tighten the swivel tee to a torque of 90 ± 9 N·m (66.4 ± 6.6 lb ft). Refer to Illustration 2 and 3.

  2. Install a new o-ring seal (5) onto adapter tee (6) and connect the O-Ring Face Seal end of hose assembly (1). Tighten to a torque of 90 ± 9 N·m (66.4 ± 6.6 lb ft). Refer to Illustration 3 and Table 1.

  3. Use hose clamp (4) to connect the cut end of hose assembly (1) to the upper position of oil cooler (A). Tighten clamp to a torque of 15 ± 2 N·m (11 ± 1.5 lb ft). Refer to Illustration 3 and Table 1.

  4. Install a new o-ring seal (5) onto adapter tee (6) and connect the O-Ring Face Seal end of hose assembly (3). Tighten to a torque of 90 ± 9 N·m (66.4 ± 6.6 lb ft). Refer to Illustration 3 and Table 1.

  5. Use hose clamp (4) to connect the cut end of hose assembly (3) to hydraulic tank (C). Tighten clamp to a torque of 15 ± 2 N·m (11 ± 1.5 lb ft). Refer to Illustration 2 and Table 1.

  6. Install a new o-ring seal (5) onto filter base (B) and connect the O-Ring Face Seal end of hose assembly (2). Tighten to a torque of 90 ± 9 N·m (66.4 ± 6.6 lb ft). Refer to Illustration 3 and Table 1.

  7. Use hose clamp (4) to connect the cut end of hose assembly (2) to the lower position of oil cooler (A). Tighten clamp to a torque of 15 ± 2 N·m (11 ± 1.5 lb ft). Refer to Illustration 3 and Table 1.

    Note: Ensure not to twist or kink the hoses during installation.



    Illustration 4g06024855
    Clip install position
    (3) 483-7475 Hose As
    (8) 7D-7233 Clip
    (D) 10 ± 3 degrees

  8. Reinstall clip (8) with washer and bolt from Step 2 and torque bolt to 55 ± 10 N·m (40.6 ± 7.4 lb ft). Position clip (8) as shown in Illustration 4.

    Note: Ensure to position the clip 10 ± 3 degrees from the 6 o’clock position to ensure the proper support for the hose.

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