Installation of the 255-2082 Pilot Lines Gp on Certain Hydraulic Excavators {5057, 5059} Caterpillar

Installation of the 255-2082 Pilot Lines Gp on Certain Hydraulic Excavators {5057, 5059} [M0067576]

HYDRAULIC SYSTEM

LINES GP-PILOT

Installation of the 255-2082 Pilot Lines Gp on Certain Hydraulic Excavators {5057, 5059}

1.1. Introduction

2.1. Safety Section

3.1. Required Parts

4.1. Installation Procedure

Excavator
330D (S/N: RDA1-UP; KAB1-UP; PFC1-UP; NBD1-UP; NEF1-UP; EAH1-UP; LCJ1-UP; FFK1-UP; PCK1-UP; RDK1-UP; LDR1-UP; MEY1-UP)
336D (S/N: SKE1-UP; PRF1-UP; WRK1-UP; MPL1-UP; JER1-UP; NLS1-UP; JBT1-UP; KKT1-UP; PGW1-UP; EMX1-UP)
336D2 (S/N: WBC1-UP; ELR1-UP; FAR1-UP; EFT1-UP)
340D (S/N: JTN1-UP)
Hydraulic Kit
HYDRAULIC KIT (S/N: HKD1-UP)

Introduction

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

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 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.

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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 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.

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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.

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Illustration 1	g00104545

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

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Table 1
255-2082 Pilot Lines Gp (- 14)
Item	Qty	Part No.	Part Name
(1)	1	4I-1671	Hose As
(2)	1	4I-6054	Hose As
(3)	4	4I-9523	Marker Band, BLUE
(4)	2	4I-9524	Marker Band, BROWN
(5)	2	4I-9525	Marker Band, ORANGE
(6)	2	4I-9526	Marker Band, WHITE
(7)	8	4I-9527	Marker Band, GREEN
(8)	1	5I-4396	Hose As
(9)	2	6V-0852	Dust Cap
(10)	13	7K-1181	Cable Strap
(11)	1	087-5766	Hose As
(12)	1	091-9035	Spacer
(13)	2	133-5813	Marker Band, GRAY
(14)	1	134-6921	Hose As
(15)	4	136-0207	Cable Strap
(16)	2	150-4027	Tee As
(17)	1	179-7616	Hose As
(18)	1	255-1900	Support As
(19)	1	275-1693	Support As
(20)	1	282-7566	Hose As
(21)	1	289-5283	Hose As
(22)	1	289-5286	Hose As
(23)	1	289-5289	Hose As
(24)	1	296-7079	Support As
(25)	1	296-7250	Support As
(26)	1	333-7060	Spacer
(27)	1	363-6132	Connector As
(28)	1	398-2282	Solenoid Valve Gp
(29)	4	418-6282	Hydraulic Lines Clamp Gp
(30)	1	148-8336	Connector As
(31)	2	148-8338	Connector As
(32)	7	148-8378	Elbow As
(33)	2	148-8433	Tee As
(34)	1	148-8435	Tee As
(35)	2	164-5567	Quick Disconnect Coupler As
(36)	1	3P-9847	Clip
(37)	2	5K-8451	Clip
(38)	1	6V-9829	Cap As
(39)	6	8T-4121	Hard Washer
(40)	3	8T-4136	Bolt
(41)	4	8T-4177	Bolt
(42)	1	8T-4182	Bolt
(43)	6	8T-4192	Bolt
(44)	1	8T-4195	Bolt
(45)	8	8T-4223	Hard Washer
(46)	4	8T-4224	Hard Washer
(47)	2	8T-4956	Bolt
(48)	1	8T-5436	Bolt
(49)	1	124-1008	Guard

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Illustration 2	g06048852
Overview of the 255-2082 Pilot Lines Gp

Installation Procedure

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Illustration 3	g06048931
Close up of area A (9) 6V-0852 Dust Cap (16) 150-4027 Tee As (18) 255-1900 Support As (27) 363-6132 Connector As (28) 398-2282 Solenoid Valve Gp (30) 148-8336 Connector As (32) 148-8378 Elbow As (35) 164-5567 Quick Disconnect Coupler As (41) 8T-4177 Bolts (43) 8T-4192 Bolts (45) 8T-4223 Hard Washers (46) 8T-4224 Hard Washers

Assemble valve group in area A as shown.

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Illustration 4	g06048982
(10) 7K-1181 Cable Strap (15) 136-0207 Cable Strap (18) 255-1900 Support As (19) 275-1693 Support As (24) 296-7079 Support As (25) 296-7250 Support As (26) 333-7060 Spacer (29) 418-6282 Hydraulic Lines Clamp Gp (36) 3P-9847 Clip (37) 5K-8451 Clip (39) 8T-4121 Hard Washer (40) 8T-4136 Bolt (43) 8T-4192 Bolt (44) 8T-4195 Bolt (45) 8T-4223 Hard Washer (47) 8T-4956 Bolt (48) 8T-5436 Bolt (49) 124-1008 Guard

Install valve group to the frame as shown.

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Illustration 5	g06049447
(31) 148-8338 Connector As, 24 ± 2 N·m (18 ± 1 lb ft) (32) 148-8378 Elbow As, 29 ± 3 N·m (22 ± 2 lb ft) (32) 148-8378 Elbow As, Port "DR6" only 24 ± 2 N·m (18 ± 1 lb ft) (33) 148-8433 Tee As (34) 148-8435 Tee As, 29 ± 3 N·m (22 ± 2 lb ft)

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Illustration 6	g06049903
(31) 148-8338 Connector As, 24 ± 2 N·m (18 ± 1 lb ft) (32) 148-8378 Elbow As, 29 ± 3 N·m (22 ± 2 lb ft) (33) 148-8433 Tee As (34) 148-8435 Tee As, 29 ± 3 N·m (22 ± 2 lb ft) (38) 6V-9829 Cap As

Install connectors, elbows, and tees into the main control valve and the control manifold as shown.

Note: In port "DR6" tighten elbow (32) to a torque of 24 ± 2 N·m (18 ± 1 lb ft)

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Illustration 7	g06050092
(1) 4I-1671 Hose As (2) 4I-6054 Hose As (3) 4I-9523 Marker Band, BLUE (4) 4I-9524 Marker Band, BROWN (5) 4I-9525 Marker Band, ORANGE (6) 4I-9526 Marker Band, WHITE (7) 4I-9527 Marker Band, GREEN (8) 5I-4396 Hose As (10) 7K-1181 Cable Strap (11) 087-5766 Hose As (13) 133-5813 Marker Band, GRAY (14) 134-6921 Hose As (15) 136-0207 Cable Strap (17) 179-7616 Hose As (22) 289-5286 Hose As (23) 289-5289 Hose As

Install hoses to main control valve and control manifold as shown.
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Illustration 8 g06050137

View from under the cab to show hose routing.
(7) 4I-9527 Marker Band, GREEN
(14) 134-6921 Hose As

Route hose (14) to the right-hand foot pedal under the cab as shown.

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Illustration 9	g06050154
(2) 4I-6054 Hose As (3) 4I-9523 Marker Band, BLUE (6) 4I-9526 Marker Band, WHITE (7) 4I-9527 Marker Band, GREEN (10) 7K-1181 Cable Strap (13) 133-5813 Marker Band, GRAY (15) 136-0207 Cable Strap (17) 179-7616 Hose As (20) 282-7566 Hose As (21) 289-5283 Hose As (22) 289-5286 Hose As (23) 289-5289 Hose As (49) 124-1008 Guard

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Illustration 10	g06050494
Close up of area B. (2) 4I-6054 Hose As (3) 4I-9523 Marker Band, BLUE (6) 4I-9526 Marker Band, WHITE (7) 4I-9527 Marker Band, GREEN (13) 133-5813 Marker Band, GRAY (20) 282-7566 Hose As (21) 289-5283 Hose As (22) 289-5286 Hose As (23) 289-5289 Hose As

Install and route hoses to the ports shown in the main pump compartment as shown.
Unless specified, tighten all fittings and hardware to standard torque.
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Illustration 11 g00687600
Check for leaks.