- Excavator
- 345D (S/N: DPA1-UP; BYC1-UP; HLC1-UP; RAE1-UP; YEE1-UP; NEG1-UP; EEH1-UP; RAJ1-UP; MLK1-UP; JKN1-UP; FES1-UP; PBT1-UP; BYW1-UP)
- 349D (S/N: FLA1-UP; JGB1-UP; WTD1-UP; NNF1-UP; PZG1-UP; RBJ1-UP; MEN1-UP; KHS1-UP)
- 349D2 (S/N: XAC1-UP; PFD1-UP; YAE1-UP; TAH1-UP; SDM1-UP; RAN1-UP)
- 349D (S/N: FLA1-UP; JGB1-UP; WTD1-UP; NNF1-UP; PZG1-UP; RBJ1-UP; MEN1-UP; KHS1-UP)
Introduction
This Special Instruction outlines the installation procedure to retrofit a Boom Lowering Control Valve (BLCV) and a Stick Lowering Control Valve (SLCV) on the applicable machines listed.
Safety Section
Do not perform any procedure in this special instruction until you have read this special instruction and you understand this information. 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 in order 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. If the tools, the procedure, the work method, or your actions are not recommended by AVSpare, ensure that the tools and your actions are safe for you and for others.
Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
NOTICE |
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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. |
NOTICE |
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Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation. |
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Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted. When possible, the bucket or attachment must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and bucket or attachment have correct support. The swing lock (if equipped) must be engaged before service is started. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made. |
Check and Relief Valve Installation for Reach Boom and Mass Boom (Boom Lowering Control)
296-7134 Boom Cylinder Lines Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Strap-Cable | 18 | |
2 | Clip | 4 | |
3 | Clip | 4 | |
4 | Band-Marker (Gray, P) | 4 | |
5 | Tube As. | 1 | |
6 | Tube As. | 1 | |
7 | Support As. | 2 | |
8 | Hose As. | 1 | |
9 | Block | 1 | |
10 | Support As | 1 | |
11 | Hose As. | 2 | |
12 | Vavlve Gp-Load Control (Boom Cylinder) | 2 | |
13 | Valve Gp-Manual (Boom Lower) | 1 | |
14 | Hose As. | 1 | |
15 | Tube As. | 1 | |
16 | Tube As. | 1 | |
17 | Hose As. | 2 | |
18 | Hose As. | 2 | |
19 | Connector As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Connector | 1 | ||
20 | Connector As. | 2 | |
Seal-O-Ring | 2 | ||
Connector | 2 | ||
Seal-O-Ring | 2 | ||
21 | Connector As. | 6 | |
Seal-O-Ring | 6 | ||
Seal-O-Ring | 6 | ||
Connector | 6 | ||
22 | Elbow As. | 2 | |
Seal-O-Ring | 2 | ||
Elbow | 2 | ||
Seal-O-Ring | 2 | ||
23 | Elbow As. | 2 | |
Seal-O-Ring | 2 | ||
Seal-O-Ring | 2 | ||
Elbow | 2 | ||
24 | Elbow As. | 4 | |
Seal-O-Ring | 4 | ||
Seal-O-Ring | 4 | ||
Elbow | 4 | ||
25 | Plug As. | 1 | |
Seal-O-Ring | 1 | ||
Plug | 1 | ||
26 | Tee As.r | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 2 | ||
Tee | 1 | ||
27 | Connector As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Connector | 1 | ||
28 | Seal-Rectangular | 4 | |
29 | Seal-O-Ring | 2 | |
30 | Washer-Hard | 2 | |
31 | Bolt | 2 | |
32 | Bolt | 2 | |
33 | Washer-Hard | 18 | |
34 | Bolt | 8 | |
35 | Bolt | 8 | |
36 | Bolt-Socket Head | 8 |
302-3140 Pilot Lines Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Strap-Cable | 6 | |
2 | Hose As. | 1 | |
3 | Hose As. | 1 | |
4 | Hose As. | 1 | |
5 | Connector As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Connector | 1 | ||
6 | Elbow As. | 1 | |
Seal-O-Ring | 1 | ||
Elbow | 1 | ||
7 | Elbow As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Elbow | 1 | ||
8 | Elbow As. | 1 | |
Seal-O-Ring | 1 | ||
Elbow | 1 |
302-3139 Return Lines Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Strap-Cable | 2 | |
2 | Elbow As. | 1 | |
Seal-O-Ring | 1 | ||
Elbow | 1 | ||
3 | Hose As. | 1 | |
4 | Hose As. | 1 | |
5 | Hose As. | 1 | |
6 | Valve Gp- Load Control | 1 | |
7 | Connector As | 1 | |
Seal-O-Ring | 1 | ||
Connector | 1 | ||
Seal-O-Ring | 1 | ||
8 | Tee As. | 1 | |
Seal-O-Ring | 2 | ||
Tee-Swivel | 1 | ||
9 | Tee As. | 1 | |
Seal-O-Ring | 2 | ||
Tee-Swivel | 1 | ||
10 | Tee As. | 1 | |
Seal-O-Ring | 2 | ||
Tee | 1 | ||
Seal-O-Ring | 1 |
Check and Relief Valve Installation for Heavy Lift, R-Boom (Stick Lowering Control)
323-7681 Main Control Valve Gp to 323-7682 Main Control Valve Gp Rework | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Bolt | 2 | |
2 | Cover | 1 | |
3 | Plug | 1 | |
4 | Seal-O-Ring | 1 | |
5 | Ring-Backup | 1 |
230-0138 Boom Lines Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Bolt | 2 | |
2 | Bolt | 2 | |
3 | Bolt | 6 | |
4 | Clip | 6 | |
5 | Clip | 2 | |
6 | Hose As | 1 | |
7 | Hose As. | 2 | |
8 | Nut | 6 | |
9 | Nut | 2 | |
10 | Tube As. | 1 | |
11 | Plate. | 1 | |
12 | Plate | 1 | |
13 | Plate | 1 | |
14 | Seal-O-Ring | 2 | |
15 | Strap-Cable | 7 | |
16 | Union As. | 2 | |
Seal-O-Ring | 2 | ||
Union | 2 | ||
17 | Washer-Hard | 8 | |
18 | Washer-Hard | 2 | |
19 | Bolt | 2 | |
20 | Washer-Hard | 2 |
302-3283 Pilot Lines Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Hose As. | 1 | |
2 | Strap-Cable | 10 | |
3 | Hose As. | 1 | |
4 | Block | 1 | |
5 | Union As-Cross | 1 | |
Seal-O-Ring | 2 | ||
Tee | 1 | ||
6 | Hose As. | 1 | |
7 | Connector As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Connector | 1 | ||
8 | Connector As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Connector | 1 | ||
9 | Plug As. | 1 | |
Seal-O-Ring | 1 | ||
Plug | 1 | ||
10 | Tee As. | 1 | |
Seal-O-Ring | 2 | ||
Tee-Swivel | 1 | ||
11 | Seal-O-Ring | 1 | |
13 | Ring-Backup | 1 | |
14 | Bolt | 4 | |
15 | Washer-Hard | 4 | |
16 | Band-Marker (Blue, L3) | 4 | |
17 | Band-Marker (Gray, P) | 2 |
302-9546 Stick Cylinder Lines Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Bolt | 6 | |
2 | Bolt | 2 | |
3 | Bolt | 8 | |
4 | Bolt | 4 | |
5 | Bolt | 4 | |
6 | Clamp | 2 | |
7 | Clip | 4 | |
8 | Connector As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Connector | 1 | ||
9 | Elbow As. | 2 | |
Seal-O-Ring | 2 | ||
Seal-O-Ring | 2 | ||
Elbow | 2 | ||
10 | Tube As. | 1 | |
11 | Tube As. | 1 | |
12 | Tube As. | 1 | |
13 | Seal-O-Ring | 2 | |
14 | Seal-O-Ring | 1 | |
15 | Seal-Rectangular | 2 | |
16 | Support As. | 2 | |
17 | Support As. | 2 | |
18 | Tube As. | 1 | |
19 | Valve Gp-Load Control (Stick Cylinder) | 1 | |
20 | Washer-Hard | 6 | |
21 | Washer-Hard | 10 | |
22 | Washer-Hard | 4 |
323-7682 Main Control Valve Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Washer-Hard | 4 | |
2 | Bolt | 4 | |
3 | Valve Gp-Control (RH) | 1 | |
4 | Valve Gp-Control (LH) | 1 | |
5 | Seal-O-Ring | 6 | |
6 | Seal-Rectangular | 2 | |
7 | Seal-O-Ring | 2 | |
8 | Seal-O-Ring | 1 |
Check and Relief Valve Installation for Heavy Lift, M-Boom (Stick Lowering Control)
230-0140 Boom Lines Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Bolt | 2 | |
2 | Bolt | 2 | |
3 | Bolt | 2 | |
4 | Bolt | 4 | |
5 | Clip | 2 | |
6 | Clip | 4 | |
7 | Clip | 2 | |
8 | Hose As. | 2 | |
9 | Hose As. | 1 | |
10 | Nut | 4 | |
11 | Nut. | 2 | |
12 | Nut | 2 | |
13 | Tube As. | 1 | |
14 | Plate | 1 | |
16 | Plate | 1 | |
17 | Seal-O-Ring | 2 | |
18 | Strap-Cable | 6 | |
19 | Union As. | 2 | |
Seal-O-Ring | 2 | ||
Union | 2 | ||
20 | Washer | 8 | |
21 | Washer-Hard | 4 |
302-3283 Pilot Lines Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Hose As. | 1 | |
2 | Strap-Cable | 10 | |
3 | Hose As. | 1 | |
4 | Block | 1 | |
5 | Union As-Cross | 1 | |
Seal-O-Ring | 2 | ||
Tee | 1 | ||
6 | Hose As. | 1 | |
7 | Connector As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Connector | 1 | ||
8 | Connector As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Connector | 1 | ||
9 | Plug As. | 1 | |
Seal-O-Ring | 1 | ||
Plug | 1 | ||
10 | Tee As. | 1 | |
Seal-O-Ring | 2 | ||
Tee-Swivel | 1 | ||
11 | Seal-O-Ring | 1 | |
13 | Ring-Backup | 1 | |
14 | Bolt | 4 | |
15 | Washer-Hard | 4 | |
16 | Band-Marker (Blue, L3) | 4 | |
17 | Band-Marker (Gray, P) | 2 |
302-9546 Stick Cylinder Lines Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Bolt | 6 | |
2 | Bolt | 2 | |
3 | Bolt | 8 | |
4 | Bolt | 4 | |
5 | Bolt | 4 | |
6 | Clamp | 2 | |
7 | Clip | 4 | |
8 | Connector As. | 1 | |
Seal-O-Ring | 1 | ||
Seal-O-Ring | 1 | ||
Connector | 1 | ||
9 | Elbow As. | 2 | |
Seal-O-Ring | 2 | ||
Seal-O-Ring | 2 | ||
Elbow | 2 | ||
10 | Tube As. | 1 | |
11 | Tube As. | 1 | |
12 | Tube As. | 1 | |
13 | Seal-O-Ring | 2 | |
14 | Seal-O-Ring | 1 | |
15 | Seal-Rectangular | 2 | |
16 | Support As. | 2 | |
17 | Support As. | 2 | |
18 | Tube As. | 1 | |
19 | Valve Gp-Load Control (Stick Cylinder) | 1 | |
20 | Washer-Hard | 6 | |
21 | Washer-Hard | 10 | |
22 | Washer-Hard | 4 |
323-7682 Main Control Valve Gp | |||
---|---|---|---|
Item | Part Number | Part Name | Qty |
1 | Washer-Hard | 4 | |
2 | Bolt | 4 | |
3 | Valve Gp-Control (RH) | 1 | |
4 | Valve Gp-Control (LH) | 1 | |
5 | Seal-O-Ring | 6 | |
6 | Seal-Rectangular | 2 | |
7 | Seal-O-Ring | 2 | |
8 | Seal-O-Ring | 1 |
Machine Preparation
- Position the machine on level ground.
- Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the ground. Lower the boom until the bucket is flat on the ground.
- Shut off the engine.
- Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".
Boom Lowering Control Valve - Reach Boom/Mass Boom
- Remove support (A1) and clip (A2).
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Table 13 Standard Removal Parts Before Installation of 296-7134 Boom Cylinder Lines Gp Item Part Number Part Name Qty A1 128-7591 Support As 1 A2 108-7550 Clip 1 Show/hide tableIllustration 2 g06034807 289-5734 Boom Cylinder Lines Gp
(B1)8T-4648 Bolt
(B2)8T-4223 Hard Washer
(B3)292-7437 Tube As
(B4)1P-3704 Rectangular Seal
(B5)8T-4139 Bolt
(B6)8T-4223 Hard Washer
(B7)462-3581 Support As
(B8)106-7550 Plate As - Remove the four bolts (B1) and washers (B2) that secure tube (B3) to the left boom cylinder. Remove the two bolts (B5) and washers (B6) that secure clip (B8) to support (B7). Remove the tube and discard seal (B4).
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Table 14 Standard Removal Parts Before Installation of 296-7134 Boom Cylinder Lines Gp Item Part Number Part Name Qty B1 8T-4648 Bolt 4 B2 8T-4223 Hard Washer 4 B3 292-7437 Tube As 1 B4 1P-3704 Rectangular Seal 1 B5 8T-4139 Bolt 2 B6 8T-4223 Hard Washer 2 B7 462-3581 Support As 1 B8 106-7550 Plate As 1 - Repeat the previous step for the right boom cylinder.
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Illustration 3 g06034835 263-1964 Load Control Valve Gp
(C1)225-4820 Plug As
(C2)225-4820 Plug As - Remove plug (C1) and plug (C2) from the load control valve.
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Table 15 Standard Removal Parts Before Installation of 296-7134 Boom Cylinder Lines Gp Item Part Number Part Name Qty C1 225-4820 Plug As 1 C2 225-4820 Plug As 1 Show/hide tableIllustration 4 g02818876 296-7134 Boom Cylinder Lines Gp - Install 296-7134 Boom Cylinder Lines Gp shown in Illustration 4. Refer to Table 1 for the list of parts.
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Illustration 5 g06035329 302-2985 Pilot Lines Gp
(D1)329-2793 Hose As - Remove hose (D1).
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Table 16 Standard Removal Parts Before Installation of 302-3140 Pilot Lines Gp Item Part Number Part Name Qty D1 329-2793 Hose As 1 Show/hide tableIllustration 6 g06035337 302-3140 Pilot Lines Gp
(D1)292-7163 Pump Lines Gp - Remove plug (E1).
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Table 17 Standard Removal Parts Before Installation of 302-3140 Pilot Lines Gp Item Part Number Part Name Qty E1 148-8411 Plug As 1 Show/hide tableIllustration 7 g06035342 292-7160 Boom Cylinder Lines Gp
(F1)148-8353 Elbow As - Remove adapter (F1).
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Table 18 Standard Removal Parts Before Installation of 302-3140 Pilot Lines Gp Item Part Number Part Name Qty F1 148-8353 Elbow As 1 Show/hide tableIllustration 8 g01883293 302-3140 Pilot Lines Gp - Install 302-3140 Pilot Lines Gp shown in Illustration 8. Refer to Table 2 for the list of parts.
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Illustration 9 g06035365 292-7161 Front Lines Gp
(G1)330-2318 Hose As - Remove hose (G1).
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Table 19 Standard Removal Parts Before Installation of 302-3139 Return Lines Gp Item Part Number Part Name Qty G1 330-2318 Hose As 1 Show/hide tableIllustration 10 g06035370 292-7162 Swing Motor Lines Gp
(H1)148-8431 Tee As
(H2)319-9775 Hose As - Remove tee (H1) and hose (H2).
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Table 20 Standard Removal Parts Before Installation of 302-3139 Return Lines Gp Item Part Number Part Name Qty H1 148-8431 Tee As 1 H2 319-9775 Hose As 1 Show/hide tableIllustration 11 g06035382 Boom Cylinder Lines Gp
(J1) Pilot Valve Gp - Remove pilot valve (J1).
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Table 21 Standard Removal Parts Before Installation of 302-3139 Return Lines Gp Item Part Number Part Name Qty J1 448-7593 Pilot Valve Gp (Standard) 1 448-7594 Pilot Valve Gp (Heavy Lift) 1 Show/hide tableIllustration 12 g01637137 302-3139 Return Lines Gp - Install 302-3139 Return Lines Gp shown in Illustration 12. Refer to Table 3 for the list of parts.
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Illustration 1 | g06034784 |
(A1) (A2) |
Stick Lowering Control Valve - Heavy Lift, Reach Boom
- The 323-7681 Main Control Valve Gp must be updated to the 323-7703 Main Control Valve Gp. Perform the following steps to make the conversion.
- Remove bolts (A1) and bolts (A3) that secure pilot valve (A2). Remove the pilot valve.
- Remove relief valve (A4).
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Table 22 Standard Removal Parts To Convert 323-7681 Main Control Valve Gp To 323-7682 Main Control Valve Gp Item Part Number Part Name Qty A1 447-1703 Bolt 2 A2 270-5698 Pilot Valve Gp 1 A3 447-1706 Bolt 2 A4 352-7204 Relief Valve Gp 1 Show/hide tableIllustration 14 g06035414 323-7682 Main Control Valve Gp - Install O-ring (4) and backup ring (5). Place cover (2) onto the valve and secure with two bolts (1) and the remaining two bolts and washers that were removed in the Step a. Refer to Table 4 for the list of part numbers.
- Install plug (3).
Show/hide tableIllustration 13 g06035403 323-7681 Main Control Valve Gp
(A1)447-1703 Bolt
(A2)270-5698 Pilot Valve Gp
(A3)447-1706 Bolt
(A4)352-7204 Relief Valve GpShow/hide tableIllustration 15 g06035445 245-4930 Boom Lines Gp
(B1)453-2838 Bolt
(B2)451-2175 Hard Washer - Remove two bolts (B1) and the washers.
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Table 23 Standard Removal Parts Before Installation of 230-0138 Boom Lines Gp Item Part Number Part Name Qty B1 453-2838 Bolt 2 B2 451-2175 Hard Washer 2 - For machines not equipped with auxiliary lines proceed to Step 4. For machines that are equipped with auxiliary lines, proceed to Step a.
- Remove four bolts (C1), four washers (C2) and plate (C3).
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Table 24 Standard Removal Parts Before Installation of 230-0138 Boom Lines Gp Item Part Number Part Name Qty C1 453-1256 Bolt 4 C2 451-2175 Hard Washer 4 C2 132-1596 Plate 1
Show/hide tableIllustration 16 g06035472 230-0114 Auxiliary Hydraulic Lines Gp
(C1)453-1256 Bolt
(C2)451-2175 Hard Washer
(C2)132-1596 PlateShow/hide tableIllustration 17 g01518688 230-0138 Boom Lines Gp - Remove four bolts (C1), four washers (C2) and plate (C3).
- Install 230-0138 Boom Lines Gp shown in Illustration 17. Refer to Table 5 for the list of parts.
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Illustration 18 g06035576 302-2985 Pilot Lines Gp
(D1)115-3667 Hose As
(D2)133-5813 Marker Band
(D3)148-8378 Elbow As
(D4)148-8353 Elbow As - Remove hose (D1) and marker band (D2). Remove elbow (D3) and elbow (D4).
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Table 25 Standard Removal Parts Before Installation of 302-3283 Pilot Lines Gp Item Part Number Part Name Qty D1 115-3667 Hose As 1 D2 133-5813 Marker Band 1 D3 148-8378 Elbow As 1 D4 148-8353 Elbow As 1 Show/hide tableIllustration 19 g06035584 292-7163 Pump Lines Gp
(E1)148-8411 Plug As - Remove plug (E1) from the tube.
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Table 26 Standard Removal Parts Before Installation of 302-3283 Pilot Lines Gp Item Part Number Part Name Qty E1 148-8411 Plug As 1 Show/hide tableIllustration 20 g06035605 302-3141 Return Lines Gp
(F1)148-8445 Tee As - Remove tee (F1).
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Table 27 Standard Removal Parts Before Installation of 302-3283 Pilot Lines Gp Item Part Number Part Name Qty F1 148-8445 Tee As 1 Show/hide tableIllustration 21 g02370601 302-3283 Pilot Lines Gp - Install 302-3283 Pilot Lines Gp shown in Illustration 21. Refer to Table 10 for the list of parts.
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Illustration 22 g06035619 129-5973 Stick Cylinder Lines Gp
(G1)134-6844 Tube As
(G2)7Y-7992 Bolt
(G3)8T-4223 Hard Washer
(G4)1P-3704 Rectangular Seal
(G5)457-5821 Bolt
(G6)453-3454 Hard Washer
(G7)462-3576 Support As
(G8)447-1707 Bolt
(G9)3E-4356 Hard Washer
(G10)124-0909 Clip
(G11)462-3574 Support As - Remove parts (G2) through (G11) to remove tube (G1) from the stick cylinder. Leave one of the clamp assemblies attached for the installation of the next group.
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Table 28 Standard Removal Parts Before Installation of 302-9546 Stick Cylinder Lines Gp Item Part Number Part Name Qty G1 134-6844 Tube As 1 G2 7Y-7992 Bolt 4 G3 8T-4223 Hard Washer 4 G4 1P-3704 Rectangular Seal 1 G5 457-5821 Bolt 4 G6 453-3454 Hard Washer 4 G7 462-3576 Support As 1 G8 447-1707 Bolt 2 G9 3E-4356 Hard Washer 2 G10 124-0909 Clip 4 G11 462-3574 Support As 1 Show/hide tableIllustration 23 g01477732 302-9546 Stick Cylinder Lines Gp - Install 302-9546 Stick Cylinder Lines Gp shown in Illustration 23. Refer to Table 11 for the list of parts.
Stick Lowering Control Valve - Mass Boom
- The 323-7681 Main Control Valve Gp must be updated to the 323-7682 Main Control Valve Gp. Perform the following steps to make the conversion.
- Remove bolts (A1) and bolts (A3) that secure pilot valve (A2). Remove the pilot valve.
- Remove relief valve (A4).
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Table 29 Standard Removal Parts To Convert 323-7681 Main Control Valve Gp To 323-7682 Main Control Valve Gp Item Part Number Part Name Qty A1 447-1703 Bolt 2 A2 270-5698 Pilot Valve Gp 1 A3 447-1706 Bolt 2 A4 352-7204 Relief Valve Gp 1 Show/hide tableIllustration 25 g06035414 323-7682 Main Control Valve Gp - Install O-ring (4) and backup ring (5). Place cover (2) onto the valve and secure with two bolts (1) and the remaining two bolts and washers that were removed in Step a. Refer to Table 4 for the list of part numbers.
- Install plug (3).
Show/hide tableIllustration 24 g06035403 323-7681 Main Control Valve Gp
(A1)447-1703 Bolt
(A2)270-5698 Pilot Valve Gp
(A3)447-1706 Bolt
(A4)352-7204 Relief Valve GpShow/hide tableIllustration 26 g06035731 248-9445 Boom Lines Gp
(B1)453-2838 Bolt
(B2)451-2175 Hard Washer - Remove two bolts (B1) and washers (B2).
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Table 30 Standard Removal Parts Before Installation of 230-0140 Boom Lines Gp Item Part Number Part Name Qty B1 453-2838 Bolt 2 B2 451-2175 Hard Washer 2 - For machines not equipped with auxiliary lines proceed to Step 4. For machines that are equipped with auxiliary lines, proceed to Step a.
- Remove four bolts (C1), four washers (C2) and plate (C3).
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Table 31 Standard Removal Parts Before Installation of 230-0140 Boom Lines Gp Item Part Number Part Name Qty C1 453-1256 Bolt 4 C2 451-2175 Hard Washer 4 C3 132-1595 Plate 1
Show/hide tableIllustration 27 g06035747 230-0117 Auxiliary Hydraulic Lines Gp
(C1)453-1256 Bolt
(C2)451-2175 Hard Washer
(C3)132-1595 PlateShow/hide tableIllustration 28 g03586416 230-0140 Boom Lines Gp - Remove four bolts (C1), four washers (C2) and plate (C3).
- Install 230-0140 Boom Lines Gp shown in Illustration 28. Refer to Table 9 for the list of parts.
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Illustration 29 g06035576 302-2985 Pilot Lines Gp
(D1)115-3667 Hose As
(D2)133-5813 Marker Band
(D3)148-8378 Elbow As
(D4)148-8353 Elbow As - Remove hose (D1) and marker band (D2). Remove elbow (D3) and elbow (D4).
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Table 32 Standard Removal Parts Before Installation of 302-3283 Pilot Lines Gp Item Part Number Part Name Qty D1 115-3667 Hose As 1 D2 133-5813 Marker Band 1 D3 148-8378 Elbow As 1 D4 148-8353 Elbow As 1 Show/hide tableIllustration 30 g06035584 292-7163 Pump Lines Gp
(E1)148-8411 Plug As - Remove plug (E1) from the tube.
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Table 33 Standard Removal Parts Before Installation of 302-3283 Pilot Lines Gp Item Part Number Part Name Qty E1 148-8411 Plug As 1 Show/hide tableIllustration 31 g06035605 302-3141 Return Lines Gp
(F1)148-8445 Tee As - Remove tee (F1).
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Table 34 Standard Removal Parts Before Installation of 302-3283 Pilot Lines Gp Item Part Number Part Name Qty F1 148-8445 Tee As 1 Show/hide tableIllustration 32 g02370601 302-3283 Pilot Lines Gp - Install 302-3283 Pilot Lines Gp shown in Illustration 32. Refer to Table 10 for the list of parts.
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Illustration 33 g06035619 129-5973 Stick Cylinder Lines Gp
(G1)134-6844 Tube As
(G2)7Y-7992 Bolt
(G3)8T-4223 Hard Washer
(G4)1P-3704 Rectangular Seal
(G5)457-5821 Bolt
(G6)453-3454 Hard Washer
(G7)462-3576 Support As
(G8)447-1707 Bolt
(G9)3E-4356 Hard Washer
(G10)124-0909 Clip
(G11)462-3574 Support As - Remove parts (G2) through (G11) to remove tube (G1) from the stick cylinder. Leave one of the clamp assemblies attached for the installation of the next group.
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Table 35 Standard Removal Parts Before Installation of 302-9546 Stick Cylinder Lines Gp Item Part Number Part Name Qty G1 134-6844 Tube As 1 G2 7Y-7992 Bolt 4 G3 8T-4223 Hard Washer 4 G4 1P-3704 Rectangular Seal 1 G5 457-5821 Bolt 4 G6 453-3454 Hard Washer 4 G7 462-3576 Support As 1 G8 447-1707 Bolt 2 G9 3E-4356 Hard Washer 2 G10 124-0909 Clip 4 G11 462-3574 Support As 1 Show/hide tableIllustration 34 g01477732 302-9546 Stick Cylinder Lines Gp - Install 302-9546 Stick Cylinder Lines Gp shown in Illustration 34. Refer to Table 11 for the list of parts.