Installation of the 260-7976 Pilot Lines Gp on Certain 320Dand 323D Excavators{5057, 5059} Caterpillar


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Installation of the 260-7976 Pilot Lines Gp on Certain 320Dand 323D Excavators{5057, 5059} [GEHS0045]
HYDRAULIC SYSTEM
LINES GP-PILOT
Installation of the 260-7976 Pilot Lines Gp on Certain 320Dand 323D Excavators{5057, 5059}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Hose Connection Chart
5.1. Installation Procedure
6.2. Installation of the 260-7976 Pilot Lines Gp
Excavator:
320D (S/N: KGF1-UP; MCH1-UP; FAL1-UP; PHX1-UP)
323D (S/N: NDE1-UP; JLG1-UP; BYM1-UP)
Work Tool:
HYDRAULIC KIT (S/N: HKD1-UP)

Introduction

The Special Instruction, GEHS0045 is for the installation of the 260-7976 Pilot Lines Gp Revision level 11 If you need more information about the installation of the Pilot Lines Gp on your machine, consult your AVSpare dealer.

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 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.

----------------------

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

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

----------------------

Required Parts

Table 1
Parts List for 260-7976 Pilot Lines Gp Revision -11    
Item     Qty     Pt. No.     Part Name    
(1)     1     4I-1671     Hose As    
(2)     1     4I-3988     Hose As    
(3)     1     4I-6054     Hose As    
(4)     2     4I-9521     Hose Band (RED)    
(5)     2     4I-9522     Hose Band (YELLOW)    
(6)     4     4I-9523     Hose Band (BLUE)    
(7)     2     4I-9524     Hose Band (BROWN)    
(8)     2     4I-9525     Hose Band (ORANGE)    
(9)     2     4I-9526     Hose Band (WHITE)    
(10)     6     4I-9527     Hose Band (GREEN)    
(11)     1     5I-4396     Hose As    
(12)     4     6V-0852     Cap-Dust    
(13)     7     7K-1181     Cable Strap    
(14)     2     7Y-4366     Hose As    
(15)     2     087-4402     Hose As    
(16)     2     164-6874     Elbow Fitting    
(17)     1     398-2282     Solenoid Valve Gp    
(18)     1     259-7430     Solenoid Valve Gp    
(19)     1     266-1133     Hose As    
(20)     1     266-1179     Hose As    
(21)     1     275-1442     Clip    
(22)     1     275-1443     Clip    
(23)     1     275-1444     Grommet    
(24)     1     278-6470     Hose As    
(25)     1     289-5475     Support As    
(26)     1     330-2384     Hose As    
(27)     1     363-6132     Connector As    
(28)     1     363-6134     Adapter As    
(29)     3     148-8336     Connector As    
(30)     1     148-8338     Connector As    
(31)     11     148-8378     Elbow As    
(32)     1     148-8433     Tee As    
(33)     2     150-3036     Elbow As    
(34)     2     150-4027     Tee As    
(35)     4     164-5567     Quick Disconnect Coupler As    
(36)     3     8T-4121     Hard Washer    
(37)     3     8T-4136     Bolt    
(38)     4     8T-4177     Bolt    
(39)     4     8T-4224     Hard Washer    
(40)     2     8T-6870     Bolt    



Illustration 1g02733496

Hose Connection Chart

Table 2
Port Name     Band Color     Hose Number     Port Name    
Control valve     "aR2"     RED (4)     (2)     Selector valve     "A2"    
"bR2" BROWN (7)     (11)     Pilot Manifold     "DR4"    
F2 valve     "PU2"     YELLOW (5)     (3)     Selector valve     "A1"    
"PL2" ORANGE (8)     (1)     Pilot Manifold     "DR4"    
Negative control line flow control valve     "B2"     BLUE (6)     (19)     Pump     "Pn1"    
"A2" GREEN (10)     (24)     "Pn2"
"B1" BLUE (6)     (26)     Control valve     "HR"    
"A1" GREEN (10)     (20)     "HL"
"P" WHITE (9)     (15b)     Divider Block     "PB2"    
"T" GREEN (10)     (15a)     "DB2"
2 Solenoid valve     "P"     -     (14a)     "PB5"
"T" -     (14b)     "DB5"

Installation Procedure




Illustration 2g00104545

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your AVSpare dealer.

Installation of the 260-7976 Pilot Lines Gp

Table 3
Required Tools    
Tool     Pt. No.     Description     Qty    
(A)     FT-2674     Vacuum Cap     1    



    Illustration 3g01344378

  1. Release the hydraulic system pressure. Refer to Disassembly and Assembly, RENR8649, "System Pressure - Release".

  1. Remove the cap from the hydraulic tank. Install Tooling (A) onto the hydraulic tank. Attach an air supply hose onto Tooling (A). Apply 276 to 414 kPa (40 to 60 psi). This procedure will create a vacuum in the hydraulic system.



    Illustration 4g02734377

    Negative Flow Control (NFC) valve assembly

    (12) 6V-0852 Dust Cap

    (17) 398-2282 Solenoid Valve Gp

    (27) 363-6132 Connector As

    (31) 148-8378 Elbow As

    (34) 150-4027 Tee As

    (35) 164-5567 Quick Disconnect Coupler As

  1. Preassemble fittings onto Negative Flow Control (NFC) valve group (17) .



    Illustration 5g02734628

    Pump Compartment

    (17) 398-2282 Solenoid Valve Gp

    (38) 8T-4177 Bolt

    (39) 8T-4224 Hard Washer

  1. Mount the (NFC) valve group (17) to the previously installed support assembly.



    Illustration 6g02734644

    Two-bank solenoid valve

    (12) 6V-0852 Dust Cap

    (16) 164-6874 Elbow Fitting

    (18) 259-7430 Solenoid Valve Gp

    (25) 289-5475 Support As

    (28) 363-6134 Adapter As

    (31) 148-8378 Elbow As

    (35) 164-5567 Quick Disconnect Coupler As

    (36) 8T-4121 Hard Washer

    (37) 8T-4136 Bolt

    (40) 8T-6870 Bolt

  1. Preassemble fittings on to the two bank solenoid valve.



    Illustration 7g02735017

    (18) 259-7430 Solenoid Valve Gp

    (36) 8T-4121 Hard Washer

    (37) 8T-4136 Bolt

  1. Install valve (18) .



    Illustration 8g02735178

    (9) 4I-9526 Marker Band (White)

    (10) 4I-9527 Marker Band (Green)

    (15) 087-4402 Hose As

  1. Install hoses (15) .



    Illustration 9g02735355

    (6) 4I-9523 Marker Band (Blue)

    (19) 266-1133 Hose As

  1. Install hose (19) .



    Illustration 10g02735364

    (6) 4I-9523 Marker Band (Blue)

    (10) 4I-9527 Marker Band (Green)

    (20) 266-1179 Hose As

    (26) 330-2384 Hose As

    (31) 148-8378 Elbow As

  1. Install hose (20), and (26) .



    Illustration 11g02735397

    (10) 4I-9527 Marker Band (Green)

    (24) 278-6470 Hose As

  1. Install hose (24) .



    Illustration 12g02735401

    (14) 7Y-4366 Hose As

  1. Install hoses (14) .



    Illustration 13g02735402

    (2) 4I-3988 Hose As

    (3) 4I-6054 Hose As

    (4) 4I-9521 Marker Band (Red)

    (5) 4I-9522 Marker Band (Yellow)

    (29) 148-8336 Connector As

    (31) 148-8378 Elbow As

  1. Install hose (2), and (3) .



    Illustration 14g02736316

    (1) 4I-1671 Hose As

    (7) 4I-9524 Marker Band (Brown)

    (8) 4I-9525 Marker Band (Orange)

    (11) 5I-4396 Hose As

    (31) 148-8378 Elbow As

  1. Install hose (1), and (11) .

  1. Ensure that all bolts and fittings are tightened to proper torque. Check for leaks.

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