Installation of the 300-1190 Auxiliary Hydraulic Lines Gp {5057} Caterpillar


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Installation of the 300-1190 Auxiliary Hydraulic Lines Gp {5057} [REHS5143]
HYDRAULIC SYSTEM
LINES GP-AUXILIARY
Installation of the 300-1190 Auxiliary Hydraulic Lines Gp {5057}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Installation Procedure
Excavator:
320D (S/N: MDE1-UP; MCH1-UP; PHX1-UP; JGZ1-UP)

Introduction

This special instruction covers the installation procedure for 300-1190 Auxiliary Hydraulic Lines Gp (High Pressure) for 320D Hydraulic Excavators.

Do not perform any of the procedures until you have read the information in this publication.

Safety Section

------ 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.

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------ 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.

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

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

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 implement must always be lowered to the ground before service is started. When it is necessary for the implement to be in the raised position while tests or adjustments are done, be sure that the implements 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.

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

Note: If existing hydraulic lines will be disconnected, apply a vacuum to the hydraulic tank to minimize oil loss.




Illustration 1g00104545

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

Required Parts




Illustration 2g03360698

Table 1
Parts List for 300-1190 Auxiliary Hydraulic Lines Gp    
Item     Qty     Part Number     Part Name    
(1)     1     124-1107     Grommet    
(2)     1     129-5874     Grommet    
(3)     2     138-5708     Half Clip    
(4)     2     153-8798     Plate    
(5)     6     173-7916     Half Clamp    
(6)     1     173-7995     Plate    
(7)     2     193-6606     Plate    
(8)     1     202-7127     Plate    
(9)     2     202-7128     Plate    
(10)     1     216-6589     Hose As    
(11)     1     247-9030     Tube Gp    
(11a)     1     247-9033     Tube As    
(11b)     1     247-9034     Tube As    
(11c)     1     1P-3703     Rectangular Seal    
(11d)     4     8T-4139     Bolt    
(12)     1     277-0786     Support As    
(13)     1     288-7502     Hose As    
(14)     1     306-1611     Tube Gp    
(14a)     1     306-1614     Tube As    
(14b)     1     306-1615     Tube As    
(14c)     1     1P-3705     Rectangular Seal    
(14d)     4     8T-4183     Bolt    
(15)     2     124-1108     Clip    
(16)     2     1P-3703     Rectangular Seal    
(17)     2     1P-3704     Rectangular Seal    
(18)     4     1P-5767     Half Flange    
(19)     4     6V-0400     Half Flange    
(20)     4     7X-2549     Bolt    
(21)     2     7X-2553     Bolt    
(22)     6     7Y-4538     Half Clamp    
(23)     10     8T-4139     Bolt    
(24)     14     8T-4184     Bolt    
(25)     10     8T-4194     Bolt    
(26)     42     8T-4223     Hard Washer    
(27)     4     8T-4648     Bolt    
(28)     2     9X-8257     Washer    

Installation Procedure




    Illustration 3g02154625

    Detail A

    (8) 202-7127 Plate

    (9) 202-7128 Plate

    (20) 7X-2549 Bolt

    (26) 8T-4223 Hard Washer

  1. Remove the existing bolts from the clamps.

    Note: Plates (9) are placed under plate (8) .

  1. Position two plates (9) and one plate (8) on the boom. Install four hard washers (26) and four bolts (20) in plates (8) and (9) .



    Illustration 4g02154626

    Detail B

    (7) 193-6606 Plate

    (12) 277-0786 Support As

    (26) 8T-4223 Hard Washer

    (27) 8T-4648 Bolt

  1. Remove the existing bolts from the clamps.

    Note: plates (7) are placed under support assembly (12) .

  1. Position two plates (7) and one support assembly (12) on the boom. Install four hard washers (26) and four bolts (27) in plates (7) and (12) .



    Illustration 5g02154627

    Detail D

    (4) 153-8798 Plate

    (24) 8T-4184 Bolt

    (26) 8T-4223 Hard Washer

  1. Install two plates (4) at the boom nose. Use two hard washers (26) and two bolts (24) for each plate.



    Illustration 6g02145205

    (A) 220 mm (9 inch)

    (B) 240 mm (9.45 inch)

  1. Install grommet (2) on tube assembly (11b). Refer to Illustration 6 for the approximate location.

  1. Position tube assembly (11b) on the boom. Install two clips (15) on grommet (2). Install clips (15) on plate (8) with hard washers (26) and bolts (23). Do not tighten the bolts.

  1. Install two half clamps (22) on tube assembly (11b). Install the clamps on plate (12) with hard washers (26) and bolts (23). Do not tighten the bolts.

  1. Install rectangular seal (11c) in tube assembly (11b) .



    Illustration 7g03360711

    Detail C

    (11a) 247-9033 Tube As

    (22) 7Y-4538 Half Clamp

    (24) 8T-4184 Bolt

    (26) 8T-4223 Hard Washer

  1. Remove the existing bolts from the clamps.

  1. Position tube assembly (11a) on the boom. Install two half clamps (22) on tube assembly (11a). Install the clamps to the boom with hard washers (26) and bolts (24). Do not tighten the bolts.

    Note: Refer to Detail D

  1. Install two half clamps (22) on tube assembly (11a). Install the clamps on plate (4) with hard washers (26) and bolts (23). Do not tighten the bolts.

  1. Connect tube assemblies (11a) and (11b). Use four bolts (11d) .

  1. Position tube (11) according to Illustration 6. Tighten all of the bolts for the clamps.

  1. Install grommet (1) on tube assembly (14b). Refer to Illustration 6 for the approximate location.

  1. Position tube assembly (14b) on the boom. Install two half clips (3) on grommet (1). Install clips (3) on plate (8) with washers (28) and bolts (21). Do not tighten the bolts.

  1. Install two half clamps (5) on tube assembly (14b). Install the clamps on plate (12) with hard washers (26) and bolts (23). Do not tighten the bolts.

  1. Install rectangular seal (14c) in tube assembly (14b) .



    Illustration 8g03360712

    Detail C

    (5) 173-7916 Half Clamp

    (6) 173-7995 Plate

    (14a) 306-1614 Tube As

    (25) 8T-4194 Bolt

    (26) 8T-4223 Hard Washer

  1. Remove the existing bolts from the clamps.

  1. Position tube assembly (14a) on the boom. Install two half clamps (5) on tube assembly (14a). Install plate (6) and the clamps to the boom with hard washers (26) and bolts (25). Do not tighten the bolts.

    Note: Refer to Detail D

  1. Install two half clamps (5) on tube assembly (14a). Install the clamps on plate (4) with hard washers (26) and bolts (25). Do not tighten the bolts.

  1. Connect tube assemblies (14a) and (14b). Use four bolts (14d) .

  1. Position tube (14) according to Illustration 6. Tighten all of the bolts for the clamps.

  1. Install two rectangular seals (16) in hose as (13). Connect the 45 degree end of hose as (13) to tube (11). Use two half flanges (19), four hard washers (26), and four bolts (24). Connect the other end of hose (13) to the supply line (left side) of the front lines. Use two half flanges (19), four hard washers (26), and four bolts (24) .

  1. Install two rectangular seals (17) in hose assembly (10). Attach the 45 degree end of hose assembly (10) to tube (14). Use two half flanges (18), four hard washers (26), and four bolts (25). Connect the other end of hose (10) to the return line (right side) of the front lines. Use two half flanges (18), four hard washers (26), and four bolts (25).

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