Installation of the 300-1191 Auxiliary Hydraulic Lines Gp {5057} Caterpillar


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Installation of the 300-1191 Auxiliary Hydraulic Lines Gp {5057} [REHS5144]
HYDRAULIC SYSTEM
LINES GP-AUXILIARY
Installation of the 300-1191 Auxiliary Hydraulic Lines Gp {5057}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Dimensions
5.1. Installation Procedure
Excavator:
320D (S/N: MCH1-UP; PHX1-UP)

Introduction

This special instruction covers the installation procedure for 300-1191 Auxiliary Hydraulic Lines Gp (Medium Pressure) on 320D Hydraulic Excavators.

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

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.

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

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

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Illustration 1g00104545

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

Required Parts




Illustration 2g02146693

Table 1
Parts List for 300-1191 Auxiliary Hydraulic Lines Gp    
Item     Qty     Part Number     Part Name    
(1)     2     153-8867     Clip    
(2)     4     173-7895     Clip    
(3)     4     179-5260     Clip    
(4)     1     202-3915     Plate    
(5)     1     247-9129     Tube As    
(6)     1     247-9132     Tube Gp    
(6A)     1         247-9135     Tube As    
(6B)     1         247-9138     Tube As    
(6C)     1         7J-9108     O-Ring Seal    
(7)     1     247-9141     Tube As    
(8)     1     247-9144     Tube Gp    
(8A)     1         247-9147     Tube As    
(8B)     1         268-6787     Tube As    
(8C)     1         7J-9108     O-Ring Seal    
(9)     1     247-9298     Clip As    
(10)     1     268-6790     Clip As    
(11)     2     294-3794     Clip As    
(12)     2     294-3795     Clip As    
(13)     1     294-3796     Plate    
(14)     1     294-3797     Plate    
(15)     2     093-1291     Clamp    
(16)     4     6V-8398     O-Ring Seal    
(17)     2     7J-9108     O-Ring Seal    
(18)     2     7X-2549     Bolt    
(19)     2     7Y-4868     Clip    
(20)     2     8T-4121     Hard Washer    
(21)     12     8T-4139     Bolt    
(22)     4     8T-4184     Bolt    
(23)     2     8T-4185     Bolt    
(24)     4     8T-4194     Bolt    
(25)     22     8T-4223     Hard Washer    
(26)     12     8T-4244     Nut    

Dimensions




Illustration 3g02146721

(A) 100 ± 5 mm (4 ± 0.2 inch)

(B) 300 ± 5 mm (12 ± 0.2 inch)

(C) 450 ± 5 mm (18 ± 0.2 inch)

(D) 150 ± 5 mm (6 ± 0.2 inch)

(E) 50 ± 5 mm (2 ± 0.2 inch)

(F) 220 ± 5 mm (8.7 ± 0.2 inch)

(G) 210 mm (8.3 inch)

Installation Procedure

Note: Tube assembly (5) and tube group (6) connect to the line to the (B) port of the medium pressure control valve. Tube assembly (7) and tube group (8) connect to the line to the (A) port of the medium pressure control valve.




    Illustration 4g02159873

    Detail D

    (11) 294-3794 Clip As

    (12) 294-3795 Clip As

    (13) 294-3796 Plate

    (22) 8T-4184 Bolt

    (24) 8T-4194 Bolt

    (25) 8T-4223 Hard Washer

    (26) 8T-4244 Nut

  1. Install plate (13) on the left side of the boom nose with washers (25), nuts (26), and bolts (22)

  1. Install clips (11) and (12) on plate (13) with washers (25) and bolts (24). Do not tighten the bolts.



    Illustration 5g02159899

    Detail C

    (10) 268-6790 Clip As

    (15) 093-1291 Clamp

    (19) 7Y-4868 Clip

    (20) 8T-4121 Hard Washer

    (21) 8T-4139 Bolt

    (23) 8T-4185 Bolt

    (25) 8T-4223 Hard Washer

  1. Install clip assembly (10) and clip (19) on the existing tubing with bolts (21) and washers (25). Position the clips 220 ± 5 mm (8.7 ± 0.2 inch) from the existing clips. Refer to dimension (F) in Illustration 3. Do not tighten the bolts.

  1. Position tube assembly (6B) on the boom in clips (11) and (12). Position the tube 210 mm (8.3 inch) from the center of the pin bore. Refer to dimension (G) in Illustration 3. Install clamp (15) on the tube with bolt (23) and washer (20) .



    Illustration 6g02159900

    Detail B

    (2) 173-7895 Clip

    (21) 8T-4139 Bolt

    (25) 8T-4223 Hard Washer

    (26) 8T-4244 Nut

  1. Install two clips (2) on the existing tube with bolts (21), washers (25), and nuts (26). Position the clips 150 ± 5 mm (6 ± 0.2 inch) from the existing clips. Refer to dimension (D) in Illustration 3. Do not tighten the bolts.

  1. Install seal (6C) in tube (6A). Connect tube assembly (6A) to tube assembly (6B). Install tube assembly (6A) in clips (2) .

  1. Install two clips (2) on the existing tube with bolts (21), washers (25), and nuts (26). Position the clips 450 ± 5 mm (18 ± 0.2 inch) from the existing clips. Refer to dimension (C) in Illustration 3. Do not tighten the bolts.



    Illustration 7g02159869

    Detail A

    (1) 153-8867 Clip

    (4) 202-3915 Plate

    (18) 7X-2549 Bolt

    (25) 8T-4223 Hard Washer

  1. Remove the existing bolts from the clips.

  1. Install plate (4) and clips (1) on the existing clip with bolts (18) and washers (25). Do not tighten the bolts.

  1. Install seal (17) in tube (5). Position tube assembly (5) in clips (1) and (2). Connect tube assembly (5) to tube assembly (6A) .



    Illustration 8g02173293

    Detail D

    (11) 294-3794 Clip As

    (12) 294-3795 Clip As

    (14) 294-3797 Plate

    (22) 8T-4184 Bolt

    (24) 8T-4194 Bolt

    (25) 8T-4223 Hard Washer

    (26) 8T-4244 Nut

  1. Install plate (14) on the right side of the boom nose with washers (25), nuts (26), and bolts (22)

  1. Install clips (11) and (12) on plate (14) with washers (25) and bolts (24). Do not tighten the bolts.



    Illustration 9g02173308

    Detail C

    (9) 247-9298 Clip As

    (15) 093-1291 Clamp

    (19) 7Y-4868 Clip

    (20) 8T-4121 Hard Washer

    (21) 8T-4139 Bolt

    (23) 8T-4185 Bolt

    (25) 8T-4223 Hard Washer

  1. Install clip assembly (9) and clip (19) on the existing tubing with bolts (21) and washers (25). Position the clips 220 ± 5 mm (8.7 ± 0.2 inch) from the existing clips. Refer to dimension (F) in Illustration 3. Do not tighten the bolts.

  1. Position tube assembly (8B) on the boom in clips (11) and (12). Position the tube 210 mm (8.3 inch) from the center of the pin bore. Refer to dimension (G) in Illustration 3. Install clamp (15) on the tube with bolt (23) and washer (20) .



    Illustration 10g02173344

    Detail B

    (3) 179-5260 Clip

    (21) 8T-4139 Bolt

    (25) 8T-4223 Hard Washer

    (26) 8T-4244 Nut

  1. Install two clips (3) on the existing tube with bolts (21), washers (25), and nuts (26). Position the clips 50 ± 5 mm (2 ± 0.2 inch) from the existing clips. Refer to dimension (E) in Illustration 3. Do not tighten the bolts.

  1. Install seal (8C) in tube (8A). Connect tube assembly (8A) to tube assembly (8B). Install tube assembly (8A) in clips (2) .

  1. Install two clips (3) on the existing tube with bolts (21), washers (25), and nuts (26). Position the clips 300 ± 5 mm (12 ± 0.2 inch) from the existing clips. Refer to dimension (B) in Illustration 3. Do not tighten the bolts.

  1. Install seal (17) in tube (7). Position tube assembly (7) in clips (1) and (2). Connect tube assembly (7) to tube assembly (8A) .

  1. Position the ends of tube (5) and tube (7) 100 ± 5 mm (4 ± 0.2 inch) from the clips. Refer to dimension (A) in Illustration 3.

  1. Tighten all fittings to the proper torques. Tighten all bolts to the proper torques.

    Note: Install seals (16) in tubes (6B) and (8B) prior to connecting to the stick lines. Install seals (16) in tubes (5) and (7) prior to connecting to the front lines.

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