Procedure to Install <NOBR>214-3287</NOBR> Drain Lines Group on Certain C, D, E, F, and Next Generation Series Excavators {0679, 5057} Caterpillar


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Procedure to Install <NOBR>214-3287</NOBR> Drain Lines Group on Certain C, D, E, F, and Next Generation Series Excavators {0679, 5057} [REHS5145]
HYDRAULIC SYSTEM
LINES GP-COUPLER
Procedure to Install <NOBR>214-3287</NOBR> Drain Lines Group on Certain C, D, E, F, and Next Generation Series Excavators {0679, 5057}
1.1. Introduction
2.1. Safety
3.1. Welding Requirements
4.1. Preparing the Metal for Welding
5.1. Parts list
6.1. For Use with the HM2615 and HM4015 Mulchers
7.1. Installation Procedure
Work Tool
HM2615 (S/N: B761-UP)
HM4015 (S/N: BF31-UP)
HYDRAULIC KIT (S/N: HKB1-UP; HKD1-UP)

Introduction

This Special Instruction covers the installation procedure for 214-3287 Drain Lines Group on certain C, D, and E, F, and Next Generation Hydraulic Excavators utilizing the Work Tool Hydraulic Kits listed above.

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

Safety

------ 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.




Illustration 1g00104545

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

Welding Requirements

Welding quality is critical to the success of the installation procedures. Welds must be smooth and continuous. Do not undercut the welds. No overlap is allowed. Grind the ends of the welds to a smooth radius.

Prepare the metal for welding according to the next section. Refer to the illustrations in this special instruction for welding symbols and specifications.

All electrodes must be dried. The electrodes can be dried by heating the electrodes to 300°C (572°F). The electrodes must be dried for at least 30 minutes.

Do not weld in windy conditions. Do not weld when temperatures are below 16°C (60°F).

Penetration characteristics vary greatly depending on the following conditions:

  • Electrode diameter

  • Shielding gas

  • Welding current

  • Plate thickness

The following items also affect the welds:

  • Geometry of welded joints

  • Surface conditions

  • Composition of the base metal and of the electrode

A root pass is required before each weld is finished.

Maintain a 3 mm (0.12 inch) minimum root opening on all cross welds and circle welds.

For more welding information, consult the AVSpare Service Welding Guide, SEBD0512.

Preparing the Metal for Welding

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

Personal injury can result from flame cutting or welding on painted areas.

The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.

Do not flame cut or weld on painted areas.



NOTICE

Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.


All grease, paint, and foreign objects must be removed before welding. Any of these materials will discharge gas which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen embrittlement causes cracks in the weld deposit.

Remove foreign objects with a wire brush, a buffer, or a grinder. Shot blasting the appropriate areas will also remove foreign material.

Remove any oil or grease with a AVSpare approved solvent.

Note: After welding, allow all areas to cool to room temperature. After the areas have cooled, primer the area welded. After the primer has dried, coat the area with Cat 4C-4200 Yellow Paint.

Parts list

Table 1
Parts List for 214-3287 Drain Lines Gp - 02 
Item  Qty  Part Number  Description 
217-7838  Plate 
218-0966  Hose As 
219-1493  Hose As 
222-3482  Film 
124-2117  Coupling 
3D-2824  O-Ring Seal 
3K-0360  O-Ring Seal 
5K-9090  O-Ring Seal 
6V-8398  O-Ring Seal 
10  6V-8556  Nut 
11  6V-8557  Face Seal Nut 
12  6V-8731  Union 
13  6V-8782  Tee 
14  6V-8785  Tee 
15  6V-8942  O-Ring Reducer 
16  6V-8944  O-Ring Reducer 
17  6V-8995  Union 
18  6V-9169  Bulkhead Nut 
19  6V-9175  Tee 
20  6V-9746  O-Ring Seal 
21  7J-9108  O-Ring Seal 
22  7M-8485  O-Ring Seal 
23  100  7K-1181  Cable Strap 


Illustration 2g03644834

For Use with the HM2615 and HM4015 Mulchers

Note: DO NOT CONNECT TO THE SWIVEL MOTOR SHOWN IN DETAIL (A).



    Illustration 3g06393698

  1. Route and connect the case drain directly to the port block on the hydraulic as shown.

    Note: Install a 289-8194 Oil Filter Gp between the Mulcher and drain location.The filter should be placed in the pump compartment of the machine.

Installation Procedure

  1. Release the pressure in the implement hydraulic circuits (boom, stick, and bucket) before any hydraulic lines or components are disconnected or removed.

  2. In order to prevent oil leakage, apply a vacuum to the hydraulic tank or drain the hydraulic tank. If you drain the hydraulic tank, drain the oil into a container that is large enough to contain the oil. Dispose of the oil in a proper manner.


    Illustration 4g03644798
    (A) 32.5 mm (1.3 inch)
    (B) 55 mm (2.2 inch)

  3. Weld plate (1) to the side of the stick.


    Illustration 5g03644917
    Detail E
    (1) 217-7838 Plate
    (2) 218-0966 Hose As
    (9) 6V-8398 O-Ring Seal
    (17) 6V-8995 Union
    (18) 6V-9169 Nut

  4. Connect hose (2) to plate (1)


    Illustration 6g03645019
    Detail D
    (2) 218-0966 Hose As

  5. Route hose (2) towards the boom. Position hose (2) as shown. Secure with straps (23) as needed.


    Illustration 7g03645050
    Detail C
    (2) 218-0966 Hose As
    (9) 6V-8398 O-Ring Seal
    (12) 6V-8731 Union

  6. Connect the first length of hose (2) to the second length of hose (2) at the stick pin. Use union (12) and two O-ring seals (9) to connect the hoses. Secure with straps (23) as needed.


    Illustration 8g03645121
    Detail B
    (5) 124-2117 Coupling
    (9) 6V-8398 O-Ring Seal
    (12) 6V-8731 Union

  7. Connect hose (2) to hose (3) using union (12), two O-ring seals (9), and coupling (5). Route hose (3) towards the boom. Refer to Illustration 2 for the hose layout.

    Note: Cut hose (3) to the required length. Connect coupling (5) to hose (3).



    Illustration 9g03645196
    Detail A
    (6) 3D-2824 O-Ring Seal
    (7) 3K-0360 O-Ring Seal
    (8) 5K-9090 O-Ring Seal
    (9) 6V-8398 O-Ring Seal
    (10) 6V-8556 Nut
    (11) 6V-8557 Face Seal Nut
    (13) 6V-8782 Tee
    (14) 6V-8785 Tee
    (15) 6V-8942 O-Ring Reducer
    (16) 6V-8944 O-Ring Reducer
    (19) 6V-9175 Tee
    (20) 6V-9746 O-Ring Seal
    (21) 7J-9108 O-Ring Seal
    (22) 7M-8485 O-Ring Seal

  8. Install the correct hardware onto the machine based on the model of the machine. Refer to the following notes.

    Note: A:If the machine is a 318C, 320C, 322C, 325C or, 330C install tee (14) and the hardware that goes with.

    Note: B:If the machine is a 307C install tee (13), one O-ring seal (7), and two O-ring seals (9).

    Note: C:If the machine is 312C or 315C use tee (19) and the hardware that goes with.

    Note: Do not connect to the swivel motor when installing for use with the HM2615 or HM4015 Mulchers.Refer to the first section for HM2615 and HM4015 Mulchers.

  9. Attach film (4) to the right side window of the cab.

  10. Use cable straps (23) as needed to secure the hose.

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