Installation Procedure for 260-7983 Pump Lines Gp (Hydraulic oil cooler, Pilot System) on Certain Hydraulic Excavators{5057, 6307} Caterpillar

Installation Procedure for 260-7983 Pump Lines Gp (Hydraulic oil cooler, Pilot System) on Certain Hydraulic Excavators{5057, 6307}

Usage:

320D BZP

Excavator:: 320D (S/N: MCH1-UP; FAL1-UP; BZP1-UP; DFT1-UP; PHX1-UP)
Work Tool:: GLC85 (S/N: JSF1-UP)

Introduction

The Special Instruction, REHS3884 is for the installation of the 260-7983 Pump Lines Gp (HYD OIL COOLER, PILOT SYSTEM). If you need more information about the installation of the pilot lines on your machine, consult your Caterpillar dealer.

Safety Section

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Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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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.

Required Parts

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Table 1
Parts List for 260-7983 Pump Lines Gp (Hydraulic oil cooler, Pilot System) - 08
Item	Qty	Pt. No.	Part Name
(1)	1	6V-0852	Dust Cap
(2)	4	9X-2201	Hose Clamp
(3)	1	105-7781	Spacer
(4)	1	106-8715	Elbow As
(5)	1	180-9286	Tee As
(6)	1	199-2045	Spacer
(7)	1	266-0955	Flange
(8)	1	278-6912	Tube As
(9)	1	282-7055	Tube As
(10)	1	289-5681	Hose As
(11)	1	289-5731	Hose As
(12)	1	319-9996	Hose As
(13)	4	105-3478	Bolt
(14)	1	113-6708	Hose
(15)	1	150-4049	Elbow As
(16)	1	164-5567	Quick Disconnect Coupler As
(17)	1	164-5606	Connector As
(18)	2	171-6723	Elbow As
(19)	1	1P-3703	Seal - Rectangular
(20)	2	1P-4578	Half Flange
(21)	2	1P-4579	Half Flange
(22)	1	4J-0522	O-Ring Seal
(23)	2	4J-0524	O-Ring Seal
(24)	3	5P-7468	Clip
(25)	3	5P-7469	Clip
(26)	3	6V-1874	Grommet
(27)	1	7X-2550	Bolt
(28)	4	8T-4121	Hard Washer
(29)	4	8T-4183	Bolt
(30)	1	8T-4192	Bolt
(31)	4	8T-4196	Bolt
(32)	6	8T-4223	Hard Washer
(33)	1	8T-4648	Bolt
(34)	4	8T-4956	Bolt
(35)	4	447-1709	Bolt
(36)	1	8T-7971	Hard Washer
(37)	1	9M-3786	O-Ring Seal
(38)	4	451-2175	Washer

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Illustration 1	g03339939

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Illustration 2	g03339960

Installation Section

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Illustration 3	g01666679

Remove cover guards (X), (Y), and (Z) .

Make sure that the hydraulic tank has been drained.

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Illustration 4	g01623872

Remove the tank supply line (B) and tube (A) .

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Illustration 5	g03340048

Install tube (8) into the hydraulic tank. Use seal (37), bolts (35), and washers (38) .

Connect hose (14) between tube (8) on the hydraulic tank and the existing supply tube on the hydraulic pump. Secure the hose with clamps (2) .

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Illustration 6	g03340086

Assemble elbow (4) and connector (17) into the valve block. Refer to illustration 11.

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Illustration 7	g01667100

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Illustration 8	g01667101

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Illustration 9	g03340116

Remove the existing supply tube (AA) for the hydraulic oil cooler. Replace tube (AA) with tube (9). Use seal (23) and bolts (34) .

Assemble elbow (15) to the port on the back side of tube (9) .

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Illustration 10	g03340124

Assemble tee (5) to the "OUT" port on top of the auxiliary hydraulic pump (C) .

Insert fitting (16), dust cap (1), and elbow (18) onto the auxiliary pump (C) .

Connect the straight end of hose (12) to elbow (18) on auxiliary pump (C) .

Route hose (12) out of the pump compartment along the back side of the hydraulic tank. Continue the routing of hose (12) across the front side of the main valve to the valve block.

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Illustration 11	g03340163

Connect the angled end of hose (12) to connector (17) on valve block.

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Illustration 12	g03340176

On the left side of the hydraulic tank, secure hose (12). Use clips (24) and (25), grommet (26), bolt (30), and washer (32).

On the upper left side of the hydraulic tank, secure hose (12). Use clips (24) and (25), grommet (26), bolt (33), washer (36), and spacer (3) .

In the pump compartment, secure hose (12) to the back side of the hydraulic tank. Use clips (24) and (25), grommet (26), bolt (27), washer (32), and spacer (6) .

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