- Excavator:
- 320D (S/N: KGF1-UP; MCH1-UP; TDH1-UP; FAL1-UP; KLM1-UP; SPN1-UP; PHX1-UP)
- Work Tool:
- HYDRAULIC KIT (S/N: HKD1-UP)
Introduction
This special instruction covers the installation procedure for the 275-1399 Front Lines Gp .
Do not perform any procedure that is outlined in this publication and do not order any parts until you understand the information that is contained in this document.
Safety Section
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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. |
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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 attachments have been lowered, 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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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on. |
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Tampering with the electronic system installation of the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
Required Parts
| Parts List for 275-1399 Front Lines Gp Revision -14 | |||
| Item | Qty | Pt. No. | Part Name |
| (1) | 1 | 7Y-3729 | Special Flange |
| (2) | 1 | 7Y-3731 | Flange |
| (3) | 4 | 105-3477 | Bolt |
| (4) | 4 | 105-3483 | Bolt |
| (5) | 1 | 187-6720 | Block |
| (6) | 1 | 187-6851 | Plate |
| (7) | 1 | 187-6974 | Hose As |
| (8) | 1 | 187-7051 | Hose As |
| (9) | 1 | 187-7077 | Block |
| (10) | 1 | 266-0912 | Bracket |
| (11) | 1 | 266-0913 | Support As |
| (12) | 1 | 266-1278 | Block |
| (13) | 2 | 266-1279 | Flange |
| (14) | 2 | 266-1303 | Hose As |
| (15) | 1 | 268-5145 | Elbow As |
| (16) | 1 | 275-1439 | Block |
| (17) | 1 | 275-1440 | Block |
| (18) | 1 | 278-6426 | Block |
| (19) | 1 | 278-6427 | Block |
| (20) | 1 | 278-6428 | Support As |
| (21) | 1 | 278-6430 | Hose As |
| (22) | 1 | 296-7067 | Support As |
| (23) | 3 | 297-0370 | Check Valve Gp |
| (24) | 1 | 317-4712 | Hose As |
| (25) | 2 | 323-7558 | Solenoid and Relief Valve Gp |
| (26) | 1 | 325-8865 | Support As |
| (27) | 1 | 330-2445 | Hose As |
| (28) | 1 | 330-2448 | Elbow As |
| (29) | 1 | 337-1424 | Support As |
| (30) | 1 | 354-3838 | Plate As |
| (31) | 1 | 434-8214 | Pressure Sensor Gp |
| (32) | 2 | 099-8232 | O-Ring Seal |
| (33) | 8 | 101-7401 | Bolt |
| (34) | 8 | 101-7404 | Bolt |
| (35) | 4 | 105-3485 | Bolt |
| (36) | 4 | 108-4282 | Bolt |
| (37) | 1 | 148-8327 | Connector As |
| (38) | 1 | 148-8330 | Connector As |
| (39) | 2 | 148-8335 | Connector As |
| (40) | 1 | 148-8347 | Elbow As |
| (41) | 1 | 148-8355 | Elbow As |
| (42) | 1 | 148-8357 | Elbow As |
| (43) | 1 | 153-6237 | Elbow As |
| (44) | 1 | 164-4180 | Plug As |
| (45) | 1 | 164-5606 | Connector As |
| (46) | 6 | 1P-3702 | Rectangular Seal |
| (47) | 3 | 1P-3703 | Rectangular Seal |
| (48) | 3 | 1P-3704 | Rectangular Seal |
| (49) | 2 | 1P-4578 | Half Flange |
| (50) | 1 | 4J-0522 | O-Ring Seal |
| (51) | 1 | 5K-9090 | O-Ring Seal |
| (52) | 1 | 5P-7466 | Clip |
| (53) | 1 | 5P-7467 | Clip |
| (54) | 2 | 5P-7470 | Clip |
| (55) | 2 | 5P-7471 | Clip |
| (56) | 1 | 5P-8112 | Grommet |
| (57) | 2 | 5P-8182 | Grommet |
| (58) | 1 | 6V-9746 | O-Ring Seal |
| (59) | 14 | 8T-4121 | Hard Washer |
| (60) | 6 | 8T-4136 | Bolt |
| (61) | 4 | 8T-4139 | Bolt |
| (62) | 8 | 8T-4176 | Bolt |
| (63) | 8 | 8T-4183 | Bolt |
| (64) | 2 | 8T-4195 | Bolt |
| (65) | 6 | 8T-4196 | Bolt |
| (66) | 39 | 8T-4223 | Hard Washer |
| (67) | 7 | 8T-4956 | Bolt |
| (68) | 12 | 8T-5092 | Bolt |
| (69) | 4 | 8T-6466 | Bolt |
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| Illustration 1 | g02731209 |
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| Illustration 2 | g02731250 |
Installation Procedure
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| Illustration 3 | g00104545 |
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 or before you repair the equipment. These warning tags Special Instruction, SEHS7332 are available from your Caterpillar dealer.
| Required Tools | |||
| Tool | Pt. No. | Description | Qty |
| (A) | FT-2674 | Vacuum Cap | 1 |
- Release the hydraulic system pressure. Refer to Disassembly and Assembly, RENR8614, "System Pressure - Release".
- 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.
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| Illustration 4 | g00690963 |
- Assemble the left side valve arrangement (A) as shown.
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| Illustration 5 | g02731294 |
(A) Left side valve arrangement (4) 105-3483 Bolt (9) 187-7077 Block (18) 278-6426 Block (23) 297-0370 Check Valve Gp (25) 323-7558 Solenoid and Relief Valve Gp (31) 434-8214 Pressure Sensor Gp (32) 099-8232 O-Ring Seal (38) 148-8330 Connector As (39) 148-8335 Connector As (42) 148-8357 Elbow As (47) 1P-3703 Rectangular Seal (62) 8T-4176 Bolt (66) 8T-4223 Hard Washer (68) 8T-5092 Bolt | |
- Apply the lubricant being sealed to the male threads of sensor (31). Tighten sensor (31) to a torque of 100 ± 10 N·m (74 ± 7 lb ft).
- Assemble the required parts as shown.
Note: The assembly from step 5 will be used in step 6.
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| Illustration 6 | g02731300 |
(2) 7Y-3731 Flange (5) 187-6720 Block (23) 297-0370 Check Valve Gp (25) 323-7558 Solenoid and Relief Valve Gp (32) 099-8232 O-Ring Seal (34) 101-7404 Bolt (35) 105-3485 Bolt (39) 148-8335 Connector As (44) 164-4180 Plug As (47) 1P-3703 Rectangular Seal (48) 1P-3704 Rectangular Seal (62) 8T-4176 Bolt (66) 8T-4223 Hard Washer | |
- Assemble the right side valve arrangement (B) as shown.
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| Illustration 7 | g02731331 |
(B) Right side valve arrangement (6) 187-6851 Plate (15) 268-5145 Elbow As (19) 278-6427 Block (23) 297-0370 Check Valve Gp (37) 148-8327 Connector As (48) 1P-3704 Rectangular Seal (61) 8T-4139 Bolt (66) 8T-4223 Hard Washer (68) 8T-5092 Bolt | |
- Install valves (A), and (B) .
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| Illustration 8 | g02731342 |
(A) Left side valve arrangement (B) Right side valve arrangement (10) 266-0912 Bracket (11) 266-0913 Support As (18) 278-6426 Block (19) 278-6427 Block (20) 278-6428 Support As (22) 296-7067 Support As (29) 337-1424 Support As (59) 8T-4121 Hard Washer (60) 8T-4136 Bolt (63) 8T-4183 Bolt (64) 8T-4195 Bolt (65) 8T-4198 Bolt (66) 8T-4223 Hard Washer (67) 8T-4956 Bolt | |
- Install hoses (7), and (8) .
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| Illustration 9 | g02731348 |
(2) 7Y-3731 Flange (7) 187-6974 Hose As (8) 187-7051 Hose As (30) 354-3838 Plate As (34) 101-7404 Bolt (39) 148-8335 Connector As (42) 148-8357 Elbow As (47) 1P-3703 Rectangular Seal (51) 5K-9090 O-Ring Seal (59) 8T-4121 Hard Washer (60) 8T-4136 Bolt | |
- Install bracket (30) .
- Install hose (21) .
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| Illustration 10 | g02731352 |
(C) Manifold (5) 187-6720 Block (21) 278-6430 Hose As (26) 325-8865 Support As (28) 330-2448 Elbow As (31) 434-8214 Pressure Sensor Gp (49) 1P-4578 Half Flange (50) 4J-0522 O-Ring Seal (54) 5P-7470 Clip (55) 5P-7471 Clip (57) 5P-8182 Grommet (59) 8T-4121 Hard Washer (60) 8T-4136 Bolt (65) 8T-4198 Bolt (66) 8T-4223 Hard Washer (67) 8T-4956 Bolt | |
- Install hose (14) .
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| Illustration 11 | g02731355 |
(1) 7Y-3729 Special Flange (3) 105-3477 Bolt (12) 266-1278 Block (13) 266-1279 Flange (14) 266-1303 Hose As (16) 275-1439 Block (17) 275-1440 Block (33) 101-7401 Bolt (34) 101-7404 Bolt (36) 108-4282 Bolt (40) 148-8347 Elbow As (43) 153-6237 Elbow As (45) 164-5606 Connector As (46) 1P-3702 Rectangular Seal (58) 6V-9746 O-Ring Seal (69) 8T-6466 Bolt | |
- Install block (12) .
- Install block (16) .
- Install block (17) .
- Install hose (14) .
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| Illustration 12 | g02731357 |
(1) 7Y-3729 Special Flange (12) 266-1278 Block (14) 266-1303 Hose As (15) 268-5145 Elbow As (24) 317-4712 Hose As (27) 330-2445 Hose As (29) 337-1424 Support As (39) 148-8335 Connector As (41) 148-8355 Elbow As (45) 164-5606 Connector As (46) 1P-3702 Rectangular Seal (52) 5P-7466 Clip (53) 5P-7467 Clip (56) 5P-8112 Grommet (58) 6V-9746 O-Ring Seal (59) 8T-4121 Hard Washer (64) 8T-4195 Bolt (66) 8T-4223 Hard Washer (67) 8T-4956 Bolt (69) 8T-6466 Bolt | |
- Install hose (24) .
- Install hose (27) .
- Tighten all hardware and fittings to proper torque unless otherwise specified. Refer to Specifications, SENR3130, "Torque Specifications".
- Inspect for fluid leaks when the installation of the hydraulic kit is complete.
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| Illustration 13 | g00687600 |
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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue, causing serious injury, and possible death. Always use a board or cardboard when checking for a leak. Do not check for pin hole leaks in pump or motor hoses during a steer stall condition. If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury immediately. |
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