Procedure to Install the 420-3637 Connecting Lines Gp (Thumb) on Certain Hydraulic Excavators{5057} Caterpillar

Excavator:

320E (S/N: TNJ1-UP; WBK1-UP; TFX1-UP)

324E (S/N: PNW1-UP)

Work Tool:

Thumb (S/N: THC1-UP; THD1-UP)

Introduction

This Special Instruction contains the procedure for installing 420-3637 Connecting Lines Gp . The machine must be equipped with auxiliary hydraulic lines on the stick. For additional information about the installation of the connecting lines, consult the local Cat^® dealer.

Safety

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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 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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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.

Required Tools

Machine Preparation

Illustration 1	g03177260
Service arrangement of an Excavator

1. Clear all personnel from the machine and from the area around the machine.

2. Start the engine.

3. Set the engine speed dial at "10".

4. Place the hydraulic activation control lever in the LOCKED arrangement.

5. Arrange the machine on level ground. Check the visibility and adjust the mirrors for the best vision close to the machine.

6. Arrange the machine into the servicing arrangement. Refer to Illustration 1.

7. Stop the engine.

8. Release the hydraulic system pressure. Refer to the Operation and Maintenance Manual, "System Pressure Release".

9. Place the hydraulic activation control lever in the UNLOCKED arrangement.

10. Turn the engine start switch to the OFF arrangement.

11. Attach tooling (A) onto the hydraulic tank. Attach an air supply hose onto the assembly. Apply 276 to 414 kPa (40 to 60 psi). This procedure will pull a vacuum on the hydraulic system.

12. Precede to the Connecting Lines Gp being installed on the machine.

Required Parts

Procedure to Install the Connecting Lines Gp

Illustration 2	g03420657
Left side view of boom and stick (B) Existing boom lines (C) Existing flanges (2) 420-3640 Hose As (3) 4J-0520 O-Ring Seal (4) 5P-7468 Clip (5) 5P-7469 Clip (6) 5P-8245 Hard Washer (7) 5P-8444 Grommet (8) 5S-7382 Bolt (9) 6V-8675 Bolt (10) 8C-3206 Half Flange (11) 8T-4896 Hard Washer (12) 1P-3703 Rectangular Seal

Illustration 3	g03420661
Left side close-up view of stick (2) 420-3640 Hose As (3) 4J-0520 O-Ring Seal (4) 5P-7468 Clip (5) 5P-7469 Clip (6) 5P-8245 Hard Washer (7) 5P-8444 Grommet (8) 5S-7382 Bolt (9) 6V-8675 Bolt (10) 8C-3206 Half Flange (11) 8T-4896 Hard Washer

1. Insert rectangular seal (12) in between the flanges (C) on the left side of the machine.

2. Connect hose assembly (2) to existing boom lines (B) as shown in Illustration2 using the existing hardware.

3. Arrange hose assembly (2) as shown in Illustration 3. Connect the hose assembly to the thumb cylinder using the following parts: O-ring seal (3), two half flanges (10), four bolts (8) and four washers (6). Refer to Illustration 3 for hardware installation.

4. Push wire guard on hose assembly (2) back towards the boom lines so the guarding is not between the clips and the hose.

5. Secure hose assembly (2) to the stick using the following parts: grommet (7), clips (4) and (5), bolt (9) and washer (6). Refer to Illustration 3 for hardware installation.

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Illustration 4	g03420664
Right side view of boom and stick (B) Existing boom lines (C) Existing flanges (1) 420-3640 Hose As (3) 4J-0520 O-Ring Seal (4) 5P-7468 Clip (5) 5P-7469 Clip (6) 5P-8245 Hard Washer (7) 5P-8444 Grommet (8) 5S-7382 Bolt (9) 6V-8675 Bolt (10) 8C-3206 Half Flange (11) 8T-4896 Hard Washer (13) 1P-3704 Rectangular Seal

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Illustration 5	g03420665
Right side close-up view of stick (1) 420-3640 Hose As (3) 4J-0520 O-Ring Seal (4) 5P-7468 Clip (5) 5P-7469 Clip (6) 5P-8245 Hard Washer (7) 5P-8444 Grommet (8) 5S-7382 Bolt (9) 6V-8675 Bolt (10) 8C-3206 Half Flange (11) 8T-4896 Hard Washer

6. Insert rectangular seal (13) in between the flanges (C) on the right side of the machine.

7. Connect hose assembly (1) to existing boom lines (B) as shown in Illustration 4 using the existing hardware.

8. Arrange hose assembly (1) as shown in Illustration 5. Connect the hose assembly to the thumb cylinder using the following parts: O-ring seal (3), two half flanges (10), four bolts (8) and four washers (6). Refer to Illustration 5 for hardware installation.

9. Push wire guard on hose assembly (1) back towards the boom lines so the guarding is not between the clips and the hose.

10. Secure hose assembly (1) to the stick using the following parts: grommet (7), clips (4) and (5), bolt (9) and washer (6). Refer to Illustration 5 for hardware installation.

11. Remove tooling (A) from the hydraulic tank.

12. Test the operation of the thumb cylinder.

13. Inspect the fittings for hydraulic leaks.