Installation Procedure for 2nd Auxiliary Lines Kit on Certain Mini Hydraulic Excavators {5057} Caterpillar

Mini Hydraulic Excavator

301.5 (S/N: MNH1-UP)

301.6 (S/N: MY61-UP)

301.7CR (S/N: JH71-UP)

301.8 (S/N: H8X1-UP)

302CR (S/N: RHM1-UP)

Introduction

This Special Instructions contains the procedure to install auxiliary lines kit on the machines listed above.

Note: For 301.5 machine use 558-6755 Auxiliary Lines Kit.
For 301.6 machines use 558-6756 Auxiliary Lines Kit.
For 301.7CR machines use 558-6757 Auxiliary Lines Kit.
For 301.8 machines use 558-6758 Auxiliary Lines Kit.
For 302CR machines use 558-6759 Auxiliary Lines Kit.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference Section

Reference: Operation and Maintenance Manual, M0088895, Access Door and Cover Locations

Reference: Torque Specifications, SENR3130

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Required Parts

Required Tools

Installation Procedure for 527-6032 Diverter Valve Gp

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Illustration 1	g06425584
(1) 540-1224 Bracket As (T1) Fixture

1. Place the bracket assembly (1) to the fixture (T1). Refer to Illustration 1.
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   Illustration 2	g06425585
   (1) 540-1224 Bracket As (2) 095-0642 Bolt (3) 527-6032 Diverter Valve Gp

2. Install diverter valve group (3) to the bracket assembly (1) using bolt (2), torque to 3.3 ± 0.7 N·m (29.2 ± 6.2 lb in). Refer to Illustration 2.

For 301.5, 301.6, and 301.8 Machines

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Illustration 3	g06425586
Straight up (3) 527-6032 Diverter Valve Gp (4) 148-8369 Elbow As

1. Install elbow assembly (4) to diverter valve group (3), torque to 30 ± 5 N·m (266 ± 44 lb in). Refer to Illustration 3.
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   Illustration 4	g06425587
   (3) 527-6032 Diverter Valve Gp (5) 148-8316 Connector As

2. Install connector assembly (5) to diverter valve group (3), torque to 30 ± 5 N·m (266 ± 44 lb in). Refer to Illustration 4.
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   Illustration 5	g06425588
   (3) 527-6032 Diverter Valve Gp (6) 148-8351 Elbow As

3. Install elbow assembly (6) to diverter valve group (3), torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 5.
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   Illustration 6	g06425589
   (3) 527-6032 Diverter Valve Gp (7) 267-4046 Elbow As

4. Install elbow assembly (7) to diverter valve group (3), torque to 30 ± 5 N·m (266 ± 44 lb in). Refer to Illustration 6.
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   Illustration 7	g06425590
   (3) 527-6032 Diverter Valve Gp (8) 267-4048 Elbow As (A) 8T-2353 Adapter (B) 3J-7354 O-Ring Seal

5. Install adapter (A) and O-Ring seal (B) to diverter valve group (3), torque to 30 ± 5 N·m (266 ± 44 lb in). Refer to Illustration 7.

6. Install elbow assembly (8) to adapter (A), torque to 55 ± 8 N·m (41 ± 6 lb ft). Refer to Illustration 7.
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   Illustration 8	g06425591
   (3) 527-6032 Diverter Valve Gp (9) 540-1228 Hose As

7. Install hose assembly (9) to diverter valve group (3), torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 8.
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   Illustration 9	g06425592
   (3) 527-6032 Diverter Valve Gp (10) 540-1229 Hose As

8. Install hose assembly (10) to diverter valve group (3), torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 9.

For 301.7CR and 302CR Machines

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Illustration 10	g06425593
(3) 527-6032 Diverter Valve Gp (4) 148-8369 Elbow As

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Illustration 11	g06425594
(D1) 15 Degree (4) 148-8369 Elbow As

1. Install elbow assembly (4) to diverter valve group (3), torque to 30 ± 5 N·m (266 ± 44 lb in). Refer to Illustration 10 and Illustration 11.
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   Illustration 12	g06425595
   (3) 527-6032 Diverter Valve Gp (5) 148-8316 Connector As

2. Install connector assembly (5) to diverter valve group (3), torque to 30 ± 5 N·m (266 ± 44 lb in). Refer to Illustration 12.
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   Illustration 13	g06425596
   (3) 527-6032 Diverter Valve Gp (6) 148-8351 Elbow As

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   Illustration 14	g06425597
   (6) 148-8351 Elbow As (D1) 15 Degree

3. Install elbow assembly (6) to diverter valve group (3), torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 13 and Illustration 14.
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   Illustration 15	g06425598
   (D1) 15 Degree (7) 267-4046 Elbow As

4. Install elbow assembly (7) to 527-6032 Diverter Valve Gp, torque to 30 ± 5 N·m (266 ± 44 lb in). Refer to Illustration 15.
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   Illustration 16	g06425599
   (8) 267-4048 Elbow As (A) 8T-2353 Adapter (B) 3J-7354 O-Ring Seal

5. Install adapter (A) and O-Ring seal (B) to 527-6032 Diverter Valve Gp, torque to 30 ± 5 N·m (266 ± 44 lb in). Refer to Illustration 16.

   Note: Install O-Ring seal (B) to adapter (A) by hand.

6. Install elbow assembly (8) to adapter (A), torque to 55 ± 8 N·m (41 ± 6 lb ft). Refer to Illustration 16.
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   Illustration 17	g06425600
   301.7CR machines (11) 541-0258 Hose As (12) 541-0259 Hose As

7. Install hose assembly (11) and hose assembly (12) to 527-6032 Diverter Valve Gp, torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 17.
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   Illustration 18	g06425601
   For 302CR machines (13) 533-1117 Hose As (14) 533-1118 Hose As

8. Install hose assembly (13) and hose assembly (14) to 527-6032 Diverter Valve Gp, torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 17.

Routing Hoses Through Boom

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Illustration 19	g06425602
(15) For 301.5, 301.6, and 301.7CR machines use 540-2228 Hose As / For 301.8 machines use 542-2203 Hose As / For 302CR machines use 542-2013 Hose As (16) For 301.5, 301.6, and 301.7CR machines use 540-2229 Hose As / For 301.8 machines use 542-2205 Hose As / For 302CR machines use 542-2014 Hose As (C) Line mark

1. Mark a line on both sides of the hose assembly (15). Refer to Illustration 19.
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   Illustration 20	g06425603
   (E) Rope

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   Illustration 21	g06425604
   (E) Rope

2. Route two leading ropes (E) from auxiliary hole as shown in Illustration 20 and Illustration 21.
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   Illustration 22	g06425605
   (E) Rope (F) Vinyl tape

   Note: Wind vinyl tape (F) around the hose coupling to avoid slipping off. Consider to the pressure from other hoses, apply lubricant to hoses before passing through.

3. Connect hose assembly to leading rope (E) at boom side, then pull out the rope (E) with hose assembly from the bottom side of the boom. Refer to Illustration 22.

4. Continue routing to the main control valve side with leading rope (E).

Auxiliary Lines Connection

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Illustration 23	g06425606
(17) 150-4052 Union As (18) 6V-9828 Cap (19) 2P-1279 Locknut

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Illustration 24	g06425607
(17) 150-4052 Union As (18) 6V-9828 Cap (19) 2P-1279 Locknut

1. Install union assembly (17), cap (18), and lock nut (19) to the bracket attached on the boom. Refer to Illustration 23 and Illustration 24.
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   Illustration 25	g06425608
   (15) For 301.5, 301.6, and 301.7CR machines use 540-2228 Hose As / For 301.8 machines use 542-2203 Hose As / For 302CR machines use 542-2013 Hose As (16) For 301.5, 301.6, and 301.7CR machines use 540-2229 Hose As / For 301.8 machines use 542-2205 Hose As / For 302CR machines use 542-2014 Hose As (20) 3S-2093 Cable Strap

2. Secure hose assembly (15) using two cable strap (20) on both sides. Refer to Illustration 25.

3. Secure hose assembly (16) using cable strap (20). Refer to Illustration 25.
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   Illustration 26	g06425609
   (G) Hose assembly

4. Remove both hose assembly (G) connected to swing cylinder. Refer to Illustration 26.
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   Illustration 27	g06425610
   (21) 4J-5477 O-Ring Seal

5. Remove the existing O-Ring seal and replace with new O-Ring seal (21). Refer to Illustration 27.
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   Illustration 28	g06425611
   (21) 4J-5477 O-Ring Seal

6. Install O-Ring seal (21) to main control valve. Refer to Illustration 28.
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   Illustration 29	g06427721
   (H) Yellow plastic plug

7. Remove yellow plastic plug (H) from frame. Refer to Illustration 29.

   Note: To open the canopy or cab refer to Operation and Maintenance Manual, M0088895, Access Door and Cover Locations.

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   Illustration 30	g06425613
   For 301.5, 301.6, and 301.8 machines (3) 527-6032 Diverter Valve Gp (22) 8T-4200 Bolt (23) 8T-4224 Hard Washer

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   Illustration 31	g06425615
   For 301.7CR and 302CR machines (3) 527-6032 Diverter Valve Gp (22) 8T-4200 Bolt (23) 8T-4224 Hard Washer

8. Install assembled diverter valve group (3) to the frame using bolt (22) and washer (23). Refer to Illustration 30 and Illustration 31.
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   Illustration 32	g06425616
   (24) 7K-1181 Cable Strap

9. Remove cable strap (24). Refer to Illustration 32.
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   Illustration 33	g06425617
   (24) 7K-1181 Cable Strap (J) Connector (K) Connector

10. Secure the connector (J) and connector (K) using cable strap (24). Refer to Illustration 33.

11. Connect the connector (J) to Quick coupler.

12. Connect the connector (K) to auxiliary solenoid with BK strap.
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    Illustration 34	g06425618
    (G) Hose assembly

13. Clean the hydraulic oil around in the adapter threads before connecting the hose (G). Refer to Illustration 34.

14. Connect the hoses (G) to swing cylinder, torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 34.
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    Illustration 35	g06425619
    (25) For 301.5 machines use 540-1227 Hose As / For 301.6 and 301.8 machines use 541-0255 Hose As / For 301.7CR and 302CR machines use 540-1226 Hose As (26) For 301.5 machines use 540-1226 Hose As / For 301.6 and 301.8 machines use 541-0254 Hose As / For 301.7CR and 302CR machines use 533-1115 Hose As

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    Illustration 36	g06425620
    (25) For 301.5 machines use 540-1227 Hose As / For 301.6 and 301.8 machines use 541-0255 Hose As / For 301.7CR and 302CR machines use 540-1226 Hose As (26) For 301.5 machines use 540-1226 Hose As / For 301.6 and 301.8 machines use 541-0254 Hose As / For 301.7CR and 302CR machines use 533-1115 Hose As (L) Straight line

15. Connect the hose assembly (25) and hose assembly (26) from main control valve group side to small valve. Tighten the hose assembly (25) and hose assembly (26) in the order shown, torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 35 and Illustration 36.
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    Illustration 37	g06425621
    (24) 7K-1181 Cable Strap

16. Connect the hoses to adapter from boom side to small valve, torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 37.

    1. Connect hose with one cable strap (24) at lower position.

    2. Connect hose with two cable strap (24) at upper position
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    Illustration 38	g06425622
    Left side view (15) For 301.5, 301.6, and 301.7CR machines use 540-2228 Hose As / For 301.8 machines use 542-2203 Hose As / For 302CR machines use 542-2013 Hose As (17) 150-4052 Union As

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    Illustration 39	g06425625
    Right side view (16) For 301.5, 301.6, and 301.7CR machines use 540-2229 Hose As / For 301.8 machines use 542-2205 Hose As / For 302CR machines use 542-2014 Hose As (17) 150-4052 Union As

17. Connect the hose assembly (15) and hose assembly (16) to union assembly (17), torque to 27 ± 4 N·m (239 ± 35 lb in). Refer to Illustration 38 and Illustration 39.
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    Illustration 40	g06425626
    (24) 7K-1181 Cable Strap

18. Secure the hoses using cable strap (24). Refer to Illustration 40.

Machine Configuration Using ET-01

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Illustration 41	g06425627
(M) ET cable

1. Connect ET cable to machine port. Refer to Illustration 41.
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   Illustration 42	g06425628
   (M) ET Cable

2. Connect the ET cable (M) to the computer USB port, then switch ON the machine. Refer to Illustration 42.
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   Illustration 43	g06425629
   ET Application

3. Open ET application.
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   Illustration 44	g06425631
   Ok

4. Click "Ok"
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   Illustration 45	g06425632
   Ok (N) Machine control

5. Select machine control (N) and then click "Ok". Refer to Illustration 45.
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   Illustration 46	g06425633
   Configuration tool

6. Select "Configuration tool".
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   Illustration 47	g06425634
   Auxiliary valve #2 Installation Status

7. Double click the "Auxiliary valve #2 Installation Status", value "Not Installed". Refer to Illustration 47.
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   Illustration 48	g06425635
   OK (P) Installed

8. Select installed (P) and then click "Ok". Refer to Illustration 48.
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   Illustration 49	g06425637
   Yes

9. Click "Yes".
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   Illustration 50	g06425638
   (P) Installed

10. Check the auxiliary valve #2 installation status changed to installed (P). Refer to Illustration 50.
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    Illustration 51	g06425639
    (Q) Push button

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    Illustration 52	g06425641
    Before configuration

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    Illustration 53	g06425642
    After Configuration

11. Push the button (Q) on joystick and verify the interface change on the display. Refer to Illustration 51, Illustration 52, and Illustration 53.