- Excavator:
- 311D RR L (S/N: PNJ1-UP)
- Thumb:
- THUMB (S/N: THC1-UP; THD1-UP)
Introduction
This Special Instruction contains the procedure for installing 380-3967 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. |
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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 Tools
| Required Tools | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part Number |
Description |
| F | 1 | 311-1362 | Vacuum Cap | |
Machine Preparation
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| Illustration 1 | g03155776 |
Service arrangement of an Excavator | |
- Clear all personnel from the machine and from the area around the machine.
- Start the engine.
- Set the engine speed dial at "10".
- Place the hydraulic activation control lever in the LOCKED arrangement.
- Arrange the machine on level ground. Check the visibility and adjust the mirrors for the best vision close to the machine.
- Arrange the machine into the servicing arrangement. Refer to Illustration 1.
- Stop the engine.
- Release the hydraulic system pressure. Refer to the Operation and Maintenance Manual, "System Pressure Release".
- Place the hydraulic activation control lever in the UNLOCKED arrangement.
- Turn the engine start switch to the OFF arrangement.
- Attach tooling (F) 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.
- Precede to the Connecting Lines Gp being installed on the machine.
Required Parts
| 380-3967 Connecting Lines Gp | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 2 | 126-8790 | Manual Valve As |
| 2 | 2 | 191-9421 | Hose As |
| 3 | 2 | 376-7218 | Plate |
| 4 | 4 | 1P-4576 | Half Flange |
| 5 | 2 | 4I-6141 | Coupling As |
| 6 | 2 | 5K-9090 | O-Ring Seal |
| 7 | 4 | 5P-8245 | Hard Washer |
| 8 | 8 | 5S-7382 | Bolt |
| 9 | 4 | 6A-5591 | Bolt |
| 10 | 8 | 6V-5839 | Washer |
| 11 | 4 | 6V-7744 | Locknut |
| 12 | 2 | 6V-8716 | Connector |
| 13 | 4 | 6V-9746 | O-Ring Seal |
| 14 | 4 | 7M-8485 | O-Ring Seal |
| 15 | 4 | 8T-0644 | Bolt |
| 16 | 8 | 8T-4896 | Hard Washer |
| 17 | 2 | 9X-2235 | Swivel Tee |
Procedure to Install the Connecting Lines Gp
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| Illustration 2 | g03201735 |
Left side view of stick (A) Existing stick lines (1) 126-8790 Manual Valve As (2) 191-9421 Hose As (17) 9X-2235 Swivel Tee | |
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| Illustration 3 | g03201744 |
Left side close-up view of manual valve assembly (1) 126-8790 Manual Valve As (3) 376-7218 Plate (5) 4I-6141 Coupling As (6) 5K-9090 O-Ring Seal (7) 5P-8245 Hard Washer (9) 6A-5591 Bolt (10) 6V-5839 Washer (11) 6V-7744 Locknut (12) 6V-8716 Connector (13) 6V-9746 O-Ring Seal (14) 7M-8485 O-Ring Seal (15) 8T-0644 Bolt (17) 9X-2235 Swivel Tee | |
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| Illustration 4 | g03201785 |
Right side view of stick (A) Existing stick lines (1) 126-8790 Manual Valve As (2) 191-9421 Hose As (17) 9X-2235 Swivel Tee | |
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| Illustration 5 | g03201818 |
Right side close-up view of manual valve assembly (1) 126-8790 Manual Valve As (3) 376-7218 Plate (5) 4I-6141 Coupling As (6) 5K-9090 O-Ring Seal (7) 5P-8245 Hard Washer (9) 6A-5591 Bolt (10) 6V-5839 Washer (11) 6V-7744 Locknut (12) 6V-8716 Connector (13) 6V-9746 O-Ring Seal (14) 7M-8485 O-Ring Seal (15) 8T-0644 Bolt (17) 9X-2235 Swivel Tee | |
Note: Installation process and parts are the same for both sides of the stick.
- Install manual valve assembly (1) onto plate (3) using the following parts: two bolts (15), two washers (10) and two locknuts (11). Tighten to standard torque.
- Install O-ring seal (14) and coupling assembly (5) on to manual valve assembly (1) .
- Install O-ring seal (14) and connector (12) on to manual valve assembly (1) .
- Insert O-rings seals (6) and (13) into swivel tee (17) .
Note: Do not tighten connections until all components are installed and arranged properly.
- Install swivel tee (17) into existing stick lines (A) as shown in Illustration 2 and 4.
- Connect manual valve assembly (1) and swivel tee (17) with coupling assembly (5) .
- Mount manual valve assembly (1) to the stick by installing plate (3) using bolt (8) and washer (7). Refer to Illustrations 3 and 5.
- Insert O-ring seal (13) into connector (12) on manual valve assembly (1) and connect hose (2) .
- Route hose (2) to the thumb cylinder and connect using the following parts: two half flanges (4), four bolts (8) and four washers (16) .
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| Illustration 6 | g03201856 |
Typical example. Close-up view of the connection to the hydraulic cylinder (4) 1P-4576 Half Flange (8) 5S-7382 Bolt (16) 8T-4896 Hard Washer | |
- Tighten all connections and hardware to standard torque.
- Open manual valves (1) on each side of the stick.
Note: When finished with the operation of manual valve (1) remove valve handle and place in the cab of the machine.
- Remove tooling (F) from the hydraulic tank.
- Test the operation of the thumb cylinder.
- Inspect the fittings for hydraulic leaks.