Procedure to Install the 418-0311 Connecting Lines Gp (Thumb) on Certain Hydraulic Excavators{5057, 5362, 6547} Caterpillar

Excavator:

320D (S/N: DHK1-UP; EBY1-UP)

324D (S/N: CJX1-UP)

325D (S/N: PEH1-UP)

Work Tool:

Thumb (S/N: THC1-UP)

Introduction

This Special Instruction contains the procedure for installing 418-0311 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	g03168576
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 (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.

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

Required Parts

Procedure to Install the Connecting Lines Gp

Illustration 2	g03202725
Left side view of stick (A) Existing hose (1) 126-8790 Manual Valve As (4) 384-7932 Hydraulic Block (6) 421-8416 Hose As

Illustration 3	g03202740
Left side close-up view of manual valve assembly (1) 126-8790 Manual Valve As (2) 376-7218 Plate (4) 385-1045 Hydraulic Block (5) 385-1046 Spacer (7) 1P-3703 Rectangular Seal (9) 3D-2824 O-Ring Seal (11) 5P-8245 Hard Washer (12) 5P-9436 Plug (14) 6A-5591 Bolt (15) 6V-5839 Washer (16) 6V-7744 Locknut (17) 6V-8336 Bolt (18) 6V-8716 Connector (19) 6V-9746 O-Ring Seal (20) 7M-8485 O-Ring Seal (21) 7X-2549 Bolt (23) 8T-0644 Bolt (24) 8T-4223 Hard Washer (26) 8T-6451 Elbow

Illustration 4	g03202773
Right side view of stick (A) Existing hose (1) 126-8790 Manual Valve As (3) 384-7931 Hydraulic Block (6) 421-8416 Hose As

Illustration 5	g03202799
Right side close-up view of manual valve assembly (1) 126-8790 Manual Valve As (2) 376-7218 Plate (3) 385-1044 Hydraulic Block (5) 385-1046 Spacer (8) 1P-3704 Rectangular Seal (9) 3D-2824 O-Ring Seal (11) 5P-8245 Hard Washer (12) 5P-9436 Plug (14) 6A-5591 Bolt (15) 6V-5839 Washer (16) 6V-7744 Locknut (17) 6V-8336 Bolt (18) 6V-8716 Connector (19) 6V-9746 O-Ring Seal (20) 7M-8485 O-Ring Seal (21) 7X-2549 Bolt (23) 8T-0644 Bolt (24) 8T-4223 Hard Washer (26) 8T-6451 Elbow

1. Install manual valve assembly (1) onto plate (2) using the following parts: two bolts (23), four washers (15) and two locknuts (16). Tighten to standard torque.

2. Install O-ring seals (20) and connectors (18) on to manual valve assembly (1) .

3. Install plug (12) with O-ring seal (9) into the back of hydraulic block (4) on the left side lines.

   Note: Use hydraulic block (3) on the right side lines.

Note: Do not tighten the following connections until all components are installed and arranged properly.

4. Install O-ring seal (9) onto elbow (26) and connect to hydraulic block (4) on the left side lines.

   Note: Use hydraulic block (3) on the right side lines.

5. Disconnect existing hose (A) and install hydraulic block (4) using the following parts: two rectangular seals (7), four bolts (21) and four washers (24) on the left side lines. Arrange as shown in Illustration 3.

   Note: Use hydraulic block (3) and rectangular seals (8) on the left side lines. Refer to Illustration 5.

6. Install O-ring seals (19) into connectors (18) on manual valve assembly (1) and connect to elbow (26) .

7. Mount manual valve assembly (1) to the stick by installing plate (2) using bolts (14) and washers (11). Arrange as shown in Illustrations 3 and 5.

   Note: Use spacer (5) when the four bolt flange on the hydraulic lines is arranged vertically. The hydraulic block must be rotated horizontally for this arrangement. Otherwise this part is not needed. Use bolts (17) when spacer (5) is used. If the spacer is not needed use bolts (14) .

8. Connect hose (6) to connector (15) and route to the thumb connection. Arrange as shown in Illustrations 2 and 4.

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Illustration 6	g03202960
Typical example. Close-up view of the connection to the hydraulic cylinder (10) 4J-0520 O-Ring Seal (13) 5S-7382 Bolt (22) 8C-3206 Half Flange (25) 8T-4896 Hard Washer

9. Connect hose (5) to the thumb cylinder using the following parts: O-ring seal (10), two half flanges (22), four bolts (13) and four washers (25) .

10. Tighten all connections and hardware to standard torque.

11. Open manual valve assemblies (1) on each side of the stick.

    Note: When finished with the operation of manual valve assemblies (1) remove valve handle and place in the cab of the machine.

12. Remove tooling (F) from the hydraulic tank.

13. Test operation of the thumb cylinder.

14. Inspect the fittings for hydraulic leaks.