Hydraulic Kit Parts & Installation Module

GEBB1084-01November 2005

Hydraulic Kit Parts & Installation ModuleHydraulic Kit- Pilot Lines (C) 248-9603

345C

3Table of Contents

Safety Section

Table of Contents

Safety SectionFluid Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Lines, Tubes and Hoses. . . . . . . . . . . . . . . . . . . . . . 4

Parts SectionAbbreviations and symbols . . . . . . . . . . . . . . . . . . . 5

Parts Pageshydraulic lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation SectionInstallation instructions. . . . . . . . . . . . . . . . . . . . . . 13

Summary of Hose Routing. . . . . . . . . . . . . . . . . . . 17

Parts Ordering Section0rdering Instructions . . . . . . . . . . . . . . . . . . . . . . . 18

4Safety SectionFluid Penetration

Safety Section

Fluid Penetration

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possibly death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high pressure lines. Do not install damaged lines, damaged tubes, or damaged hoses.

Repair loose lines, loose tubes, and loose hoses. Repair damaged lines, damaged tubes, and damaged hoses. Leaks can cause fires, See your Caterpillar dealer for repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque.

Replace the parts if any of the following conditions are present:

• The end fittings are damaged or leaking.

• The outer covering is chafed or cut.

• The wire shield is exposed.

• The outer covering is ballooning locally.

• The flexible part of the hose is kinked or crushed.

• The armoring is embedded in the outer cover.

• The end fittings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly.

5Parts Section

Attachment Identification

Parts Section

Attachment Identification

Caterpillar Work Tools products are identified with SERIAL NUMBERS, MODEL NUMBERS AND REFERENCE NUMBERS. These numbers are assigned to the product and completing components for the product (i.e. - lines groups, mounting brackets, etc. These numbers are shown on the SERIAL NUMBER plate.

Caterpillar dealers use all these numbers to determine which components were assembled on your product at the factory. This permits accurate identification of replacement part numbers.

Ordering Parts

Quality replacement parts are available from Caterpillar Dealers throughout the world. Their parts inventories are up to date and include parts required to repair or rebuild your Caterpillar work Tools product.When ordering parts, you should specify the quantity, part number, and you should provide attachment reference number, part name, and the serial number, if in doubt about the part number, please provide your Caterpillar dealer with a complete description of the needed item.

How To Use The Parts Book

Caterpillar Work Tools parts books include illustrations of the groups or assemblies which make up the product. These illustrations show the components of the product.

Abbreviations And Symbols

O.D. Outside diameterI.D. Inside diameterA Not serviced as a groupB Use as requiredC Change from previous typeD Order by the meterE Order by the centimeterF Not shownG Order by the inchI Refer to hydraulic information systemM Metric partN Note belowY separate illustration* Part available from Caterpillar Work Tools

Ref No.

The numbers shown in this column refer to the numbers shown within the illustration. To identify any item within the illustration, first determine its reference number, then refer to the same number in the Ref. No. column in the bill-of-materials for more information about the part

Part Number

These numbers identify the serviceable parts.

Qty

The quantities shown in this column indicate the total number of that item used in the group or assembly covered by the illustration.

Part Name

Information this column provides is the name of the part as well as additional information such as size, which further aids in the identification of the part.

Indented Parts Names

Within each illustration is a parts list identifying each serviceable part in the illustration. When a part name is indented in this list, it means that the serviceable item is a part of the serviceable item under which it is indented.

NOTE: Continuing improvements and advancements of product design may cause changes to your attachment which may not be included in this publication. Each publication is reviewed and revised, as required, to update and include these changes in later editions.

Whenever a question arises regarding your Caterpillar Work Tools product, or this publication, please consult your Caterpillar dealer for the most current information available.

6


7


Front of Machine

8


“HL” port

“HR” port

Back view of valve block

9


N

10


D

11


Front of Machine

12


P

ND

aR4 (boom 2)

13Installation Section

Application Information

Installation Section

Application Information

This kit is for the pump and lines group of the single function uses of hydraulic kits.

Maintenance Information

There is no scheduled maintenance required for this pilot lines group. General maintenance, such as replacing worn parts is necessary.

Installation Advice

Review all illustrations and instructions supplied with this lines group before attempting the installation. Follow all safety practices and warnings. Refer to your machine service manuals for port identification nomenclature.

Installation Instructions

To avoid fit up problems and loss of hydraulic fluid, do not completely tighten hardware until kit is fully installed. Do not plumb into hydraulic system until fully installed if possible.

INSTALLING LINES - Pilot GP (C).

Refer to previous parts pages.

Illustration 1

1. Preassemble fittings on to Solenoid Valve (11).

a.Insert fitting (14) into port A of valve (11). Fasten connector (12) on to fitting (14)

b.Fasten switch (16) on to Connector (12).

c.Attach valve (11) on to bracket (24) using bolts (50) and washers (53).

Illustration 2

4. Preassemble hardware on to Pressure Reducing Valve (17):

a.Insert nipple (39), tee (38) into ports A2 and B2 of PRV. Place caps (44) on tees (38).

b.Connect one each of elbow (34) into port A1 and B1 of PRV.

c.Insert tee (36) into port “P” of the PRV.

d.Insert connector (32) into port “T” of the PRV.

e.Fasten PRV on to support (21) using bolts (51) and washers (54).

6. Mount the pressure reducing valve (17) on the cross member inside the pump compartment using bolts (49) and washers (48). See Illustration 2 for proper orientation of valve.

7. Mount solenoid valve (11) on to pump compartment using bolts (50) and washers (53). See Illustration 2 for proper orientation of valve.

8. Mount plate (26) to the machine’s frame inside the pump compartment. Use bolts (50) and

31

31

31

12

16

14

32

36

34

34

38,39,44

cross member

14Installation SectionINSTALLING LINES - Pilot GP (C).

washers (53) to fasten the plate to the frame. (Refer to illustration on page 10 for location)

9. Remove existing hoses from top of the pump. The existing hoses route from the pump to the “HL” and “HR” ports of the machine’s valve block. These hoses can be completely discarded.

10. Fasten hose (28) to tee (38) located on the A2 port of PRV (17).Route hose (28) up to the pump and connect hose into Pi2 port of pump.

11. Fasten hose (29) to tee (38) located on the B2 port of PRV (17). Route hose (29) up to pump and connect into Pi1 port of pump.

12. Gather hoses (28) and (29). Using grommet (45), clips (41), clips (40), bolts (49) and washers (48), fasten hoses to plate (26) inside the pump compartment. (Refer to illustration on page 10 for mounting location)

13. Locate two straps (7) around hose (28) and (29). (Refer to illustration on page 12 for general location of straps.)

14. Connect hose (25) to elbow (34) located on A1 port of the pressure reducing valve. Route hose (25) over to machine’s valve block and insert the hose on to the existing connector located on the “HL” port of the valve block. (“HL” port is located on back side of the valve block, on right hand side).

15. Connect hose (27) to elbow (34) located on B1 port of the pressure reducing valve. Route hose (27) over to machine’s valve block and insert the hose on to the existing connector located on the “HR” port of the valve block. (“HR” port is located on back side of the valve block, on left hand side).

16. Gather hose (25) and (27) in the pump compartment. Using grommet (45), clips (41), clips (40), bolts (49) and washers (48), fasten hoses to plate (26) inside the pump compartment. (Refer to illustration on page 10 for mounting location)

17. To prevent interference with other components of the machine, support hose (25) and (27) with one strap (7) inside the pump compartment.

(Refer to illustration on page 10 for general location)

Illustration 3

18. Locate the machine’s pilot manifold on the front side of the valve block (right hand side). Insert tee (36) into PSA2 port of the pilot manifold. Attach cap (47) to the end port of tee (36).

19. Connect hose (19) to the end port of tee (36) located on the pressure reducing valve.

20. Route hose (19) over to the pilot manifold and connect to the center port of tee (36) located on PSA2 port of the pilot manifold.

21. Fasten hose (3) to center port of tee (36) located on the “P” port of the pressure reducing valve. Route hose (3) over to solenoid valve (11) and connect into the “P” port of the solenoid valve.

22. Fasten hose (8) to connector (32) located on the “T” port of the pressure reducing valve. Route hose (8) over to the tank. Connect hose (8) to existing tee located closest to the center of the machine.

23. Connect hose (2) to connector (31) located on the “T” port of solenoid valve (11). Route hose to

Pilot Manifold

36

19

47



the tank manifold. Connect hose (2) to existing tee located closest to the outside of the machine.

24. Connect hose (20) to connector (12) located on the “A” port of valve (11). Route hose over to the machine’s valve block. Locate the bottom port of the attachment spool (ATCH) and insert connector (31) into the port. Connect hose (20) to connector (31)

25. Inside the pump compartment, gather hoses (8), (19), (20) and (2). Position guard (30) between solenoid valve (11) and tank. Wrap guard around the four hoses and secure with two of strap (7).

Illustration 4

26. Preassemble fittings on to valve (10):

a.Insert connector (31) into port CB1.

b.Insert one each of elbow (34) into port CA and CB2.

c.Insert elbow (37) into port CD.

d.Fasten valve (10) on to support (22) using bolts (52) and washers (48).

Illustration 5

27. Below machine’s valve block, mount valve (10) to the frame. Valve should be mounted on the front facing side of the valve block.

28. Connect hose (1) to elbow (34) located on port CA of valve (10). Route hose (1) over to tank manifold located in the pump compartment. Fasten hose to tee fitting located closest to the outside of the machine.

Illustration 6

29. Locate DR4 port on the left side of the valve block. Install connector (23) into port.

30. Fasten elbow (15) on to connector (23). Be sure to add o-ring (42) when installing elbow.

31. Connect second elbow (15) on to elbow (15) installed in step 30. Be use o-ring (46) in the connection.

34

34

31

37

1523

6

16Installation SectionINSTALLING LINES - Pilot GP (C).

32. Fasten check valve (6) on to elbow (15) using o-ring (42). Be sure to orient the check valve to face towards valve (10).

33. Connect hose (4) on to connector (31) located on port CB1 of valve (10). Route and connect opposite end of hose to check valve (6).

34. Insert tee (36) into the top port of the “boom up” spool (aL4), located on the back side of the valve block.

35. Fasten hose (9) to tee (36) located in the top port of aL4. Route hose down the valve block and over to valve (10). Connect the opposite end of hose to elbow (37) located on CD port of valve (10).

36. Insert elbow (33) to the top of the attachment spool (ATCH port), located on the backside of the valve block.

Illustration 7

37. Connect hose (5) to tee (33) located on the ATCH port. Route the hose down the valve block and connect into the tank manifold located directly below the valve block. Be sure to insert connector (31) into tank manifold when connecting hose.

38. Located on the back side of the valve block, insert tee (13) into the center port of the attachment spool.

Illustration 8

Illustration 9

39. Connect hose (1) to end port of tee (13) located in center port of attachment valve. Route hose down the back side of valve block and over to the pilot pressure manifold (located on the front side of the valve block, on the left hand side).

40. Remove existing hose from the P2 port of the pilot manifold (refer to illustration 9 for location). Insert tee (36) into the P2 port. Connect existing hose on to the end port of tee (36) and connect hose (1) on to center port of tee (36).

41. Connect hose (18) to the center port of tee (13) located on the middle port of the attachment valve.

Tank Manifold 5

(as viewed from front)

Pilot Pressure Manifold

1



42. Route hose (18) down the back side of the valve block over to valve (10). Connect the hose to elbow (34) located on the CB2 port of valve (10).

43. Locate the plug on top of the aR2 spool (“boom 2” spool). Remove the existing plug and replace with plug (35).

44. Tighten all hardware and fittings to proper torque.

45. Gather hoses where necessary and secure in place with straps (7). Review parts pages 7-12 to find general locations of straps.

46. Check for leaks

Summary of Hose Routing

Summary of Hose Routing

Hose Reference Hose Part Number Routing

A 272-4137 From “HR” port of valve block to port B1 of PRV

B 266-1290 From “HL” port of valve block to port A1 of PRV

C 4I-0797 From center port of attachment spool to port P2 of pilot manifold

D 4I-0797 From port CA of valve 119-5219 to tank manifold (in pump compartment)

E 192-6775 From center port of attachment spool to CB2 port of valve 119-5219

F 087-5777 From top port of aL4 valve to port CD of valve 119-5219

G 4I-5795 From top port of attachment spool to tank manifold (below valve block)

H 272-4138 From Pi2 port of pump to A2 port of PRV

I 272-4139 From Pi1 port of pump to B2 port of PRV

J 7Y-8379 From T port of PRV to tank manifold (in pump compartment)

K 218-1336 From P port of PRV to PSA2 port of pilot manifold

L 221-4882 From A port of solenoid valve to bottom port of attachment spool

M 4I-0818 From T port of solenoid valve to tank manifold (inside pump compartment)

N 4-1760 From P port of PRV to P port of solenoid valve

O 4I-1880 From check valve-7836 to port CB1 of valve 119-5219

18Installation SectionParts Ordering Instructions

Parts Ordering Instructions

Caterpillar Work Tools parts are only distributed through Caterpillar dealer parts departments. All orders and inquiries relating to service for Caterpillar Work Tools attachment service parts should be placed through your Caterpillar dealer.

Caterpillar dealer inquiries should be directed to the order desk at Caterpillar Work Tools:

Address:

Caterpillar Work Tools Inc.400 Work Tool DrivePO Box 6Wamego, KS66547-0006

Phone:

800-752-2858

Fax:

785-456-2027

When inquiring or placing an order please provide:

Part NumberQuantityDescriptionMethod of Shipment

To ensure the proper part is ordered, provide the Caterpillar Work Tools:

Attachment Group/Part NumberAttachment Serial NumberAttachment Model Number

Any or all of the above numbers will help in ordering the correct service part.

Documents

Hydraulic Kit Parts & Installation Module