- Excavator:
- 385B (S/N: FDL1-UP)
Introduction
The Special Instruction, REHS3981 is for retrofitting the 385B with a new fore boom proportional valve and other related components. If you need more information about the installation of these components on your machine, consult your Caterpillar dealer.
| NOTICE |
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Do not perform any procedure that is outlined in this publication and do not order any parts until you understand the information that is contained in this document. |
Safety Section
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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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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 Caterpillar dealer for replacement manuals. Proper care is your responsibility. |
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Required Parts
| Required Parts List | |||
|---|---|---|---|
| Item | Qty | Pt. No. | Part Name |
| (1) | 1 | 126-3494 | Hose As |
| (2) | 1 | 253-4213 | Hose As |
| (3) | 1 | 311-1038 | Pressure Control Valve Gp |
| (4) | 1 | 312-0802 | Block |
| (5) | 3 | 132-4618 | Tube Fitting |
| (6) | 2 | 233-7881 | Check Valve Gp |
| (7) | 1 | 286-9490 | Plate |
| (8) | 1 | 312-0705 | Load Control Valve Gp |
| (9) | 1 | 312-0801 | Plate As |
| (10) | 1 | 312-3136 | Adapter |
| (11) | 1 | 312-5057 | Hose As |
| (12) | 1 | 312-5058 | Hose As |
| (13) | 1 | 312-5130 | Hose As |
| (14) | 4 | 148-8367 | Elbow As |
| (15) | 1 | 148-8378 | Elbow As |
| (16) | 1 | 103-1313 | Support |
| (17) | 1 | 107-6656 | Flange |
| (18) | 1 | 288-4093 | Hose As |
| (19) | 1 | 288-6454 | Hose As |
| (20) | 1 | 288-6461 | Hose As |
| (21) | 1 | 288-6463 | Support As |
| (22) | 1 | 288-6465 | Bracket As |
| (23) | 1 | 288-8601 | Plate As |
| (24) | 1 | 289-4617 | Control Valve Gp |
| (25) | 1 | 300-3574 | Block |
| (26) | 1 | 304-4386 | Bracket |
| (27) | 1 | 8J-6875 | Shuttle Valve |
| (28) | 12 | 8T-4223 | Hard Washer |
| (29) | 2 | 8T-7930 | Bolt |
| (30) | 2 | 8T-4956 | Bolt |
| (31) | 2 | 8T-6912 | Bolt |
| (32) | 2 | 8T-4224 | Hard Washer |
| (33) | 8 | 8T-4139 | Bolt |
| (34) | 4 | 8T-0348 | Bolt |
| (35) | 4 | 7X-2543 | Bolt |
| (36) | 8 | 9X-8256 | Washer |
| (37) | 4 | 7X-2554 | Bolt |
| (38) | 6 | 9X-8257 | Washer |
| (39) | 4 | 107-2723 | Bolt |
| (40) | 2 | 7X-2553 | Bolt |
| (41) | 4 | 1P-5767 | Half Flange |
| (42) | 4 | 8T-4140 | Bolt |
| (43) | 2 | 6V-0400 | Half Flange |
| (44) | 8 | 8T-4194 | Bolt |
| (45) | 4 | 1P-4578 | Half Flange |
| (46) | 4 | 8T-4185 | Bolt |
| (47) | 8 | 8T-4121 | Hard Washer |
| (48) | 4 | 8T-4196 | Bolt |
| (49) | 2 | 8T-6974 | Bolt |
| (50) | 2 | 5C-2890 | Nut |
| (51) | 2 | 148-8439 | Tee As |
| (52) | 1 | 148-8336 | Connector As |
| NOTICE |
|---|
Use the appropriate required O-ring or D-ring seals |
Installation Procedure
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| Illustration 1 | g00104545 |
Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.
Do not tighten the hardware completely until the kit is fully installed in order to avoid fitting up problems and loss of hydraulic fluid. When possible, do not connect the hoses into the hydraulic system until the kit is fully installed.
- Disconnect hose (C) and hose (D) .
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| Illustration 2 | g01442692 |
- Remove connector (A) and the plate.
- Remove hose (B) .
- Install block (4) by using two bolts (29) and 2 washers (28) .
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| Illustration 3 | g01442726 |
- Install pressure control valve (3) onto block (4) by using two bolts (35) and two washers (36) .
- Reconnect hose (C) and hose (D) .
- Use connector (52) to connect hose (2) to pressure control valve (3) .
- Disconnect two hoses (F) and hose (E) from the locations that are shown in figure 4. Remove the brackets.
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| Illustration 4 | g01443642 |
- Save hoses (F) and hose (E) .
- Install plate (9) by using two bolts (30) and two washers (28) .
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| Illustration 5 | g01443540 |
- Install load control valve (8) on to plate (9) by using two bolts (31) and two washers (32) .
- Route hose (1) to elbow (14) which is shown in figure 5.
- Install adapter (10) and route hose (13) by using elbow (14) and elbow (15) .
- Reconnect hose (E) to load control valve (8) .
- Install plate (7) by using two bolts (37) and two washers (38) .
- Install check valves (6) by using 2 bolts (49), four washers (38), and two nuts (50) .
- Connect two tees (51) to check valves (6) .
- Route hose (11) and hose (12) .
- Install bracket (26) by using two bolts (37) and two washers (38) .
- Install valve (27) on to bracket (26) by using two bolts (35) and two washers (36) .
- Connect elbow (14) to valve (27) .
- Route hose (2) to elbow (14) on valve (27) .
- Reconnect hoses (F) to check valves (6) .
- Remove hose (G), hose (H), and hose (J) .
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| Illustration 6 | g01443769 |
- Remove block (K), adapter (L), and valve (M) .
- Remove plate (N) .
- Disconnect the other three hoses from the valve and mark the "Pi 1", "Pi 2", and "LS" as shown in figure 7.
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| Illustration 7 | g01454949 |
- Install support (16) and support (21) .
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| Illustration 8 | g01443790 |
- Attach plate (23) by using eight bolts (33) and eight washers (28) .
- Install bracket (22) by using two bolts (40) and two washers (38) .
Note: Protect hose (18) against interference with plate (23) .
- Install control valve (24) .
- Attach block (25) by using four bolts (34) .
- Install flange (17) by using four bolts (39) .
- Route hose (18) to the locations that are shown in figure 8. Use two half flanges (41), four bolts (42), and four washers (38) to connect hose (18) to block (25). Use two half flanges (43), four bolts (44), and four washers (28) to connect hose (18) to valve (24) .
- Route hose (19) to the locations that are shown in figure 8. Use two half flanges (45), four bolts (49), and four washers (47) to connect hose (19) to flange (17). Use two half flanges (45), four bolts (46), and four washers (47) to connect hose (20) to valve (24) .
- Route hose (20) to the locations that are shown in figure 8. Use two half flanges (41), four bolts (44), and four washers (28) to connect hose (21) to valve (24) .
- Reconnect the three hoses to control valve (24) that were disconnected in step 27, with respect to the markings. ( XT6-ES hose is the load sensing line.
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| Illustration 9 | g01451588 |
Port "Pi 1" | |
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| Illustration 10 | g01451594 |
Port "Pi 2" and port "LS" | |
- Tighten all hardware and fittings to the proper specifications.
- Secure all of the hoses in order to prevent the hoses from interfering with any other part of the machine.