- Excavator:
- 374D (S/N: PJA1-UP; PAP1-UP; PAS1-UP; PAX1-UP)
- Work Tool:
- HYDRAULIC KIT (S/N: HKD1-UP)
Introduction
This Special Instruction provides the information that is necessary to install the 338-6188 Front Lines Gp on certain excavators.
Safety Section
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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. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.
Note: Drain the hydraulic fluid from the hydraulic tank before opening the hydraulic system. Remember to fill the hydraulic tank with hydraulic fluid once the installation is complete.
| 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 operating any compartment or disassembling any component containing fluids. After collecting all fluids in suitable containers, dispose of all fluids according to local regulations and mandates. |
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Check valves in the hydraulic system may allow pressure to exist in the hydraulic lines after the engine has been stopped. Pressure must be relieved prior to servicing the components of the hydraulic system. Failure to relieve pressure prior to servicing may result in personal injury. |
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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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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. |
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Required Parts
| Required Parts 338-6188 Front Lines Gp |
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|---|---|---|---|
| Item | Qty | Part Number | Description |
| (1) | 4 | 124-0909 | Clip |
| (2) | 1 | 160-0964 | Manual Valve Gp |
| (3) | 4 | 170-8553 | Bolt |
| (4) | 1 | 175-1814 | Manual Valve Gp |
| (5) | 1 | 232-4144 | Relief Valve Gp |
| () | 1 | 232-4145 | Block |
| () | 1 | 352-7168 | Relief Valve Gp |
| (6) | 2 | 236-3067 | Block |
| (7) | 1 | 236-3081 | Support |
| (8) | 1 | 245-5250 | Block |
| (9) | 1 | 266-0989 | Support |
| (10) | 1 | 266-0990 | Support As |
| (11) | 1 | 296-7210 | Block |
| (12) | 1 | 296-7211 | Tube As |
| (13) | 1 | 325-8841 | Block |
| (14) | 1 | 338-6047 | Tube As |
| (15) | 1 | 338-6048 | Tube As |
| (16) | 1 | 338-6212 | Hose As |
| (17) | 1 | 347-2076 | Hose As |
| (18) | 1 | 347-2077 | Pipe As |
| (19) | 2 | 352-6914 | Relief Valve Gp |
| (20) | 1 | 356-9091 | Support As |
| (21) | 1 | 356-9103 | Support As |
| (22) | 2 | 101-7402 | Bolt |
| (23) | 4 | 105-3485 | Bolt |
| (24) | 1 | 148-8408 | Plug As |
| () | 1 | 9S-4183 | O-Ring Plug |
| () | 1 | 3D-2824 | O-Ring Seal |
| (25) | 2 | 164-4180 | Plug As |
| () | 1 | 9S-4181 | O-Ring Plug |
| () | 1 | 7M-8485 | O-Ring Seal |
| (26) | 2 | 1P-3704 | Rectangular Seal |
| (27) | 8 | 1P-3705 | Rectangular Seal |
| (28) | 4 | 1P-4579 | Half Flange |
| (29) | 4 | 1P-5767 | Half Flange |
| (30) | 2 | 4J-0522 | O-Ring Seal |
| (31) | 3 | 4J-0524 | O-Ring Seal |
| (32) | 1 | 4J-0526 | O-Ring Seal |
| (33) | 1 | 5P-1076 | Hard Washer |
| (34) | 4 | 7X-2549 | Bolt |
| (35) | 12 | 7X-2550 | Bolt |
| (36) | 8 | 8T-4139 | Bolt |
| (37) | 4 | 8T-4140 | Bolt |
| (38) | 4 | 8T-4176 | Bolt |
| (39) | 9 | 8T-4183 | Bolt |
| (40) | 5 | 8T-4192 | Bolt |
| (41) | 4 | 8T-4194 | Bolt |
| (42) | 35 | 8T-4223 | Hard Washer |
| (43) | 2 | 8T-4648 | Bolt |
| (44) | 16 | 8T-4956 | Bolt |
| (45) | 4 | 9X-8257 | Washer |
| Standard Removal | |||
| (A) | 2 | 4I-7822 | Cover |
| (B) | 2 | 1P-3705 | Rectangular Seal |
| (C) | 8 | 8T-4139 | Bolt |
| (D) | 1 | 266-1001 | Support As |
| (E) | 1 | 239-2009 | Support As |
| (F) | 1 | 245-5222 | Cover |
| (G) | 1 | 4J-0524 | O-Ring Seal |
| (H) | 4 | 8T-4139 | Bolt |
| (J) | 2 | 6E-3993 | Plug As |
| Attachment Removal | |||
| (K) | 1 | 347-2086 | Pipe As |
| (L) | 1 | 4J-0524 | O-Ring Seal |
| (M) | 4 | 105-3485 | Bolt |
| (N) | 1 | 164-4180 | Plug As |
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| Illustration 2 | g02255413 |
Component view | |
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| Illustration 3 | g02255414 |
Component view | |
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| Illustration 4 | g02256493 |
Component view | |
Installation Procedure
- Remove cover (F), seal (G), and bolts (H). If this cover is not present, proceed to the next step.
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| Illustration 5 | g02263254 |
If Equipped (F) 245-5222 Cover (G) 4J-0524 O-Ring Seal (H) 8T-4139 Bolt | |
- Remove pipe assembly (K), bolts (M), and seal (L) .
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| Illustration 6 | g02263293 |
If Equipped (K) 347-2086 Pipe As (L) 4J-0524 O-Ring Seal (M) 105-3485 Bolt (N) 164-4180 Plug As | |
- Install two plug assemblies (25) into pipe assembly (18) .
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| Illustration 7 | g02530738 |
(18) 347-2077 Pipe As (23) 105-3485 Bolt (25) 164-4180 Plug As (31) 4J-0524 O-Ring Seal | |
- Install pipe assembly (18). Use seal (31), and four bolts (23) .
- Remove plug assembly (J). Install relief valve (19) into the rear of the main valve. Tighten the relief valve to a torque of 300 ± 40 N·m (221 ± 29 lb ft).
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| Illustration 8 | g02257154 |
(J) 6E-3993 Plug As (19) 352-6914 Relief Valve Gp | |
- Remove plug assembly (J). Install relief valve (19) into the front of the main valve. Tighten the relief valve to a torque of 300 ± 40 N·m (221 ± 29 lb ft).
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| Illustration 9 | g02257394 |
(J) 6E-3993 Plug As (19) 352-6914 Relief Valve Gp | |
- Remove support (D) and support (E). Remove all bolts (AB), washers (AC), and clips (AA). Remove bolts (AD), and washers (AE). These parts will be used again.
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| Illustration 10 | g02262814 |
(D) 266-1001 Support As (E) 239-2009 Support As (AA) 128-7514 Clip (AB) 8T-4140 Bolt (AC) 9X-8257 Washer (AD) 8T-4956 Bolt (AE) 5P-1076 Hard Washer | |
- Attach support (10) to support (21). Use bolt (33) and washer (39) .
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| Illustration 11 | g02530796 |
(X) 239-2009 Support As (Y) 5P-1076 Hard Washer (Z) 8T-4183 Bolt (AD) 8T-4956 Bolt (AE) 5P-1076 Hard Washer (7) 236-3081 Support (9) 266-0989 Support (10) 266-0990 Support As (20) 356-9091 Support As (21) 356-9103 Support As (33) 5P-1076 Hard Washer (36) 8T-4139 Bolt (39) 8T-4183 Bolt (42) 8T-4223 Hard Washer (43) 8T-4648 Bolt | |
- Install support (21). Reuse support (X), bolt (AD), and washer (AE). Secure the support with four bolts (Z), and four washers (Y) .
- Install support (20) onto support (21). Secure the support with two bolts (43), and two washers (42) .
- Install support (9) onto support (21). Secure the support with two bolts (36), and two washers (42) .
- Install support (7) onto support (21). Secure the support with two bolts (36), and two washers (42) .
- Remove bolts (C), covers (A), and seals (B) .
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| Illustration 12 | g02262913 |
(A) 4I-7822 Cover (B) 1P-3705 Rectangular Seal (C) 8T-4139 Bolt | |
- Attach tube assembly (14) to block (6). Use seal (27), and four bolts (44) .
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| Illustration 13 | g02260714 |
(1) 124-0909 Clip (6) 236-3067 Block (14) 338-6047 Tube As (15) 338-6048 Tube As (21) 356-9103 Support As (27) 1P-3705 Rectangular Seal (37) 8T-4140 Bolt (44) 8T-4956 Bolt (45) 9X-8257 Washer | |
- Attach the other end of tube assembly (14) to the "AR3" return port on the main valve block. Use seal (27), and four bolts (44) .
- Secure tube (14) to support (21) with two clips (1), two washers (45), and two bolts (37) .
- Attach tube assembly (15) to block (6). Use seal (27), and four bolts (44) .
- Attach the other end of tube assembly (15) to the "BR3" extend port on the main valve block. Use seal (27), and four bolts (44) .
- Secure tube (15) to support (21) with two clips (1), two washers (45), and two bolts (37) .
- Install plug assembly (24) into relief valve group (5) .
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| Illustration 14 | g02261514 |
(5) 232-4144 Relief Valve Gp (24) 148-8408 Plug As | |
- Install relief valve group (5) onto support (20). Secure the relief valve group with five bolts (40), and five washers (42) .
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| Illustration 15 | g02259633 |
(2) 160-0964 Manual Valve Gp (3) 170-8553 Bolt (5) 232-4144 Relief Valve Gp (6) 236-3067 Block (9) 266-0989 Support (11) 296-7210 Block (20) 356-9091 Support As (27) 1P-3705 Rectangular Seal (30) 4J-0522 O-Ring Seal (35) 7X-2550 Bolt (36) 8T-4139 Bolt (40) 8T-4192 Bolt (42) 8T-4223 Hard Washer | |
- Attach manual valve group (2) to block (6). Use seal (27), and four bolts (35) .
- Install block (11) onto manual valve group (2). Use seal (30), and four bolts (3) .
- Attach block (6) to support (9). Use two bolts (36), and two washers (42) .
- Attach manual valve group (4) to block (6). Use seal (27), and four bolts (35).
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| Illustration 16 | g02260277 |
(4) 175-1814 Manual Valve Gp (6) 236-3067 Block (7) 236-3081 Support (13) 325-8841 Block (27) 1P-3705 Rectangular Seal (35) 7X-2550 Bolt (36) 8T-4139 Bolt (42) 8T-4223 Hard Washer | |
- Attach block (13) to manual valve group (4). Use seal (27), four washers (42), and four bolts (35) .
- Attach block (6) to support (7). Use two bolts (36), and washers (42) .
- Attach hose (17) to pipe assembly (18). Use seal (31), two flanges (28), four bolts (39), four washers (42) .
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| Illustration 17 | g02530817 |
(5) 232-4144 Relief Valve Gp (17) 347-2076 Hose As (28) 1P-4579 Half Flange (39) 8T-4183 Bolt (42) 8T-4223 Hard Washer | |
- Attach hose (17) to relief valve group (5). Use seal (31), two flanges (28), four bolts (39), four washers (42) .
- Install block (8) onto relief valve group (5). Use seal (27) .
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| Illustration 18 | g02261454 |
(5) 232-4144 Relief Valve Gp (8) 245-5250 Block (13) 325-8841 Block (16) 338-6212 Hose As (26) 1P-3704 Rectangular Seal (27) 1P-3705 Rectangular Seal (28) 1P-4579 Half Flange (29) 1P-5767 Half Flange (34) 7X-2549 Bolt (41) 8T-4194 Bolt (42) 8T-4223 Hard Washer | |
- Attach hose assembly (16) to block (8). Use seal (26), two half flanges (29), four bolts (34), and four washers (42) .
- Attach the other end of hose assembly (16) to block (13). Use seal (26), two half flanges (29), four bolts (41), and four washers (42) .
- Install tube assembly (12) onto block (11). Use seal (30), and two bolts (22) .
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| Illustration 19 | g02261404 |
(5) 232-4144 Relief Valve Gp (11) 296-7210 Block (12) 296-7211 Tube As (22) 101-7402 Bolt (38) 8T-4176 Bolt | |
- Attach the other end of tube assembly (12) to the side of relief valve group (5). Use seal (32), and four bolts (38) .
