- Excavator:
- 330D (S/N: GBC1-UP; GGE1-UP; THJ1-UP; ERN1-UP; RAS1-UP; T2Y1-UP)
- Work Tool:
- HYDRAULIC KIT (S/N: HKD1-UP)
Introduction
This Special Instruction is for the installation of the 260-7860 Pilot Lines Gp .
Do not perform any procedure that is outlined in this publication without reading this article first.
Safety Section
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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 sudden work tool movement. Sudden movement of the work tool can cause injury to persons near the work tool. To prevent injury or death, make sure that the area around the work tool is clear of personnel and obstructions before operating the work tool. |
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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 attachments have been lowered, 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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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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| 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. |
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| Illustration 1 | g00104545 |
Prevent the machine from movement. Park the machine on a level surface.
Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.
Required Parts
| Parts List for 260-7860 Pilot Lines Gp Revision -06 | |||
|---|---|---|---|
| Item | Qty | Pt. No. | Part Name |
| (1) | 1 | 4I-0806 | Hose As |
| (2) | 2 | 4I-1688 | Hose As |
| (3) | 4 | 4I-9521 | Marker Band (Red) |
| (4) | 4 | 4I-9522 | Marker Band (Yellow) |
| (5) | 4 | 4I-9523 | Marker Band (Blue) |
| (6) | 4 | 4I-9524 | Marker Band (Brown) |
| (7) | 4 | 4I-9525 | Marker Band (Orange) |
| (8) | 4 | 4I-9527 | Marker Band (Green) |
| (9) | 10 | 7K-1181 | Cable Strap |
| (10) | 1 | 7Y-4387 | Hose As |
| (11) | 1 | 087-5306 | Hose As |
| (12) | 1 | 087-6583 | Hose As |
| (13) | 2 | 104-8783 | Hose As |
| (14) | 4 | 136-0207 | Cable Strap |
| (15) | 4 | 164-6874 | Elbow Fitting |
| (16) | 2 | 255-1826 | Spacer |
| (17) | 1 | 259-7429 | Solenoid Valve Gp |
| (18) | 1 | 260-8148 | Plate |
| (19) | 4 | 275-1442 | Clip |
| (20) | 4 | 275-1443 | Clip |
| (21) | 4 | 275-1444 | Grommet |
| (22) | 1 | 275-1693 | Support As |
| (23) | 2 | 275-1818 | Hose As |
| (24) | 1 | 282-7566 | Hose As |
| (25) | 1 | 286-6556 | Support As |
| (26) | 1 | 289-5283 | Hose As |
| (27) | 1 | 289-5286 | Hose As |
| (28) | 1 | 289-5289 | Hose As |
| (29) | 4 | 148-8336 | Connector As |
| (30) | 1 | 148-8338 | Connector As |
| (31) | 13 | 148-8378 | Elbow As |
| (32) | 1 | 148-8433 | Tee As |
| (33) | 1 | 150-3036 | Elbow As |
| (34) | 2 | 150-4027 | Tee As |
| (35) | 6 | 164-5567 | Quick Disconnect Coupler As |
| (36) | 1 | 171-0188 | Solenoid Valve Gp |
| (37) | 1 | 3P-9847 | Clip |
| (38) | 3 | 6D-3479 | Clip |
| (39) | 2 | 6E-1435 | Spacer |
| (40) | 6 | 6V-0852 | Dust Cap |
| (41) | 2 | 7X-2549 | Bolt |
| (42) | 9 | 8T-4121 | Hard Washer |
| (43) | 5 | 8T-4136 | Bolt |
| (44) | 1 | 8T-4137 | Bolt |
| (45) | 4 | 8T-4177 | Bolt |
| (46) | 2 | 8T-4185 | Bolt |
| (47) | 1 | 8T-4195 | Bolt |
| (48) | 4 | 8T-4223 | Hard Washer |
| (49) | 4 | 8T-4224 | Hard Washer |
| (50) | 2 | 8T-4956 | Bolt |
| (51) | 4 | 8T-6870 | Bolt |
| (52) | 2 | 9M-8406 | Clip |
| Standard Removal | |||
| Item | Qty | Pt. No. | Part Name |
| (--) | 1 | 148-8407 | Plug As |
| (--) | 2 | 4I-9523 | Marker Band (Blue) |
| (--) | 2 | 4I-9527 | Marker Band (Green) |
| (a) | 1 | 282-7566 | Hose As |
| (b) | 1 | 282-7569 | Hose As |
| (--) | 6 | 7K-1181 | Guard |
| (--) | 1 | 239-9097 | Cable Strap |
| (--) | 1 | 239-9098 | Plug As |
| (--) | 2 | 8T-4139 | Bolt |
| (--) | 2 | 8T-4223 | Hard Washer |
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| Illustration 2 | g03739293 |
260-7860 Pilot Lines Gp | |
Hose Connection Table
| Port Name | Band Color | Hose No. | Port Name | ||
| Pilot Manifold | "DR2" | -- | (1) 4I-0806 | Electronic Check Valve (Left) | "LD" |
| "DR6" | -- | (11) 087-5306 | Electronic Check Valve (Right) | "RD1" | |
| Control Valve | "aR2" | Red | (12) 087-6583 | 4 Multi Solenoid Valve | "A4" |
| "bR2" | Brown | (13) 104-8783 | "A3" | ||
| Stackable F2 Valve | "PU2" | Yellow | (10) 7Y-4387 | "A2" | |
| "PL2" | Orange | (13) 104-8783 | "A1" | ||
| NFC Valve | "B2" | Blue | (24) 282-7566 | Pump | "Pi1" |
| "A2" | Green | (26) 289-5283 | "Pi2" | ||
| "B1" | Blue | (27) 289-5286 | Control Valve | "HR" | |
| "A1" | Green | (28) 289-5289 | "HL" | ||
| "P" | -- | (2) 4I-1688 | Divider Block | "PB5" | |
| "T" | -- | (2) 4I-1688 | "DB5" | ||
| 4 Multi Solenoid Valve | "P" | -- | (23) 275-1818 | "PB4" | |
| "T" | -- | (23) 275-1818 | "DB4" | ||
Standard Removal
- Remove hoses (a) and (b) prior to installing 260-7860 Pilot Lines Gp .
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| Illustration 3 | g03735932 |
(a) 282-7566 Hose As (b) 282-7569 Hose As | |
Installation Procedure
- Assemble valve group (A) .
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| Illustration 4 | g03739447 |
4 Multi Solenoid Valve - Valve Group (A) (15) 164-6874 Elbow Fitting (17) 259-7429 Solenoid Valve Gp (25) 286-6556 Support As (31) 148-8378 Elbow As (33) 150-3036 Elbow As (35) 164-5567 Quick Disconnect Coupler As (40) 6V-0852 Dust Cap (42) 8T-4121 Hard Washer (43) 8T-4136 Bolt (51) 8T-6870 Bolt | |
- Assemble valve group (B) .
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| Illustration 5 | g03739448 |
NFC Valve - Valve Group (B) (29) 148-8336 Connector As (30) 148-8338 Connector As (31) 148-8378 Elbow As (34) 150-4027 Tee As (35) 164-5567 Quick Disconnect Coupler As (36) 171-0188 Solenoid Valve Gp (40) 6V-0852 Dust Cap (45) 8T-4177 Bolt (49) 8T-4224 Hard Washer | |
- Install valve group (A) to the frame.
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| Illustration 6 | g03739449 |
(3) 4I-9521 Marker Band (Red) (4) 4I-9522 Marker Band (Yellow) (6) 4I-9524 Marker Band (Brown) (7) 4I-9525 Marker Band (Orange) (10) 7Y-4387 Hose As (12) 087-6583 Hose As (13) 104-8783 Hose As (23) 275-1818 Hose As | |
- Connect one hose (23) from port "P" on valve group (A) to port "PB4" on the divider block.
- Connect the other hose (23) from port "T" on valve group (A) to port "DB4" on the divider block.
- Connect one hose (13) from port "A1" on valve group (A) to port "PL2" on the stackable control valve F2.
- Connect hose (10) from port "A2" on valve group (A) to port "PU2" on the stackable control valve F2.
- Connect the other hose (13) from port "A3" on valve group (A) to port "bR2" on the control valve.
- Connect hose (12) from port "A4" on valve group (A) to port "aR2" on the control valve.
- Install valve group (B) to the frame.
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| Illustration 7 | g03739451 |
(2) 4I-1688 Hose As (5) 4I-9523 Marker Band (Blue) (8) 4I-9527 Marker Band (Green) (14) 136-0207 Cable Strap (19) 275-1442 Clip (20) 275-1443 Clip (21) 275-1444 Grommet (22) 275-1693 Support As (23) 275-1818 Hose As (24) 282-7566 Hose As (26) 289-5283 Hose As (27) 289-5286 Hose As (28) 289-5289 Hose As (29) 148-8336 Connector As (37) 3P-9847 Clip (42) 8T-4121 Hard Washer (43) 8T-4136 Bolt (47) 8T-4195 Bolt (48) 8T-4223 Hard Washer (50) 8T-4956 Bolt | |
- Connect one hose (23) from port "P" on valve group (A) to port "PB4" on the divider block.
- Connect the other hose (23) from port "T" on valve group (A) to port "DB4" on the divider block.
- Connect one hose (2) from port "T" on valve group (B) to port "DB5" on the divider block.
- Connect the other hose (2) from port "P" on valve group (B) to port "T" on the divider block.
- Connect hose (27) from port "B1" on valve group (B) to port "HR" on the control valve.
- Connect hose (24) from port "B2" on valve group (B) to port "Pi1" on the pump.
- Connect hose (26) from port "A2" on valve group (B) to port "Pi2" on the pump.
- Connect hose (28) from port "A1" on valve group (B) to port "HL" on the control valve.
- Connect hose (27) from port "B1" on valve group (B) to port "HR" on the control valve.
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| Illustration 8 | g03739453 |
(3) 4I-9521 Marker Band (Red) (4) 4I-9522 Marker Band (Yellow) (5) 4I-9523 Marker Band (Blue) (6) 4I-9524 Marker Band (Brown) (7) 4I-9525 Marker Band (Orange) (8) 4I-9527 Marker Band (Green) (9) 7K-1181 Cable Strap (10) 7Y-4387 Hose As (12) 087-6583 Hose As (13) 104-8783 Hose As (27) 289-5286 Hose As (28) 289-5289 Hose As (29) 148-8336 Connector As (31) 148-8378 Elbow As | |
- Connect hose (28) from port "A1" on valve group (B) to port "HL" on the control valve.
- Connect one hose (13) from port "A1" on valve group (A) to port "PL2" on the stackable control valve F2.
- Connect hose (10) from port "A2" on valve group (A) to port "PU2" on the stackable control valve F2.
- Connect the other hose (13) from port "A3" on valve group (A) to port "bR2" on the control valve.
- Connect hose (12) from port "A4" on valve group (A) to port "aR2" on the control valve.
- Connect hose (1) from port "LD" on the electronic check valve (right) to port "DR2" on the pilot manifold.
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| Illustration 9 | g03739456 |
(1) 4I-0806 Hose As (9) 7K-1181 Cable Strap (16) 255-1826 Spacer (18) 260-8148 Plate (31) 148-8378 Elbow As (38) 6D-3479 Clip (39) 6E-1435 Spacer (41) 7X-2549 Bolt (42) 8T-4121 Hard Washer (44) 8T-4137 Bolt (46) 8T-4185 Bolt (48) 8T-4223 Hard Washer (52) 9M-8406 Clip | |
- Connect hose (11) from port "RD1" on the electronic check valve (right) to port "DR6" on the pilot manifold.
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| Illustration 10 | g03739457 |
(9) 7K-1181 Cable Strap (11) 087-5306 Hose As (31) 148-8378 Elbow As (38) 6D-3479 Clip (39) 6E-1435 Spacer (42) 8T-4121 Hard Washer (46) 8T-4185 Bolt (52) 9M-8406 Clip | |
- Connect hose (13) from port "A3" on valve group (A) to port "bR2" on the control valve.
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| Illustration 11 | g03739455 |
View from beneath control valve (1) 4I-0806 Hose As (6) 4I-9524 Marker Band (Brown) (9) 7K-1181 Cable Strap (11) 087-5306 Hose As (13) 104-8783 Hose As (31) 148-8378 Elbow As | |
- Connect hose (1) from port "LD" on the electronic check valve (left) to port "DR2" on the pilot manifold.
- Connect hose (11) from port "RD1" on the electronic check valve (right) to port "DR6" on the pilot manifold.