Installation Procedure to Retrofit Boom and Stick Lowering Control Valves, and a Stick Cylinder Lines Group on Certain 320D, 320D2, and 323DExcavators{5117, 5453, 5458} Caterpillar


Installation Procedure to Retrofit Boom and Stick Lowering Control Valves, and a Stick Cylinder Lines Group on Certain 320D, 320D2, and 323DExcavators{5117, 5453, 5458}

Usage:

320D BWZ
Excavator:
320D (S/N: DFB1-UP; KGF1-UP; TDH1-UP; FAL1-UP; KLM1-UP; WJN1-UP; GDP1-UP; SNS1-UP; BWZ1-UP)
320D2 (S/N: YEA1-UP; PBB1-UP; TMF1-UP; KHR1-UP; KBS1-UP; ZCS1-UP)
323D (S/N: GTF1-UP)

Introduction

This Special Instruction outlines the installation procedure to retrofit a 270-5974 Check and Relief Valve Ar (Boom Lowering Control Valve), a 419-5123 Check and Relief Valve Ar (Stick Lowering Control Valve), and a 419-5136 Stick Cylinder Lines Gp on the machines listed above.

Do not perform any procedure or order any parts that are outlined in this publication until you understand the information.

Safety


NOTICE

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.


------ WARNING! ------

Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted.

When possible, the bucket or attachment must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and bucket or attachment have correct support.

The swing lock (if equipped) must be engaged before service is started.

Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

----------------------

Required Parts

270-5974 Check and Relief Valve Ar

Table 1
286-6495 Boom Cylinder Lines Gp    
Item     Part Number     Part Name     Qty    
1     4I-1674     Clip     4    
2     7K-1181     Cable Strap     12    
3     119-2804     Support As     2    
4     149-1738     Clip     4    
5     225-4785     Load Control Valve Gp     2    
6     266-1110     Tube As     1    
7     266-1111     Tube As     1    
8     266-1114     Tube As     1    
9     266-1115     Tube As     1    
10     266-1116     Support As     2    
11     266-1147     Hose As (1)     1    
323-6157 Permanent Coupling As     2    
161-1833 Hydraulic Hose     44 cm (17.3 inch)    
12     320-0013     Hose As     2    
13     278-6587     Block     1    
14     278-6593     Hose As (1)     2    
124-2150 Permanent Coupling     2 (one per hose assembly)    
7I-1024 Hose Guard    
90 cm (35.4 inch) (per hose assembly)    
122-6871 Hydraulic Hose    
86 cm (33.9 inch) (per hose assembly)    
124-2119 Permanent Coupling     2 (one per hose assembly)    
15     278-6875     Support As     1    
16     278-6877     Support As     1    
17     286-6731     Hose As     2    
18     286-6720     Tube As     1    
19     286-6721     Tube As     1    
20     148-8326     Connector As (2)     2    
3J-7354 O-Ring Seal     2    
6V-8397 O-Ring Seal     2    
6V-9872 Connector     2    
21     148-8336     Connector As (2)     4    
3J-1907 O-Ring Seal     4    
6V-8397 O-Ring Seal     4    
6V-8636 Connector     4    
22     148-8341     Connector As (2)     2    
3D-2824 O-Ring Seal     2    
6V-8713 Connector     2    
7J-9108 O-Ring Seal     2    
23     148-8371     Elbow As (3)     1    
6V-8397 O-Ring Seal     1    
8C-8988 Elbow     1    
24     148-8378     Elbow As (3)     2    
3J-1907 O-Ring Seal     2    
6V-8397 O-Ring Seal     2    
6V-8724 Elbow     2    
25     148-8390     Elbow As (3)     1    
2M-9780 O-Ring Seal     1    
6V-8626 Elbow     1    
7J-9108 O-Ring Seal     1    
26     148-8407     Plug As (4)     2    
3J-1907 O-Ring Seal     2    
9S-4191 Plug     2    
27     148-8411     Plug As (4)     2    
3K-0360 O-Ring Seal     2    
9S-4185 Plug     2    
28     148-8435     Tee As (5)     2    
3J-1907 O-Ring Seal     2    
6V-8397 O-Ring Seal     4    
6V-8781 Tee     2    
29     164-5578     Tee As (5)     1    
3D-2824 O-Ring Seal     1    
6V-9175 Tee     1    
6V-9746 O-Ring Seal     1    
7J-9108 O-Ring Seal     1    
30     1P-3703     Rectangular Seal     6    
31     4I-9521     Marker Band (RED, L1)     2    
32     4I-9522     Marker Band (YELLOW, L2)     2    
33     4I-9525     Marker Band (ORANGE, R1)     2    
34     4I-9526     Marker Band (WHITE, R2)     2    
35     6V-9746     O-Ring Seal     4    
36     7J-9108     O-Ring Seal     2    
37     280-2747     Bolt     8    
38     8T-4121     Hard Washer     18    
39     8T-4136     Bolt     2    
40     8T-4185     Bolt     8    
41     8T-4192     Bolt     2    
42     8T-4196     Bolt     8    
43     8T-4223     Hard Washer     12    
44     8T-4956     Bolt     10    
45     8T-6466     Bolt     8    
46     307-5121     Guard     1    
( 1 ) Hose assembly is not serviceable.
( 2 ) Connector assembly is not serviceable.
( 3 ) Elbow assembly is not serviced.
( 4 ) Plug assembly is not serviced.
( 5 ) Tee assembly is not serviced.

Table 2
282-7161 Return Lines Gp    
Item     Part Number     Part Name     Qty    
1     7K-1181     Cable Strap     1    
2     107-1567     Hose As     1    
3     319-9845     Hose As (1)     1    
124-2123 O-Ring Face Seal Coupling     2    
122-6873 Hydraulic Hose    
122 cm (48 inch)    
4     201-9378     Block     1    
5     307-4920     Fitting     1    
6     148-8357     Elbow As (2)     1    
5K-9090 O-Ring Seal     1    
6V-9008 Elbow     1    
7M-8485 O-Ring Seal     1    
7     148-8411     Plug (3)     1    
3K-0360 O-Ring Seal     1    
9S-4185 Plug     1    
8     1P-3703     Rectangular Seal     1    
9     4J-5268     O-Ring Seal     1    
10     148-8327     Connector As (4)     1    
3D-2824 O-Ring Seal     1    
6V-8637 Connector     1    
6V-9746 O-Ring Seal     1    
( 1 ) Hose assembly is not serviceable.
( 2 ) Elbow assembly is not serviceable.
( 3 ) Plug assembly is not serviceable.
( 4 ) Connector assembly is not serviceable.

Table 3
282-7162 Pilot Lines Gp    
Item     Part Number     Part Name     Qty    
1     4I-0800     Hose As     1    
2     5I-8825     Hose As (1)     1    
149-8474 Permanent Coupling     1    
149-8493 Permanent Coupling     1    
188-4653 Hydraulic Hose    
69 cm (27.2 inch)    
3     4I-3981     Hose As (1)     1    
149-8474 Permanent Coupling     2    
188-4653 Hydraulic Hose    
269 cm (105.9 inch)    
4     7K-1181     Cable Strap     12    
5     133-5813     Marker Band (GRAY, P)     2    
6     199-1863     Hose As (1)     1    
149-8474 Permanent Coupling     2    
423-1971 Hose    
332 cm (130.7 inch)    
7     148-8363     Elbow As (2)     1    
3K-0360 O-Ring Seal     1    
6V-8397 O-Ring Seal     1    
6V-9876 Elbow     1    
8     148-8433     Tee As (3)     1    
6V-8397 O-Ring Seal     2    
6V-9836 Swivel Tee     1    
9     5K-8451     Clip     1    
10     8T-4121     Hard Washer     1    
11     8T-4191     Bolt     1    
( 1 ) Hose assembly is not serviceable.
( 2 ) Elbow assembly is not serviceable.
( 3 ) Tee assembly is not serviceable.

419-5123 Check and Relief Valve Ar (STICK LOWER CONT, REACH BOOM)

Table 4
242-6505 Boom Lines Gp (STICK LOAD CONTROL)    
Item     Part Number     Part Name     Qty    
1     5I-4393     Hose As (1)     1    
149-8476 Permanent Coupling     2    
423-1972 Hose    
83 cm (32.7 inch)    
2     5Q-4213     Clip     6    
3     7K-1181     Cable Strap     5    
4     202-3915     Plate     1    
5     268-6850     Hose As (1)     2    
146-3340 Permanent Coupling     4    
6V-8397 O-Ring Seal     4    
135-7855 Hose    
697.6 cm (274.6 inch)    
6     288-7410     Tube As     1    
7     282-5567     Plate     1    
8     149-5452     Union As (2)     2    
6V-8397 O-Ring Seal     2    
6V-8994 Union     1    
9     5Q-4212     Clip     2    
10     6V-8398     O-Ring Seal     2    
11     6V-9168     Nut     2    
12     7X-2549     Bolt     2    
13     8T-4139     Bolt     6    
14     8T-4223     Hard Washer     8    
15     8T-4244     Nut     6    
16     179-5030     Clip (3)     6    
17     8T-7930     Bolt (4)     2    
( 1 ) Hose assembly is not serviceable.
( 2 ) Union assembly is not serviceable.
( 3 ) For use with auxiliary medium pressure lines. Replaces clip (2) .
( 4 ) For use with auxiliary medium pressure lines. Replaces bolt (12) .

Table 5
260-7970 Pilot Lines Gp (LOAD CONTROL, STICK CYLINDER)    
Item     Part Number     Part Name     Qty    
1     7K-1181     Cable Strap     7    
2     201-9379     Block     1    
3     275-1712     Hose As (1)     1    
7I-7439 Hose Guard    
139 cm (54.7 inch)    
149-8474 Permanent Coupling     1    
149-8493 Permanent Coupling     1    
423-1971 Hose    
294 cm (115.7 inch)    
4     275-1713     Hose As     1    
5     282-7079     Hose As (1)     1    
7I-7439 Hose Guard    
220 cm (86.6 inch)    
149-8476 Permanent Coupling     1    
149-8502 Permanent Coupling As     1    
205-3719 Hose    
168.5 cm (66.3 inch)    
6     148-8336     Connector As (2)     1    
3J-1907 O-Ring Seal     1    
6V-8397 O-Ring Seal     1    
6V-8636 Connector     1    
7     148-8364     Elbow As (3)     1    
3K-0360 O-Ring Seal     1    
6V-8398 O-Ring Seal     1    
6V-8625 Elbow     1    
8     148-8433     Tee As (4)     1    
6V-8397 O-Ring Seal     2    
6V-9836 Swivel Tee     1    
9     148-8434     Tee As (4)     1    
6V-8397 O-Ring Seal     2    
6V-9843 Tee     1    
10     136-0207     Cable Strap     6    
11     133-5813     Marker Band (GRAY, P)     2    
12     4I-9523     Marker Band (BLUE, L3)     4    
13     6V-9829     Cap As     1    
( 1 ) Hose assembly is not serviceable.
( 2 ) Connector assembly is not serviceable.
( 3 ) Elbow assembly is not serviceable.
( 4 ) Tee assembly is not serviceable.

419-5136 Stick Cylinder Lines Gp (STICK LOWERING CONTROL)

Table 6
419-5136 Stick Cylinder Lines Gp    
Item     Part Number     Part Name     Qty    
1     5Q-4213     Clip     4    
2     093-1294     Clamp     2    
3     247-9073     Tube As     1    
4     247-9074     Tube As     1    
5     247-9076     Tube As     1    
6     247-9078     Tube As     1    
7     352-7243     Check and Relief Valve Gp     1    
8     420-1013     Support As     2    
9     420-1015     Support As     2    
10     108-1782     Bolt     4    
11     148-8328     Connector As (1)     1    
3D-2824 O-Ring Seal     1    
6V-8398 O-Ring Seal     1    
6V-8633 Connector     1    
12     148-8368     Elbow As (2)     2    
3J-1907 O-Ring Seal     1    
4J-5477 O-Ring Seal     1    
6V-8627 Elbow     1    
13     1P-3703     Rectangular Seal     1    
14     1P-3704     Rectangular Seal     1    
15     6V-8397     O-Ring Seal     2    
16     6V-8398     O-Ring Seal     1    
17     6V-9746     O-Ring Seal     1    
18     8T-4121     Hard Washer     10    
19     8T-4139     Bolt     4    
20     8T-4186     Bolt     2    
21     8T-4196     Bolt     8    
22     8T-4223     Hard Washer     8    
23     8T-4648     Bolt     4    
( 1 ) Connector assembly is not serviceable.
( 2 ) Elbow assembly is not serviceable.

Machine Preparation

  1. Position the machine on level ground.

  1. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the ground. Lower the boom until the bucket is flat on the ground.

  1. Shut off the engine.

  1. Release the pressure in the hydraulic system. Refer to the appropriate Testing and Adjusting, "Hydraulic System Pressure - Release" procedure for your machine.

Installation Procedure for the 270-5974 Check and Relief Valve Ar

Removal of Standard Parts

Before installing 286-6495 Boom Cylinder Lines Gp of the 270-5974 Check and Relief Valve Ar , remove the standard parts listed in Tables 7, 8 and 9.

242-6732 Boom Cylinder Lines Gp (LH)

Table 7
Standard Removal Parts    
Item     Part Number     Part Name     Qty    
1     247-8869     Tube As     1    
2     222-0126     Tube As     1    
3     095-1597     O-Ring Seal     2    
4     9X-6032     Bolt     8    
5     137-3709     Support As     1    
6     4I-3621     Support     1    
7     8T-4196     Bolt     2    
8     8T-4896     Hard Washer     2    
9     8T-3653     Bolt     1    
10     3B-4509     Lockwasher     1    
11     094-1920     Clamp     2    



Illustration 1g03827987

242-6732 Boom Cylinder Lines Gp

(1) 247-8869 Tube As

(2) 222-0126 Tube As

(3) 095-1597 O-Ring Seal

(4) 9X-6032 Bolt

(5) 137-3709 Support As

(6) 4I-3621 Support

(7) 8T-4196 Bolt

(8) 8T-4896 Hard Washer

(9) 8T-3653 Bolt

(10) 3B-4509 Lockwasher

(11) 094-1920 Clamp

  1. Remove the standard parts listed in Table 7 and shown in Illustration 1.

242-6737 Boom Cylinder Lines Gp (RH)

Table 8
Standard Removal Parts    
Item     Part Number     Part Name     Qty    
1     095-1597     O-Ring Seal     2    
2     9X-6032     Bolt     8    
3     222-0124     Tube As     1    
4     247-8870     Tube As     1    
5     094-1920     Clamp     2    
6     8T-3653     Bolt     1    
7     3B-4509     Lockwasher     1    
8     8T-4196     Bolt     2    
9     8T-4896     Hard Washer     2    
10     4I-3621     Support     1    
11     137-3709     Support As     1    



Illustration 2g03828035

242-6737 Boom Cylinder Lines Gp

(1) 095-1597 O-Ring Seal

(2) 9X-6032 Bolt

(3) 222-0124 Tube As

(4) 247-8870 Tube As

(5) 094-1920 Clamp

(6) 8T-3653 Bolt

(7) 3B-4509 Lockwasher

(8) 8T-4196 Bolt

(9) 8T-4896 Hard Washer

(10) 4I-3621 Support

(11) 137-3709 Support As

  1. Remove the standard parts listed in Table 8 and shown in Illustration 2.

239-1699 Boom Cylinder Lines Gp (BOOM)

Table 9
Standard Removal Parts    
Item     Part Number     Part Name     Qty    
1     124-1062     Support As     1    
2     8T-4192     Bolt     2    
3     8T-4223     Hard Washer     2    
4     6V-9746     O-Ring Seal     4    



Illustration 3g03827965

Right side view of 239-1699 Boom Cylinder Lines Gp

(1) 124-1062 Support As

(2) 8T-4192 Bolt

(3) 8T-4223 Hard Washer

(4) 6V-9746 O-Ring Seal

(A) Swing drive

  1. Remove the standard parts listed in Table 9 and shown in Illustration 3.

Installation of 286-6495 Boom Cylinder Lines Group




    Illustration 4g03788680

    286-6495 Boom Cylinder Lines Gp

    (1) 4I-1674 Clip

    (2) 7K-1181 Cable Strap

    (3) 119-2804 Support As

    (4) 149-1738 Clip

    (5) 225-4785 Load Control Valve Gp

    (6) 266-1110 Tube As

    (7) 266-1111 Tube As

    (8) 266-1114 Tube As

    (9) 266-1115 Tube As

    (10) 266-1116 Support As

    (11) 266-1147 Hose As

    (12) 320-0013 Hose As

    (13) 278-6587 Block

    (14) 278-6593 Hose As

    (15) 278-6875 Support As

    (16) 278-6877 Support As

    (17) 286-6731 Hose As

    (18) 286-6720 Tube As

    (19) 286-6721 Tube As

    (20) 148-8326 Connector As

    (21) 148-8336 Connector As

    (22) 148-8341 Connector As

    (23) 148-8371 Elbow As

    (24) 148-8378 Elbow As

    (25) 148-8390 Elbow Gp

    (26) 148-8407 Plug As

    (27) 148-8411 Plug

    (28) 148-8435 Tee As

    (29) 164-5578 Tee As

    (30) 1P-3703 Rectangular Seal

    (31) 4I-9521 Marker Band

    (32) 4I-9522 Marker Band

    (33) 4I-9525 Marker Band

    (34) 4I-9526 Marker Band

    (35) 6V-9746 O-Ring Seal

    (36) 7J-9108 O-Ring Seal

    (37) 280-2747 Bolt

    (38) 8T-4121 Hard Washer

    (39) 8T-4136 Bolt

    (40) 8T-4185 Bolt

    (41) 8T-4192 Bolt

    (42) 8T-4196 Bolt

    (43) 8T-4223 Hard Washer

    (44) 8T-4956 Bolt

    (45) 8T-6466 Bolt

    (46) 307-5121 Guard

    (A) Upper frame

    (B) Boom cylinder

  1. Install 286-6495 Boom Cylinder Lines Gp . Refer to Table 1 for a list of the required parts. Refer to Illustration 4 for the location of the parts. Refer to Tables 10 and 11 for the required parts to build hose assemblies (11) and (14). Refer to Tables 12, 13, and 14 for the required parts to build connector assemblies (20), (21), and (22). Refer to Tables 15 and 16 for the required parts to build elbow assemblies (24) and (25). Refer to Tables 17 and 18 for the required parts to build plug assemblies (26) and (27). Refer to Tables 19 and 20 for the required parts to build tee assemblies (28) and (29). Refer to Table 21 for specifications.

    Table 10
    Hose Assembly    
    Item     Part Number     Part Name     Qty    
    11     266-1147     Hose As     1    
    -     323-6157     Permanent Coupling As     2    
    -     161-1833     Hydraulic Hose    
    44 cm (17.3 inch)    

    Total assembled length of hose assembly (11) ... 510 ± 5 mm (20.1 ± 0.12 inch)

    Table 11
    Hose Assembly    
    Item     Part Number     Part Name     Qty    
    14     278-6593     Hose As     2    
    -     124-2150     Permanent Coupling     2 (one per hose assembly)    
    -     7I-1024     Hose Guard    
    90 cm (35.4 inch) (Length per hose assembly)    
    -     122-6871     Hydraulic Hose    
    86 cm (33.0 inch) (Length per hose assembly)    
    -     124-2119     Permanent Coupling     2 (one per hose assembly)    

    Total assembled length for each hose assembly (14) ... 940 ± 15 mm (37.0 ± 0.6 inch)

    Table 12
    Connector Assembly    
    Item     Part Number     Part Name     Qty    
    20     148-8326     Connector As     2    
    -     3J-7354     O-Ring Seal     2    
    -     6V-8397     O-Ring Seal     2    
    -     6V-9872     Connector     2    

    Table 13
    Connector Assembly    
    Item     Part Number     Part Name     Qty    
    21     148-8336     Connector As     4    
    -     3J-1907     O-Ring Seal     4    
    -     6V-8397     O-Ring Seal     4    
    -     6V-8636     Connector     4    

    Table 14
    Connector Assembly    
    Item     Part Number     Part Name     Qty    
    22     148-8341     Connector As     2    
    -     3D-2824     O-Ring Seal     2    
    -     6V-8713     Connector     2    
    -     7J-9108     O-Ring Seal     2    

    Table 15
    Elbow Assembly    
    Item     Part Number     Part Name     Qty    
    24     148-8378     Elbow As     2    
    -     3J-1907     O-Ring Seal     2    
    -     6V-8397     O-Ring Seal     2    
    -     6V-8724     Elbow     2    

    Table 16
    Elbow Assembly    
    Item     Part Number     Part Name     Qty    
    25     148-8390     Elbow As     1    
    -     2M-9780     O-Ring Seal     1    
    -     6V-8626     Elbow     1    
    -     7J-9108     O-Ring Seal     1    

    Table 17
    Plug Assembly    
    Item     Part Number     Part Name     Qty    
    26     148-8407     Plug As     2    
    -     3J-1907     O-Ring Seal     2    
    -     9S-4191     Plug     2    

    Table 18
    Plug Assembly    
    Item     Part Number     Part Name     Qty    
    27     148-8411     Plug As     2    
    -     3K-0360     O-Ring Seal     2    
    -     9S-4185     Plug     2    

    Table 19
    Tee Assembly    
    Item     Part Number     Part Name     Qty    
    28     148-8435     Tee As     2    
    -     3J-1907     O-Ring Seal     2    
    -     6V-8397     O-Ring Seal     4    
    -     6V-8781     Tee     2    

    Table 20
    Tee Assembly    
    Item     Part Number     Part Name     Qty    
    29     164-5578     Tee As     1    
    -     3D-2824     O-Ring Seal     1    
    -     6V-9175     Tee     1    
    -     6V-9746     O-Ring Seal     1    
    -     7J-9108     O-Ring Seal     1    

    Table 21
    Specification for 286-6495 Boom Cylinder Lines Gp    
    Item     Qty     Part     Specification Description    
    2     12     7K-1181 Cable Strap     Sharp corners at the cutting edge of each cable strap shall not be allowed.    
    14     2     278-6593 Hose As    
    114.5 ± 17 N·m (1013.4 ± 150.5 lb in)    
    42     8     8T-4196 Bolt    
    32 ± 6 N·m (283.22400 ± 53.10450 lb in)    
    C     -     -     Orientation of tee assembly is 5 ± 3 degrees.    
    D     -     -     Orientation of tee assembly is 30 ± 3 degrees.    
    E     -     -     Orientation of tee assembly is 30 ± 3 degrees.    
    F     -     -     Orientation of elbow assembly is 5 ± 3 degrees.    
    G     -     -     Orientation of elbow group is 30 ± 3 degrees.    
    H     -     -     Orientation of elbow assembly is 25 ± 3 degrees.    
    J     -     -     Orientation of connector assembly is 45 ± 1 degrees.    
    K     -     -     Orientation of support assembly is 45 ± 3 degrees.    
    L     -     -     Orientation of support assembly is 45 ± 3 degrees.    

Removal of Standard Parts

Before installing 282-7161 Return Lines Gp of 270-5974 Check and Relief Valve Ar , remove the standard parts listed in Tables 22 and 23.

248-9846 Hydraulic Oil Cooler Lines Gp (CONTROL VALVE, PUMP)

Table 22
Standard Removal Parts    
Item     Part Number     Part Name     Qty    
1     199-7403     Hose As     1    



Illustration 5g03828109

248-9846 Hydraulic Oil Cooler Lines Gp

(1) 199-7403 Hose As

(A) Upper frame

  1. Remove the standard part listed in Table 22 and shown in Illustration 5.

239-1714 Front Lines Gp

Table 23
Standard Removal Parts    
Item     Part Number     Part Name     Qty    
1     255-5683     Load Control Valve Gp     1    
2     1P-3703     Rectangular Seal     1    
3     4J-5268     O-Ring Seal     1    



Illustration 6g03828123

239-1714 Front Lines Gp

(1) 255-5683 Load Control Valve Gp

(2) 1P-3703 Rectangular Seal

(3) 4J-5268 O-Ring Seal

  1. Remove the standard parts listed in Table 23 and shown in Illustration 6.

Installation of 282-7161 Return Lines Group




    Illustration 7g03789576

    Right side view of 282-7161 Return Lines Gp

    (1) 7K-1181 Cable Strap

    (2) 107-1567 Hose As

    (3) 319-9845 Hose As

    (4) 201-9378 Block

    (5) 307-4920 Fitting

    (6) 148-8357 Elbow As

    (7) 148-8411 Plug

    (8) 1P-3703 Rectangular Seal

    (9) 4J-5268 O-Ring Seal

    (10) 148-8327 Connector As

    (A) Main control valve

    (B) Upper frame

    (C) Swivel

  1. Install 282-7161 Return Lines Gp . Refer to Table 2 for a list of the required parts. Refer to Illustration 7 for the location of the parts. Refer to Table 24 for the required parts to build hose assembly (3). Refer to Table 25 for the required parts to build elbow assembly (6). Refer to Table 26 for the required parts to build plug assembly (7). Refer to Table 27 for the required parts to build plug assembly (10). Refer to Table 28 for specifications.

    Table 24
    Hose Assembly    
    Item     Part Number     Part Name     Qty    
    3     319-9845     Hose As     1    
    -     124-2123     O-Ring Face Seal Coupling     2    
    -     122-6873     Hydraulic Hose    
    122 cm (48 inch)    

    Total assembled length of hose assembly (3) ... 1300 ± 13 mm (51.2 ± 0.5 inch)

    Table 25
    Elbow Assembly    
    Item     Part Number     Part Name     Qty    
    6     148-8357     Elbow As     1    
    -     5K-9090     O-Ring Seal     1    
    -     6V-9008     Elbow     1    
    -     7M-8485     O-Ring Seal     1    

    Table 26
    Plug Assembly    
    Item     Part Number     Part Name     Qty    
    7     148-8411     Plug As     1    
    -     3K-0360     O-Ring Seal     1    
    -     9S-4185     Plug     1    

    Table 27
    Connector Assembly    
    Item     Part Number     Part Name     Qty    
    10     148-8327     Connector As     1    
    -     3D-2824     O-Ring Seal     1    
    -     6V-8637     Connector     1    
    -     6V-9746     O-Ring Seal     1    

    Table 28
    Specification for 282-7161 Return Lines Gp    
    Item     Qty     Part     Specification Description    
    1     1     7K-1181 Cable Strap     Sharp corners at the cutting edge of each cable strap shall not be allowed.    
    2     1     107-1567 Hose As    
    114.5 ± 17 N·m (1013.4 ± 150.5 lb in)    

Removal of Standard Parts

Before installing 282-7162 Pilot Lines Gp of 270-5974 Check and Relief Valve Ar , remove the standard parts listed in Tables 7, 8, and 9.

248-9851 Pilot Lines Gp (MAIN CONTROL VALVE)

Table 29
Standard Removal Parts    
Item     Part Number     Part Name     Qty    
1     087-4531     Hose As     1    
2     330-2568     Hose As     1    
3     087-5762     Hose As     1    
4     087-5772     Hose As     1    
5     148-8336     Connector As     1    
6     148-8433     Tee As     1    
7     7K-1181     Cable Strap     5    



Illustration 8g03830812

248-9851 Pilot Lines Gp

(7) 7K-1181 Cable Strap

(A) Connects to main hydraulic pump

(B) Connects to Hydraulic oil pilot oil filter and valve

(C) Main control valve mounting

(D) Main control valve




Illustration 9g03830695

248-9851 Pilot Lines Gp

(1) 087-4531 Hose As

(2) 330-2568 Hose As

(3) 087-5762 Hose As

(4) 087-5772 Hose As

(7) 7K-1181 Cable Strap




Illustration 10g03830846

248-9851 Pilot Lines Gp

(5) 148-8336 Connector As

(6) 148-8433 Tee As

  1. Remove the standard parts listed in Table 29 and shown in Illustrations 8, 9, and 10.

248-9853 Return Lines Gp

Table 30
Standard Removal Parts    
Item     Part Number     Part Name     Qty    
1     148-8411     Plug     1    



Illustration 11g03828183

Rear view of 248-9853 Return Lines Gp

(1) 148-8411 Plug

(A) Hydraulic tank

  1. Remove the standard part listed in Table 30 and shown in Illustration 11.

Installation of 282-7162 Pilot Lines Gp




Illustration 12g03789955

Top view of 282-7162 Pilot Lines Gp

(1) 4I-0800 Hose As

(4) 7K-1181 Cable Strap

(7) 148-8363 Elbow As

(9) 5K-8451 Clip

(10) 8T-4121 Hard Washer

(11) 8T-4191 Bolt

(A) Main control valve

(B) Upper frame




Illustration 13g03813484

Rear view of 282-7162 Pilot Lines Gp

(2) 5I-8825 Hose As

(3) 4I-3981 Hose As

(4) 7K-1181 Cable Strap

(5) 133-5813 Marker Band

(6) 199-1863 Hose As

(8) 148-8433 Tee As

(A) Main control valve

  1. Install 282-7162 Pilot Lines Gp . Refer to Table 3 for a list of the required parts. Refer to Illustrations 12 and 13 for the location of the parts. Refer to Tables 31, 31, and 31 for the required parts to build hose assemblies (2), (3) and (6). Refer to Table 34 for the required parts to build elbow assembly (7). Refer to Table 35 for the required parts to build tee assembly (8). Refer to Table 36 for specifications.

Table 31
Hose Assembly    
Item     Part Number     Part Name     Qty    
2     5I-8825     Hose As     1    
-     149-8474     Permanent Coupling     1    
-     149-8493     Permanent Coupling     1    
-     188-4653     Hydraulic Hose    
69 cm (27.2 inch)    

Total assembled length of hose assembly (2) ... 750 ± 7 mm (29.5 ± 0.3 inch)

Table 32
Hose Assembly    
Item     Part Number     Part Name     Qty    
3     4I-3981     Hose As     1    
-     149-8474     Permanent Coupling     2    
-     188-4653     Hydraulic Hose    
269 cm (105.9 inch)    

Total assembled length of hose assembly (3) ... 2750 ± 28 mm (108.3 ± 1.1 inch)

Table 33
Hose Assembly    
Item     Part Number     Part Name     Qty    
6     199-1863     Hose As     1    
-     149-8474     Permanent Coupling     2    
-     423-1971     Hydraulic Hose    
332 cm (130.7 inch)    

Total assembled length of hose assembly (6) ... 3380 ± 34 mm (133.1 ± 1.3 inch)

Table 34
Elbow Assembly    
Item     Part Number     Part Name     Qty    
7     148-8363     Elbow As     1    
-     3K-0360     O-Ring Seal     1    
-     6V-8397     O-Ring Seal     1    
-     6V-9876     Elbow     1    

Table 35
Tee Assembly    
Item     Part Number     Part Name     Qty    
8     148-8433     Tee As     1    
-     6V-8397     O-Ring Seal     2    
-     6V-9836     Swivel Tee     1    

Table 36
Specification for 282-7162 Pilot Lines Gp    
Item     Qty     Part     Specification Description    
4     12     7K-1181 Cable Strap     Sharp corners at the cutting edge of each cable strap shall not be allowed.    

Installation Procedure for 419-5123 Check and Relief Valve Ar (Stick Lowering Control Valve)

Removal of Standard Parts

Before installing 242-6505 Boom Lines Gp of the 419-5123 Check and Relief Valve Ar , the parts listed below need to be removed from 239-1732 Boom Lines Gp and the 242-6476 Auxiliary Hydraulic Lines Gp (MED PRESSURE).

Table 37
239-1732 Boom Lines Gp    
Item     Part Number     Part Name     Qty    
1     8T-4139     Bolt     2    
2     8T-4223     Hard Washer     2    

Table 38
242-6476 Auxiliary Hydraulic Lines Gp    
Item     Part Number     Part Name     Qty    
3     7X-2549     Bolt     2    
4     8T-4223     Hard Washer     2    



Illustration 14g03828679

(1) 8T-4139 Bolt

(2) 8T-4223 Hard Washer

(3) 7X-2549 Bolt

(4) 8T-4223 Hard Washer

  1. Remove the standard parts listed in Tables 37 and 38, and shown in Illustration 14.

Installation of 242-6505 Boom Lines Gp (STICK LOAD CONTROL)




    Illustration 15g03790320

    242-6505 Boom Lines Gp

    (1) 5I-4393 Hose As

    (2) 5Q-4213 Clip

    (3) 7K-1181 Cable Strap

    (4) 202-3915 Plate

    (5) 268-6850 Hose As

    (6) 288-7410 Tube As

    (7) 282-5567 Plate

    (8) 149-5452 Union As

    (9) 5Q-4212 Clip

    (10) 6V-8398 O-Ring Seal

    (11) 6V-9168 Nut

    (12) 7X-2549 Bolt

    (13) 8T-4139 Bolt

    (14) 8T-4223 Hard Washer

    (15) 8T-4244 Nut




    Illustration 16g03792758

    Right side view of 242-6505 Boom Lines Gp

  1. Install 242-6505 Boom Lines Gp . Refer to Table 4 for a list of the required parts. Refer to Illustration 15 for the location of the parts. Refer to Tables 39, and 40 for the required parts to build hose assemblies (1), and (5). Refer to Illustration 16 and Table 42 for specifications.

Table 39
Hose Assembly    
Item     Part Number     Part Name     Qty    
1     5I-4393     Hose As     1    
-     149-8476     Permanent Coupling     2    
-     423-1972     Hose    
83 cm (32.7 inch)    

Total assembled length of hose assembly (1) ... 900 ± 7 mm (35.4 ± 0.3 inch)

Table 40
Hose Assembly    
Item     Part Number     Part Name     Qty    
5     268-6850     Hose As     2    
-     146-3340     Permanent Coupling     4    
-     6V-8397     O-Ring Seal     4    
-     135-7855     Hose    
697.6 cm (274.6 inch)    

Total assembled length for each hose assembly (5) ... 3550 ± 36 mm (139.78 ± 1.4 inch)

Table 41
Union Assembly    
Item     Part Number     Part Name     Qty    
8     149-5452     Union As     2    
-     6V-8397     O-Ring Seal     2    
-     6V-8994     Union     1    

Table 42
Specification for 242-6505 Boom Lines Gp    
Item     Qty     Part     Specification Description    
1     1     5I-4393 Hose As    
76 ± 4 N·m (56 ± 3 lb ft)    
3     5     7K-1181 Cable Strap     Sharp corners at the cutting edge of each cable strap shall not be allowed.    
A     -     -     Distance from the end of the hose assembly to the center of the mounting bolts is
60.0 ± 5.0 mm (2.36 ± 0.2.0 inch)    
B     -     -     Distance from the centerline of mounting pin to the center of the mounting bolts is
275.0 mm (10.83 inch)    

Removal of Standard Parts

Before installing 260-7970 Pilot Lines Gp of the 419-5123 Check and Relief Valve Ar , the parts listed below need to be removed from 248-9851 Pilot Lines Gp , 239-1714 Front Lines Gp , 275-1397 Return Lines Gp , 260-7969 Pilot Lines Gp , 282-7480 Front Lines Gp , and 282-7162 Pilot Lines Gp .

Table 43
248-9851 Pilot Lines Gp (MAIN CONTROL VALVE)    
Item     Part Number     Part Name     Qty    
1     4T-1739     Hose As     1    
2     148-8435     Tee As     1    
3     148-8336     Connector As     2    
4     7K-1181     Cable Strap     2    



Illustration 17g03830536

(1) 4T-1739 Hose As

(4) 7K-1181 Cable Strap

(A) Connects to main hydraulic pump

(B) Connects to hydraulic oil pilot oil filter and valve

(C) Main control valve mounting

(D) Main control valve




Illustration 18g03830965

(2) 148-8435 Tee As




Illustration 19g03831013

(3) 148-8336 Connector As

  1. Remove the standard parts listed in Table 43, and shown in Illustrations 17, 18, and 19.

Table 44
239-1714 Front Lines Gp    
Item     Part Number     Part Name     Qty    
1     255-5680     Load Control Valve Gp     1    



Illustration 20g03830537

(1) 255-5680 Load Control Valve Gp

(A) Upper frame

  1. Remove the standard part listed in Table 44 and shown in Illustration 20.

Table 45
275-1397 Return Lines Gp    
Item     Part Number     Part Name     Qty    
1     148-8411     Plug     1    



Illustration 21g03830538

Top view 275-1397 Return Lines Gp

(1) 148-8411 Plug

  1. Remove the standard part listed in Table 45 and shown in Illustration 21.

Table 46
260-7969 Pilot Lines Gp    
Item     Part Number     Part Name     Qty    
1     7Y-8379     Hose As     1    



Illustration 22g03830539

Top view 260-7969 Pilot Lines Gp

(1) 7Y-8379 Hose As

(A) Upper frame

(B) Swing drive

(C) Hydraulic tank

  1. Remove the standard part listed in Table 46 and shown in Illustration 22.

Table 47
282-7480 Front Lines Gp    
Item     Part Number     Part Name     Qty    
1     6V-9830     Cap As     1    



Illustration 23g03830540

Top view of 282-7480 Front Lines Gp

(1) 6V-9830 Cap As

(A) Main control valve

  1. Remove the standard part listed in Table 47 and shown in Illustration 23.

Table 48
282-7162 Pilot Lines Gp    
Item     Part Number     Part Name     Qty    
1     4I-0800     Hose As     1    



Illustration 24g03830541

Top view of 282-7162 Pilot Lines Gp

(1) 4I-0800 Hose As

(A) Main control valve

(B) Upper frame

  1. Remove the standard part listed in Table 48 and shown in Illustration 24.

Installation of 260-7970 Pilot Lines Gp (LOAD CONTROL, STICK CYLINDER)




    Illustration 25g03790595

    Top view of 260-7970 Pilot Lines Gp

    (2) 201-9379 Block

    (7) 148-8364 Elbow As

    (A) Swing drive

    (B) Main control valve

    (C) Upper frame




    Illustration 26g03790616

    Right side view of 260-7970 Pilot Lines Gp

    (1) 7K-1181 Cable Strap

    (3) 275-1712 Hose As

    (4) 275-1713 Hose As

    (5) 282-7079 Hose As

    (8) 148-8433 Tee As

    (10) 136-0207 Cable Strap

    (11) 133-5813 Marker Band

    (12) 4I-9523 Marker Band

    (A) Swing drive

    (B) Upper frame




    Illustration 27g03813554

    Rear view of 260-7970 Pilot Lines Gp

    (1) 7K-1181 Cable Strap

    (6) 148-8336 Connector As

    (9) 148-8434 Tee As

    (13) 6V-9829 Cap As

    (A) Main control valve

    (B) Hydraulic tank

  1. Install 260-7970 Pilot Lines Gp . Refer to Table 5 for a list of the required parts. Refer to Illustrations 25, 26, and 27 for the location of the parts. Refer to Tables 49 and 50 for the required parts to build hose assemblies (3) and (5). Refer to Table 51 for the required parts to build connector assembly (6). Refer to Table 52 for the required parts to build elbow assembly (7). Refer to Tables 53 and 54 for the required parts to build tee assemblies (8) and (9). Refer to Table 55 for specifications.

    Table 49
    Hose Assembly    
    Item     Part Number     Part Name     Qty    
    3     275-1712     Hose As     1    
    -     7I-7439     Hose Guard    
    139 cm (54.7 inch)    
    -     149-8474     Permanent Coupling     1    
    -     149-8493     Permanent Coupling     1    
    -     423-1971     Hose    
    294 cm (115.7 inch)    

    Total assembled length of hose assembly (3) ... 3000 ± 25 mm (118.1 ± 1.0 inch)

    Table 50
    Hose Assembly    
    Item     Part Number     Part Name     Qty    
    5     282-7079     Hose As     1    
    -     7I-7439     Hose Guard    
    220 cm (86.6 inch)    
    -     149-8476     Permanent Coupling     1    
    -     149-8502     Permanent Coupling     1    
    -     205-3719     Hose    
    168.5 cm (66.3 inch)    

    Total assembled length of hose assembly (5) ... 1760 ± 15 mm (69.3 ± 0.6 inch)

    Table 51
    Connector Assembly    
    Item     Part Number     Part Name     Qty    
    6     148-8336     Connector As     1    
    -     3J-1907     O-Ring Seal     1    
    -     6V-8397     O-Ring Seal     1    
    -     6V-8636     Connector     1    

    Table 52
    Elbow Assembly    
    Item     Part Number     Part Name     Qty    
    7     148-8364     Elbow As     1    
    -     3K-0360     O-Ring Seal     1    
    -     6V-8398     O-Ring Seal     1    
    -     6V-8625     Elbow     1    

    Table 53
    Tee Assembly    
    Item     Part Number     Part Name     Qty    
    8     148-8433     Tee As     1    
    -     6V-8397     O-Ring Seal     2    
    -     6V-9836     Swivel Tee     1    

    Table 54
    Tee Assembly    
    Item     Part Number     Part Name     Qty    
    9     148-8434     Tee As     1    
    -     6V-8397     O-Ring Seal     2    
    -     6V-9843     Swivel Tee     1    

    Table 55
    Specification for 260-7970 Pilot Lines Gp    
    Item     Qty     Part     Specification Description    
    5     1     282-7079 Hose As    
    76 ± 4 N·m (56 ± 3 lb ft)    
    6     1     148-8336 Connector As    
    29 ± 3 N·m (257 ± 27 lb in)    
    10     6     136-0207 Cable Strap     Sharp corners at the cutting edge of each cable strap shall not be allowed.    

Removal of Standard Parts

Before installing 419-5136 Stick Cylinder Lines Gp , the parts listed below need to be removed from 242-6735 Stick Cylinder Lines Gp .

242-6735 Stick Cylinder Lines Gp

Table 56
Standard Removal Parts    
Item     Part Number     Part Name     Qty    
1     6V-8200     Bolt     4    
2     095-1600     O-Ring Seal     1    
3     247-8883     Tube As     1    
4     8T-4196     Bolt     2    
5     8T-4896     Hard Washer     2    
6     124-1020     Support     1    
7     124-1019     Support As     1    
8     096-4480     Clamp     1    
9     8T-4910     Bolt     1    
10     8T-4223     Hard Washer     1    



Illustration 28g03829050

242-6735 Stick Cylinder Lines Gp

(1) 6V-8200 Bolt

(2) 095-1600 O-Ring Seal

(3) 247-8883 Tube As

(4) 8T-4196 Bolt

(5) 8T-4896 Hard Washer

(6) 124-1020 Support

(7) 124-1019 Support As

(8) 096-4480 Clamp

(9) 8T-4910 Bolt

(10) 8T-4223 Hard Washer

  1. Remove the standard parts listed in Table 56 and shown in Illustration 28.

Installation of 419-5136 Stick Cylinder Lines Gp




Illustration 29g03829083

419-5136 Stick Cylinder Lines Gp

(1) 5Q-4213 Clip

(2) 093-1294 Clamp

(3) 247-9073 Tube As

(4) 247-9074 Tube As

(5) 247-9076 Tube As

(6) 247-9078 Tube As

(7) 352-7243 Check and Relief Valve Gp

(8) 420-1013 Support As

(9) 420-1015 Support As

(10) 108-1782 Bolt

(11) 148-8328 Connector As

(12) 148-8368 Elbow As

(13) 1P-3703 Rectangular Seal

(14) 1P-3704 Rectangular Seal

(15) 6V-8397 O-Ring Seal

(16) 6V-8398 O-Ring Seal

(17) 6V-9746 O-Ring Seal

(18) 8T-4121 Hard Washer

(19) 8T-4139 Bolt

(20) 8T-4186 Bolt

(21) 8T-4196 Bolt

(22) 8T-4223 Hard Washer

(23) 8T-4648 Bolt

  1. Install 419-5136 Stick Cylinder Lines Gp . Refer to Table 6 for a list of the required parts. Refer to Illustration 29 for the location of the parts. Refer to Table 57 and Illustration 30 for specifications.



Illustration 30g03831130

Table 57
Specification for 419-5136 Stick Cylinder Lines Gp    
Item     Qty     Part     Specification Description    
4     1     247-9074 Tube As     Torque to
76 ± 4 N·m (56 ± 3 lb ft).    
B     -     -     Distance from the centerline of the mounting pin to the support assembly is
280.0 ± 3.0 mm (11.02 ± 0.12 inch).    
C     -     -     Distance from the centerline of the mounting pin to the support assembly is
1250.0 ± 3.0 mm (49.21 ± 0.12 inch).    
20     2     8T-4186 Bolt     Torque to
30 ± 7 N·m (266 ± 62 lb in).    
21     8     8T-4196 Bolt     Torque to
39 ± 8 N·m (29 ± 6 lb ft).    
D     -     -     Orientation of the support assemblies is 30 ± 3 degrees.    

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