Installation of the 467-8461 Front Lines Gp on Certain Hydraulic Excavators {5057} Caterpillar

Installation of the 467-8461 Front Lines Gp on Certain Hydraulic Excavators {5057}

Usage:

Excavator: 320D2 (S/N: PBB1-UP; KBS1-UP); 323D2 (S/N: XBK1-UP)

Introduction

This Special Instruction covers the installation procedure for 467-8461 Front Lines Gp on the models and applications listed above.

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 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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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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Illustration 1	g00104545

Prevent the machine from movement. Park the machine on a level surface.

Attach a "Do Not Operate" 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.

Required Parts

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Table 1
467-8461 Front Lines Gp (- 02)
Item	Qty	Part No.	Description
(1)	4	4I-9521	Marker Band (RED)
(2)	4	4I-9522	Marker Band (YELLOW)
(3)	1	5I-4376	Fitting
(4)	16	7K-1181	Cable Strap
(5)	1	104-8783	Hose As
(6)	1	150-4027	Tee As
(7)	1	168-1968	Tee As
(8)	1	187-5954	Hose As
(9)	3	241-6215	Elbow As
(10)	1	266-1194	Hose As
(11)	1	266-1389	Hose As
(12)	1	285-2423	Tube As
(13)	1	286-6486	Hose As
(14)	1	319-4407	Pressure Switch
(15)	2	328-2035	Solenoid Valve and Manifold Gp
(16)	2	337-2709	Grommet
(17)	1	338-6971	Pressure Sensor Gp
(18)	1	292-7555	Hose As
(19)	1	454-0504	Check Valve Gp
(20)	2	457-9869	Spacer
(21)	1	466-3340	Hose As
(22)	1	467-1480	Tube As
(23)	1	474-9622	Hose As
(24)	1	474-9625	Hose As
(25)	1	468-7013	Support As
(26)	4	101-7402	Bolt
(27)	4	101-7404	Bolt
(28)	2	148-8336	Connector As
(29)	4	148-8353	Elbow As
(30)	1	148-8363	Elbow As
(31)	3	148-8378	Elbow As
(32)	2	148-8407	Plug As
(33)	2	148-8415	Reducer As
(34)	4	150-3036	Elbow As
(35)	1	164-5567	Quick Disconnect Coupler As
(36)	1	164-6874	Elbow Fitting
(37)	1	169-5862	Elbow As
(38)	1	4J-0527	O-Ring Seal
(39)	1	4J-5267	O-Ring Seal
(40)	1	6V-0852	Dust Cap
(41)	1	6V-9746	O-Ring Seal
(42)	4	8T-4121	Hard Washer
(43)	2	8T-4136	Bolt
(44)	3	8T-4194	Bolt
(45)	2	8T-4198	Bolt
(46)	3	8T-4223	Hard Washer

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Table 2
Standard Removal
Item	Qty	Part No.	Description
-	3	135-8573	Bolt As
-	1	236-3212	Hydraulic Hose Gp
-	1	4J-5267	O-Ring Seal
-	4	101-7404	Bolt
-	1	199-7394	Pipe As
-	1	4J-0527	O-Ring Seal
-	4	101-7402	Bolt
-	1	148-8378	Elbow As
-	1	164-5567	Quick Disconnect Coupler As
-	1	6V-0852	Dust Cap

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Illustration 2	g06126511
Overview of the 467-8461 Front Lines Gp

Installation Procedure

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Illustration 3	g03740298
Close up of Area A (1) ( 15a) 328-2035 Solenoid Valve and Manifold Gp (15b) 328-2035 Solenoid Valve and Manifold Gp (20) 457-9869 Spacer (25) 468-7013 Support As (28) 148-8336 Connector As (31) 148-8378 Elbow As (32) 148-8407 Plug As (34) 150-3036 Elbow As (42) 8T-4121 Hard Washer (44) 8T-4194 Bolt (45) 8T-4198 Bolt (46) 8T-4223 Hard Washer

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Illustration 4	g03740602
Close up of Area A (2) ( 6) 150-4027 Tee As (15) 328-2035 Solenoid Valve and Manifold Gp (25) 468-7013 Support As (29) 148-8353 Elbow As (31) 148-8378 Elbow As (34) 150-3036 Elbow As (42) 8T-4121 Hard Washer (44) 8T-4194 Bolt (45) 8T-4198 Bolt (46) 8T-4223 Hard Washer

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Illustration 5	g03740750
Close up of Area A (3) ( 19) 454-0504 Check Valve Gp (25) 468-7013 Support As (42) 8T-4121 Hard Washer (43) 8T-4136 Bolt (44) 8T-4194 Bolt (46) 8T-4223 Hard Washer

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Illustration 6	g03740768
Close up of Area A (4) ( 19) 454-0504 Check Valve Gp (31) 148-8378 Elbow As (32) 148-8407 Plug As (34) 150-3036 Elbow As

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Illustration 7	g06126545
Close up of Area A (5) ( 9) 241-6215 Elbow As (19) 454-0504 Check Valve Gp (29) 148-8353 Elbow As

Assemble all parts in "Area A" as shown.

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Illustration 8	g06126553
Install hoses to valves. (4) 7K-1181 Cable Strap (10) 266-1194 Hose As (11) 266-1389 Hose As (13) 286-6486 Hose As (15a) 328-2035 Solenoid Valve and Manifold Gp (15b) 328-2035 Solenoid Valve and Manifold Gp (18) 292-7555 Hose As (19) 454-0504 Check Valve Gp

Connect hose (18) to port "T" on solenoid valves (15a), and (15b).
Route hose (11) from port "C2" on solenoid valve (15b) to port "S2" on check valve (19).
Route hose (13) from port "P" on solenoid valve (15a) to port "C1" on solenoid valve (15b).

Route hose (10) from port "C1" on solenoid valve (15a) to port "P2" on check valve (19).

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Illustration 9	g03740787
(3) 5I-4376 Fitting (25) 468-7013 Support As (28) 148-8336 Connector As (29) 148-8353 Elbow As (35) 164-5567 Quick Disconnect Coupler As (36) 164-6874 Elbow Fitting (40) 6V-0852 Dust Cap (44) 8T-4194 Bolt (46) 8T-4223 Hard Washer

Install assembled valve groups to the machine frame above the main hydraulic pump as shown.

Install connectors and elbows to port "M1" on hydraulic pump

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Illustration 10	g03740808
(9) 241-6215 Elbow As (17) 338-6971 Pressure Sensor Gp, 64 ± 3 N·m (47 ± 2 lb ft) (22) 467-1480 Tube As (27) 101-7404 Bolt (39) 4J-5267 O-Ring Seal (41) 6V-9746 O-Ring Seal

Install tube (22) and pressure sensor (17) to the main control valve as shown.

Note: Remove existing hose group 236-3212.

Note: Apply thin layer of hydraulic oil on male threads of pressure sensor (17) before installing.

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Illustration 11	g03740853
(7) 168-1968 Tee As, 29 ± 2 N·m (21 ± 1 lb ft) (12) 285-2423 Tube As (14) 319-4407 Pressure Switch (26) 101-7402 Bolt (30) 148-8363 Elbow As (37) 169-5862 Elbow As (38) 4J-0527 O-Ring Seal

Install tube, elbows, tee, and pressure switch.

Note: Remove existing tube from the machine.

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Illustration 12	g03740857
(1) 4I-9521 Marker Band (RED) (2) 4I-9522 Marker Band (YELLOW) (4) 7K-1181 Cable Strap (8) 187-5954 Hose As (16) 337-2709 Grommet (23) 474-9622 Hose As (24) 474-9625 Hose As (33) 148-8415 Reducer As, 76 ± 4 N·m (56 ± 3 lb ft)

Install hoses (8), (23), and (24).
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Illustration 13 g03741019

(5) 104-8783 Hose As

Route hose (5) from tube (12) to port (T) on solenoid valve (15a).

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Illustration 14	g06126554
(1) 4I-9521 Marker Band (RED) (2) 4I-9522 Marker Band (YELLOW) (4) 7K-1181 Cable Strap (5) 104-8783 Hose As (16) 337-2709 Grommet (15a) 328-2035 Solenoid Valve and Manifold Gp (15b) 328-2035 Solenoid Valve and Manifold Gp (21) 466-3340 Hose As (23) 474-9622 Hose As (24) 474-9625 Hose As

Route hoses (5), (23), and (24) and connect to port locations as shown.
Note: Some hoses removed from valves to show other hose routing.
Connect hose (21) to port "M1" on the main pump and port "P" on solenoid valve (15b).
Unless specified, tighten all fittings and hardware to standard torque.
Check for leaks.