Installation of the 494-9529 Front Lines Gp on Certain Hydraulic Excavators {5057} Caterpillar

Excavator

349F (S/N: BZ210001-UP; KEA10001-UP; HPD10001-UP)

352F (S/N: WNA10001-UP; YEG10001-UP; A9J10001-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

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 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.

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

Illustration 2	g06324188
Overview of the 494-9529 Front Lines Gp.

Installation Procedure

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Illustration 3	g06211150
Valve group (A) ( 7) 328-2035 Solenoid Valve and Manifold Gp (11) 451-2175 Hard Washer (12) 453-1256 Bolt (13) 454-0504 Check Valve Gp (15) 456-6653 Support As (16) 456-6657 Support As (19) 457-9869 Spacer (20) 459-1279 Hose As (21) 459-1282 Hose As (22) 148-8378 Elbow As (25) 150-4044 Connector As (33) 8T-4121 Hard Washer (34) 8T-4136 Bolt (37) 8T-4195 Bolt (38) 8T-4198 Bolt

1. Assemble valve group (A).
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   Illustration 4	g03712160
   Valve group (A) ( 7) 328-2035 Solenoid Valve and Manifold Gp (11) 451-2175 Hard Washer (12) 453-1256 Bolt (13) 454-0504 Check Valve Gp (15) 456-6653 Support As (16) 456-6657 Support As (19) 457-9869 Spacer (20) 459-1279 Hose As (21) 459-1282 Hose As (22) 148-8378 Elbow As (23) 148-8407 Plug As (24) 150-3036 Elbow As (25) 150-4044 Connector As (27) 164-6874 Elbow Fitting (33) 8T-4121 Hard Washer (34) 8T-4136 Bolt (37) 8T-4195 Bolt (38) 8T-4198 Bolt

2. Assemble valve group (A).
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   Illustration 5	g06397050
   (1) 4I-9521 Marker Band, (RED) (2) 4I-9522 Marker Band, (YELLOW) (3) 7K-1181 Cable Strap (6) 275-1684 Hose As (8) 338-6971 Pressure Sensor Gp, 64 ± 3 N·m (47 ± 2 lb ft) (9) 348-1344 Hose As (10) 350-0931 Hose As (17) 549-5184 Tube As (18) 457-4686 Hose As (27) 164-6874 Elbow Fitting (30) 1P-3703 Rectangular Seal (31) 6V-0400 Half Flange (35) 8T-5041 Bolt (36) 8T-4184 Bolt (39) 8T-4223 Hard Washer (41) 549-5185 Block (42) 285-2663 Fitting As (43) 148-8310 Adapter As (44) 1P-3704 Rectangular Seal

3. Install valve group (A).

4. Install tube assembly (17) with pressure sensor (8).

5. Install the hoses onto valve group (A) and tube assembly (17).
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   Illustration 6	g06324664
   (1) 4I-9521 Marker Band, (RED) (2) 4I-9522 Marker Band, (YELLOW) (3) 7K-1181 Cable Strap (6) 275-1684 Hose As (10) 350-0931 Hose As (30) 1P-3703 Rectangular Seal (31) 6V-0400 Half Flange (39) 8T-4223 Hard Washer (40) 8T-4910 Bolt

6. Route the hoses to the boom.
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   Illustration 7	g06211249
   (2) 4I-9522 Marker Band, (YELLOW) (4) 150-4027 Tee As (9) 348-1344 Hose As (18) 457-4686 Hose As (22) 148-8378 Elbow As

7. Connect hoses (9) to the hydraulic drain tube.

8. Route hose (18) to the pump compartment.
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   Illustration 8	g06211250
   (4) 150-4027 Tee As (14) 454-5075 Pressure Sensor Gp, 30 ± 5 N·m (22 ± 4 lb ft) (28) 165-4931 Elbow As (29) 169-5862 Elbow As

9. Install fittings and pressure sensor into port "aR3" of the control valve.
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   Illustration 9	g03712164
   (5) 168-1968 Tee As (18) 457-4686 Hose As (26) 164-5567 Quick Disconnect Coupler As (32) 6V-0852 Dust Cap

10. Connect hose (18) to port "a1" of the main pump as shown.

11. Unless specified, tighten all fittings and hardware to standard torque.

12. Check for leaks.