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Installation Procedure for Auxiliary Lines Kit on Certain 308 Mini Hydraulic Excavators {5057} Caterpillar


Installation Procedure for Auxiliary Lines Kit on Certain 308 Mini Hydraulic Excavators {5057}

Usage:

308 GG8
Mini Hydraulic Excavator
308 (S/N: GG81-UP)

Introduction

This Special Instructions contains the procedure to install the 561-8196 Auxiliary Lines Kit and 561-8197 Auxiliary Lines Kit on the machines listed above.

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

Reference Section

Reference: Torque Specifications , SENR3130

Safety Section

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

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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------ 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.

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

Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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

When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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

Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment required to do the job.

Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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

Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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

Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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

Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Required Parts

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Table 1
Required parts 
Item  Qty  Part Number  Part Name 
1  2  562-9524  Gasket 
2  1  564-1385  Control Valve Gp 
3  1  564-1382  Fastener Kit 
4  5  136-0207  Cable Strap 
5  2  148-8318  Connector As 
6  1  513-9284  Hose As 
7  1  513-9285  Hose As 
8  1  148-8336  Connector As 
9  4  7K-1181  Cable Strap 
10  1  536-9975  Hose As 
11  1  515-8027  Tube As 
12  1  566-2322  Tube As 
13  1  515-8026  Tube As 
14  1  566-2321  Tube As 
15  2  515-8025  Tube As 
16  4  9R-1004  Clip 
17  4  9R-1005  Clip 
18  2  8T-5005  Bolt 
19  12  8T-4121  Hard Washer 
20  2  198-4766  Hard Washer 
21  5  8T-6466  Bolt 
22  1  536-9974  Plate 
23  1  6V-9168  Nut 
24  3  3E-6909  Clip 
25  1  8T-4185  Bolt 
26  3  6V-8398  O-Ring Seal 
27  2  7J-9108  O-Ring Seal 
28  4  8T-1887  Clip 
29  4  8T-1888  Clip 
30  2  8T-4178  Bolt 
31  2  296-6980  Spacer 
32  3  6V-8397  O-Ring Seal 
33  3  169-5701  Connector As 
34  3  6V-9169  Nut 
35  2  153-2996  Fitting As 
36  1  153-2997  Fitting As 
37  2  161-2560  Dust Cap 
38  1  161-2561  Dust Cap 
39  1  567-4455  Hose As(1) 
567-4456 Hose As(2)
40  2  515-8022  Hose As(1) 
515-8031 Hose As(2)
-  2  564-1387  Plug As 
-  1  279-4732  Cable Strap 
-  2  279-4733  Cable Strap 
-  2  279-4734  Cable Strap 
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(1) For 561-8196 Auxiliary Lines Kit
(2) For 561-8197 Auxiliary Lines Kit

Installation Procedure

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    Illustration 1g06422046
    (A) 510-9956 Access Door As
    (B) 510-9918 Cover As

  1. Unlatch the access door assembly (A) and keep the door open. Remove cover assembly (B) to access the back side of the hydraulic tank. Refer to Illustration 1.
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    Illustration 2g06422048
    (C) Cotter pin and washer
    (E) Rod As

  2. Remove the cotter pin and washer (C) to disassemble the rod assembly (E) from 549-3304 Cover. Refer to Illustration 2.
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    Illustration 3g06422690
    (F) 549-3304 Cover
    (G) 554-1892 Enclosure Cover As

  3. Remove the cover (F) by loosening the bolts. Refer to Illustration 3.
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    Illustration 4g06422053
    (G) 554-1892 Enclosure Cover As

  4. Remove the enclosure cover assembly (G) by loosening the bolts. Refer to Illustration 3 and Illustration 4.
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    Illustration 5g06422055
    (H) Battery disconnect switch
    (J) 543-8772 Cover

  5. Turn OFF the battery disconnect switch (H) and remove the bolts on the cover (J). Refer to Illustration 5.
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    Illustration 6g06422059
    Bracket
    (J) 543-8772 Cover

  6. Lift up the cover (J) from the bracket to access the main control valve group. Refer to Illustration 6.
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    Illustration 7g06422061
    (K) Implement valve top section
    (L) 514-6645 Hose As
    (M) Pump pressure sensor

  7. Disconnect the hose assembly (L) and pump pressure sensor (M) to remove the implement valve top section (K). Refer to Illustration 7.
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    Illustration 8g06422064
    (K) Implement valve top section
    (N) Tie rod nuts

  8. Remove the implement valve top section (K) by loosening the tie rod nuts (N). Refer to Illustration 8.
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    Illustration 9g06422065
    (1) 562-9524 Gasket

  9. Replace the old gasket with the new gasket (1). Refer to Illustration 9.
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    Illustration 10g06422066
    (1) 562-9524 Gasket
    (2) 564-1385 Control Valve Gp

  10. Place the control valve group (2) with the solenoid valve oriented towards the right side of the machine and place another gasket (1) on the control valve group (2). Refer to Illustration 10.
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    Illustration 11g06422068
    (3) 564-1382 Fastener Kit
    (K) Implement valve top section
    (L) 514-6645 Hose As
    (M) Pump pressure sensor
    (Q) 155-2269 Connector Plug As
    (R) Solenoid 24
    (S) Solenoid 25

  11. Install implement valve top section (K) to the main control valve using fastener kit (3). Tighten the fastener kit (3) in the order shown in Illustration 11.

  12. Connect pump pressure sensor (M) to implement valve top section (K). Refer to Illustration 11.

  13. Install hose assembly (L) to implement valve top section (K). Refer to Illustration 11.

  14. Ensure that the harness connector plug assembly (Q) are connected, port B to solenoid 24 (R) and port A to solenoid 25 (S). Refer to Illustration 11.
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    Illustration 12g06422070
    (T) 096-4884 Locknut
    (U) 515-5459 Plate
    (V) 513-6085 Grommet

  15. Remove locknut (T), plate (U), and grommet (V) on the upper frame between the cab and the fuel tank. Refer to Illustration 12.
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    Illustration 13g06422072
    (4) 136-0207 Cable Strap

  16. Remove cable straps (4) and one inner strap holding the hose guard. Refer to Illustration 13.
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    Illustration 14g06422073
    Bolts
    (W) 349-2666 Plate
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    Illustration 15g06422082
    (X) 575-9386 Grommet

  17. Remove the plate (W) by loosening the bolts on the swing frame to enable routing of the auxiliary hoses through grommet (X). Refer to Illustration 14 and Illustration 15.
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    Illustration 16g06422084
    (5) 148-8318 Connector As

  18. Install the connector assembly (5) to port A and port B on 564-1385 Control Valve Gp, torque to 100 ± 15 N·m (74 ± 11 lb ft). Refer to Illustration 16.
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    Illustration 17g06422085
    (6) 513-9284 Hose As

  19. Install hose assembly (6) to port B, torque to 45 ± 5 N·m (33 ± 4 lb ft). Refer to Illustration 17.
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    Illustration 18g06422117
    (7) 513-9285 Hose As

  20. Install hose assembly (7) to port A, torque to 45 ± 5 N·m (33 ± 4 lb ft). Refer to Illustration 18.
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    Illustration 19g06422118
    (Y) 148-8407 Plug As

  21. Remove plug assembly (Y) from the hydraulic tank. Refer to Illustration 19.
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    Illustration 20g06422119
    (8) 148-8336 Connector As

  22. Install connector assembly (8) to the hydraulic tank as shown in Illustration 20. Torque to 55 ± 8 N·m (41 ± 6 lb ft3).
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    Illustration 21g06422120
    (9) 7K-1181 Cable Strap
    (10) 536-9975 Hose As

  23. Secure hose assembly (10) using cable strap (9). Refer to Illustration 21.

  24. Install hose assembly (10) to the 148-8336 Connector As, torque to 45 ± 5 N·m (33 ± 4 lb ft). Refer to Illustration 21.
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    Illustration 22g06422121
    (4) 136-0207 Cable Strap
    (6) 513-9284 Hose As
    (7) 513-9285 Hose As
    (10) 536-9975 Hose As
    (Z) 513-6084 Grommet

  25. Route hose assembly (6), hose assembly (7), and hose assembly (10) towards the grommet (Z). Refer to Illustration 22.

  26. Remove the existing cable strap and replace with new cable strap (4) to secure the hoses. Refer to Illustration 22.
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    Illustration 23g06422122
    (6) 513-9284 Hose As
    (7) 513-9285 Hose As
    (Z) 513-6084 Grommet

  27. Route the hose assembly (6) and hose assembly (7) through the grommet (Z) by aligning the tape mark to show outside the grommet hole. Refer to Illustration 23.
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    Illustration 24g06422123
    (10) 536-9975 Hose As
    (Z) 513-6084 Grommet

  28. Route the hose assembly (10) through the grommet (Z). Refer to Illustration 24.
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    Illustration 25g06422124
    (T) 096-4884 Locknut
    (U) 515-5459 Plate
    (V) 513-6085 Grommet

  29. Install the previously removed grommet (V), plate (U), and locknut (T). Torque to 100 ± 20 N·m (74 ± 15 lb ft). Refer to Illustration 25.
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    Illustration 26g06422145
    (6) 513-9284 Hose As
    (7) 513-9285 Hose As
    (10) 536-9975 Hose As

  30. Route the hose assembly (6), hose assembly (7), and hose assembly (10) through the upper frame and swing frame as shown in Illustration 26.

  31. Route the hose assembly (6), hose assembly (7), and hose assembly (10) behind the stick, bucket, and auxiliary lines. Refer to Illustration 26.
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    Illustration 27g06422146
    (4) 136-0207 Cable Strap

  32. Secure the auxiliary hoses using cable strap (4) along with stick lines, bucket lines, and auxiliary lines. Refer to Illustration 27.
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    Illustration 28g06422161
    (4) 136-0207 Cable Strap
    (AA) 199-1986 Guard

  33. Wrap the hose guard (AA) as shown in Illustration 28 and use cable strap (4) to hold all the hoses running through the swing frame including the boom cylinder lines.
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    Illustration 29g06422163
    Tape mark

  34. Ensure that the tape marks on the auxiliary hoses are aligned with the swing frame grommet. Refer to Illustration 29.
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    Illustration 30g06422167
    (W) 349-2666 Plate

  35. Install the previously removed grommet retainer plate (W) on the swing frame and tighten the 8T-4183 Bolt to 100 ± 20 N·m (74 ± 15 lb ft).
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    Illustration 31g06422757
    Auxiliary tubes
    (11) 515-8027 Tube As
    (12) 566-2322 Tube As
    (13) 515-8026 Tube As
    (14) 566-2321 Tube As
    (15) 515-8025 Tube As
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    Illustration 32g06422182
    (AB) Bolts

  36. Remove bolts (AB) on the clamps as shown in Illustration 32.
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    Illustration 33g06422184
    (15) 515-8025 Tube As
    (16) 9R-1004 Clip
    (17) 9R-1005 Clip
    (18) 8T-5005 Bolt
    (19) 8T-4121 Hard Washer
    (20) 198-4766 Hard Washer

  37. Use clip (16), clip (17), and hard washer (20) to position the tube assembly (15). Refer to Illustration 33.
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    Illustration 34g06422187
    (15) 515-8025 Tube As
    (D1) 93.0 ± 3.0 mm (3.66 ± 0.12 inch)

  38. Use bolt (18) and washer (19) to clamp the tube assembly (15). Refer to Illustration 33 and Illustration 34.
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    Illustration 35g06422188
    (15) 515-8025 Tube As
    (16) 9R-1004 Clip
    (17) 9R-1005 Clip
    (19) 8T-4121 Hard Washer
    (21) 8T-6466 Bolt

  39. Use clip (16), clip (17), and hard washer (19) to position the tube assembly (15). Loosely clamp by using bolt (21) and hard washer (19). Refer to Illustration 35.
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    Illustration 36g06422189
    (19) 8T-4121 Hard Washer
    (21) 8T-6466 Bolt
    (22) 536-9974 Plate

  40. Use bolt (21) and hard washer (19) to install the plate (22) on the lower tube clamp as shown in Illustration 36. Torque to 55 ± 10 N·m (41 ± 7 lb ft).
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    Illustration 37g06422190
    (14) 566-2321 Tube As
    (23) 6V-9168 Nut

  41. Install tube assembly (14) to the 536-9974 Plate. Loosely clamp by using nut (23). Refer to Illustration 37.
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    Illustration 38g06422193
    (14) 566-2321 Tube As
    (19) 8T-4121 Hard Washer
    (24) 3E-6909 Clip
    (25) 8T-4185 Bolt

  42. Use clip (24) to position the tube assembly (14). Use bolt (25) and hard washer (29) to attach the clips, torque to 55 ± 10 N·m (41 ± 7 lb ft). Refer to Illustration 38.
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    Illustration 39g06422197
    (18) 8T-5005 Bolt
    (21) 8T-6466 Bolt
    (23) 6V-9168 Nut

  43. Tighten the bolt (18) and bolt (21) to 55 ± 10 N·m (41 ± 7 lb ft). Refer to Illustration 39.

  44. Tighten the nut (23) to 80 ± 12 N·m (59 ± 9 lb ft). Refer to Illustration 39.
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    Illustration 40g06422199
    (14) 566-2321 Tube As
    (26) 6V-8398 O-Ring Seal

  45. Install O-Ring seal (26) to tube assembly (14). Refer to Illustration 40.
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    Illustration 41g06422200
    (6) 513-9284 Hose As
    (7) 513-9285 Hose As
    (10) 536-9975 Hose As
    (14) 566-2321 Tube As
    (15) 515-8025 Tube As

  46. Attach hose assembly (6) with tube assembly (15), torque to 45 ± 5 N·m (33 ± 4 lb ft). Refer to Illustration 41.

  47. Attach hose assembly (7) with tube assembly (15), torque to 45 ± 5 N·m (33 ± 4 lb ft). Refer to Illustration 41.

  48. Attach hose assembly (10) with tube assembly (14), torque to 45 ± 5 N·m (33 ± 4 lb ft). Refer to Illustration 41.
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    Illustration 42g06422201
    (11) 515-8027 Tube As
    (13) 515-8026 Tube As
    (27) 7J-9108 O-Ring Seal

  49. Install O-Ring seal (27) to tube assembly (11) and tube assembly (13). Refer to Illustration 42.
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    Illustration 43g06422206
    (AC) Bolts

  50. Remove the bolts (AC) to assemble the auxiliary tubes on boom.
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    Illustration 44g06422211
    (11) 515-8027 Tube As
    (13) 515-8026 Tube As
    (15) 515-8025 Tube As

  51. Attach the tube assembly (11) loosely with tube assembly (15) on the left-hand side of the boom. Refer to Illustration 44.

  52. Attach the tube assembly (13) loosely with tube assembly (15) on the right-hand side of the boom. Refer to Illustration 44.
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    Illustration 45g06422212
    (12) 566-2322 Tube As
    (14) 566-2321 Tube As

  53. Attach the tube assembly (12) loosely with tube assembly (14). Refer to Illustration 45.
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    Illustration 46g06422213
    (11) 515-8027 Tube As
    (19) 8T-4121 Hard Washer
    (21) 8T-6466 Bolt
    (28) 8T-1887 Clip
    (29) 8T-1888 Clip

  54. Use clip (28) and clip (29) to position the tube assembly (11) on the left-hand side of the boom and loosely clamp by using bolt (21) and washer (19). Refer to Illustration 46.
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    Illustration 47g06422216
    (12) 566-2322 Tube As
    (13) 515-8026 Tube As
    (19) 8T-4121 Hard Washer
    (24) 3E-6909 Clip
    (28) 8T-1887 Clip
    (29) 8T-1888 Clip
    (30) 8T-4178 Bolt
    (31) 296-6980 Spacer

  55. Use clip (24), clip (28), clip (29), and spacer (31) to position the tube assembly (12) and tube assembly (13) on the right-hand side of the boom and loosely clamp by using bolt (30) and hard washer (19). Refer to Illustration 47.
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    Illustration 48g06422218
    (14) 566-2321 Tube As
    (15) 515-8025 Tube As

  56. Torque tube assembly (14) to 65 ± 10 N·m (48 ± 7 lb ft). Refer to Illustration 48.

  57. Torque tube assembly (15) to 110 ± 17 N·m (81 ± 13 lb ft). Refer to Illustration 48.
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    Illustration 49g06422221
    (11) 515-8027 Tube As
    (12) 566-2322 Tube As
    (13) 515-8026 Tube As
    (26) 6V-8398 O-Ring Seal
    (32) 6V-8397 O-Ring Seal

  58. Install O-Ring (26) to tube assembly (11) and tube assembly (13). Install O-Ring seal (32) to tube assembly (12). Refer to Illustration 49.
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    Illustration 50g06422223
    Right side view
    (33) 169-5701 Connector As
    (34) 6V-9169 Nut
    (35) 153-2996 Fitting As
    (36) 153-2997 Fitting As
    (37) 161-2560 Dust Cap
    (38) 161-2561 Dust Cap
    (AD) 568-5522 Film
    (AE) 568-5524 Film

  59. Install connector assembly (33), nut (34), fitting assembly (35), fitting assembly (36), dust cap (37), and dust cap (38) on the bracket attached to the stick. Refer to Illustration 50.

  60. Install the film (AD) and film (AE) as shown in Illustration 50.
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    Illustration 51g06422226
    Right side view
    (9) 7K-1181 Cable Strap
    (12) 566-2322 Tube As
    (13) 515-8026 Tube As
    (33) 169-5701 Connector As
    (39) 567-4455 Hose As or 567-4456 Hose As
    (40) 515-8022 Hose As or 515-8031 Hose As

  61. Assemble hose assembly (39) with tube assembly (12), torque to 76 ± 4 N·m (56 ± 3 lb ft). Assemble the other end of the hose assembly (39) to connector assembly (33), torque to 76 ± 4 N·m (56 ± 3 lb ft). Refer to Illustration 51.

  62. Assemble hose assembly (40) with tube assembly (13), torque to 76 ± 4 N·m (56 ± 3 lb ft). Assemble the other end of the hose assembly (40) to connector assembly (33), torque to 76 ± 4 N·m (56 ± 3 lb ft). Refer to Illustration 51.

  63. Secure the hose assembly (39) and hose assembly (40) using cable strap (9). Refer to Illustration 51.
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    Illustration 52g06422228
    Left side view
    (11) 515-8027 Tube As
    (33) 169-5701 Connector As
    (34) 6V-9169 Nut
    (35) 153-2996 Fitting As
    (38) 161-2561 Dust Cap
    (40) 515-8022 Hose As or 515-8031 Hose As
    (AF) 568-5523 Film

  64. Install connector assembly (33), fitting assembly (35), and dust cap (38) to the bracket attached on the stick. Refer to Illustration 52.

  65. Assemble hose assembly (40) with tube assembly (11), torque to 76 ± 4 N·m (56 ± 3 lb ft). Attach the other end of hose assembly (40) to connector assembly (33). Refer to Illustration 52.

  66. Install film (AF) as shown in Illustration 52.
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    Illustration 53g06422055
    (H) Battery disconnect switch
    (J) Implement valve cover

  67. Replace the implement valve cover (J) and tighten the bolts to 6 ± 1 N·m (53 ± 9 lb in). Refer to Illustration 53.

  68. Turn ON the battery disconnect switch (H). Refer to Illustration 53.
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    Illustration 54g06422690
    (F) 549-3304 Cover
    (G) 554-1892 Enclosure Cover As

  69. Reinstall the cover (F) and enclosure cover assembly (G), torque the bolts to 55 ± 10 N·m (41 ± 7 lb ft). Refer to Illustration 54.
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    Illustration 55g06422046
    (A) 510-9956 Access Door As
    (B) 510-9918 Cover As

  70. Reinstall the access door assembly (A) and cover assembly (B), torque the bolts to 55 ± 10 N·m (41 ± 7 lb ft). Refer to Illustration 55.

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A New Factory Process is Now Used on Certain Marine Engines Equipped with Alarm and Protection System {1403, 1906} A New Factory Process is Now Used on Certain Marine Engines Equipped with Alarm and Protection System {1403, 1906}
Fuel Pressure Gauge Test Kit is Now Available for Certain Generator Sets {0782} Fuel Pressure Gauge Test Kit is Now Available for Certain Generator Sets {0782}
Alternator Voltage Change Over and Wiring Configuration/Winding Resistance Data are Now Available for Certain Cat® Retail Generator Sets {1403, 1405} Alternator Voltage Change Over and Wiring Configuration/Winding Resistance Data are Now Available for Certain Cat® Retail Generator Sets {1403, 1405}
NOx Reduction System (NRS) Valve Not Responding on Certain C4.4 and C7.1 Engines {1057, 1082, 108R} NOx Reduction System (NRS) Valve Not Responding on Certain C4.4 and C7.1 Engines {1057, 1082, 108R}
New CAT® WEO Fittings Are Now Available for Certain Mini Hydraulic Excavators {1000, 7000} New CAT® WEO Fittings Are Now Available for Certain Mini Hydraulic Excavators {1000, 7000}
New CAT® WEO Fittings Are Now Available for Certain Mini Hydraulic Excavators {0618, 3016, 4133, 4257, 4304, 5057, 7554} New CAT® WEO Fittings Are Now Available for Certain Mini Hydraulic Excavators {0618, 3016, 4133, 4257, 4304, 5057, 7554}
140 Motor Grader Engine Supplement Belt Tensioner - Remove and Install
140 Motor Grader Engine Supplement Battery - Remove and Install
Loose Wire Strands May Exist at the Lug Crimps on Certain C32 and G3512 Generator Sets {4459} Loose Wire Strands May Exist at the Lug Crimps on Certain C32 and G3512 Generator Sets {4459}
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