Installation Procedure for 561-8199 Auxiliary Lines Kit on Certain 310 Mini Hydraulic Excavators {5057} Caterpillar

Mini Hydraulic Excavator

310 (S/N: GWT1-UP)

Introduction

This Special Instruction contains the procedure to install the 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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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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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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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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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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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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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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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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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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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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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

Installation Procedure

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Illustration 1	g06413811
(A) 517-8271 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 2	g06413813
   (C) Cotter pin and washer (E) Rod assembly

2. Remove the cotter pin and washer (C) to disassemble the rod assembly (E) from 558-2296 Cover. Refer to Illustration 2.
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   Illustration 3	g06413815
   (F) 558-2296 Cover (G) 558-2329 Enclosure Cover As

3. Remove the cover (F) by loosening the bolts. Refer to Illustration 3.

4. Remove the enclosure cover assembly (G) by loosening the bolts. Refer to Illustration 3.
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   Illustration 4	g06413817
   (H) Battery disconnect switch (J) 543-8772 Cover (K) Main control valve group (L) 148-8408 Plug As

5. Turn OFF the battery disconnect switch (H) and remove the bolts on the cover (J) to access main control valve group (K). Refer to Illustration 4.

6. Remove plug assembly (L) from port 2A and port 2B on main control valve group (K).
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   Illustration 5	g06413818
   (1) 148-8328 Connector As

7. Install the connector assembly (1) to port 2A and port 2B on main control valve group (K). Refer to Illustration 5.
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   Illustration 6	g06413819
   (2) 551-0633 Hose As (K) Main control valve group (D1) 10 Degrees

8. Install hose assembly (2) to port 2B with the coupling tilted at an angle (D1), torque to 65 ± 10 N·m (48 ± 7 lb ft). Refer to Illustration 6.
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   Illustration 7	g06413820
   (3) 551-0634 Hose As (K) Main control valve group (D1) 10 Degrees

9. Install hose assembly (3) to port 2A with the coupling tilted at an angle (D1), torque to 65 ± 10 N·m (48 ± 7 lb ft). Refer to Illustration 7.
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   Illustration 8	g06413821
   (2) 551-0633 Hose As (3) 551-0634 Hose As (4) 7K-1181 Cable Strap (M) 566-3102 Manifold

10. Route hose assembly (2) and hose assembly (3) towards the manifold (M). Refer to Illustration 8.

11. Secure hose assembly (2) and hose assembly (3) using cable strap (4) at 450.0 mm (17.72 inch) away from the main control valve group (K).
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    Illustration 9	g06413822
    (5) 275-1442 Clip (6) 275-1444 Grommet (7) 275-1443 Clip (8) 8T-4136 Bolt (9) 8T-4121 Hard Washer

12. Route hose assembly (2) and hose assembly (3) below the manifold (M) and clamp hoses using clip (5), grommet (6) , and clip (7). Refer to Illustration 9.

13. Use bolt (8) and washer (9) to attach the clips, torque to (8) to 55 ± 10 N·m (41 ± 7 lb ft). Refer to Illustration 9.
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    Illustration 10	g06413824
    (2) 551-0633 Hose As (3) 551-0634 Hose As

14. Route hose assembly (2) and hose assembly (3) under the manifold as shown in Illustration 10.
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    Illustration 11	g06413828
    (N) Hydraulic tank (P) 148-8407 Plug As

15. Remove plug assembly (P) from the hydraulic tank (N). Refer to Illustration 11.
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    Illustration 12	g06413829
    (10) 556-4469 Hose As

16. Install hose assembly (10) to the hydraulic tank (N) using 148-8336 Connector As as shown in Illustration 12. Torque to 45 ± 5 N·m (33 ± 4 lb ft).
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    Illustration 13	g06413830
    (N) Hydraulic tank (4) 7K-1181 Cable Strap (10) 556-4469 Hose As

17. Secure hose assembly (10) using cable strap (4) along with other drain lines. Refer to Illustration 13.
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    Illustration 14	g06413832
    (2) 551-0633 Hose As (10) 556-4469 Hose As (11) 178-3620 Strap (R) 513-7121 Hose As

18. Continue to route the hose assembly (10) through the strap (11) as shown in Illustration 14. The first strap (11) is placed approximately at 665.0 mm (26.18 inch) on the hose measured from the hydraulic tank (N) side and clipped with swing motor hose assembly (R). The second strap (11) is placed close to the manifold (M) and clipped to hose assembly (2).
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    Illustration 15	g06413834
    (10) 556-4469 Hose As (11) 178-3620 Strap (12) 136-0207 Cable Strap

19. After the manifold, route hose assembly (10) through strap (11). Secure hose assembly (10) using cable strap (12) along with 551-0633 Hose As and 551-0634 Hose As. Refer to Illustration 15.

20. Ensure that the auxiliary supply lines, return, and drain lines are connected to the respective tube assemblies on the boom.
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    Illustration 16	g06413835
    (S) Solenoid 8 (T) Solenoid 9 (U) 155-2269 Connector Plug As

21. Ensure that the harness connector plug assembly (U) are connected, port B to solenoid 9 (T) and port A to solenoid 8 (S). Refer to Illustration 16
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    Illustration 17	g06414220
    Auxiliary tubes (13) 515-8041 Tube As (14) 566-3153 Tube As (15) 515-8040 Tube As (16) 566-3152 Tube As (17) 551-0622 Tube As (18) 551-0621 Tube As

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    Illustration 18	g06413844
    (V) Bolts

22. Remove bolts (V) on the clamps as shown in Illustration 18
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    Illustration 19	g06413845
    (16) 566-3152 Tube As (17) 551-0622 Tube As (18) 551-0621 Tube As (19) 3E-6909 Clip (20) 8T-6685 Bolt (21) 8T-4121 Hard Washer (22) 8T-1887 Clip (23) 8T-1888 Clip (24) 133-6934 Spacer (25) 091-9035 Spacer

23. Use clip (22), clip (23), spacer (24), and spacer (25) to position the tube assembly (16), tube assembly (17), and tube assembly (18). Refer to Illustration 19.
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    Illustration 20	g06413846
    (16) 566-3152 Tube As (17) 551-0622 Tube As (18) 551-0621 Tube As (D2) 93.0 ± 3.0 mm (3.66 ± 0.12 inch) (D3) 59.0 ± 3.0 mm (2.33 ± 0.12 inch)

24. Use bolt (20) and washer (21) to clamp the tube assembly (16), tube assembly (17), and tube assembly (18). Refer to Illustration 19 and Illustration 20.
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    Illustration 21	g06413847
    (16) 566-3152 Tube As (17) 551-0622 Tube As (19) 3E-6909 Clip (21) 8T-4121 Hard Washer (22) 8T-1887 Clip (23) 8T-1888 Clip (25) 091-9035 Spacer (26) 8T-4172 Bolt

25. Use clip (22), clip (23), spacer (25), and clip (19) to position the tube assembly (16) and tube assembly (17) on the right-hand side of the boom. Loosely clamp by using bolt (26) and washer (21). Refer to Illustration 21.
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    Illustration 22	g06413848
    (18) 551-0621 Tube As (21) 8T-4121 Hard Washer (22) 8T-1887 Clip (23) 8T-1888 Clip (27) 8T-6466 Bolt

26. Use clip (22) and clip (23) to position the tube assembly (18) on the left-hand side of the boom and loosely clamp by using bolt (27) and washer (21). Refer to Illustration 22.

27. Tighten the bolt (26) and bolt (27) to 55 ± 10 N·m (41 ± 7 lb ft).
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    Illustration 23	g06413850
    (16) 566-3152 Tube As (17) 551-0622 Tube As (18) 551-0621 Tube As (28) 6V-8398 O-Ring Seal

28. Install O-Ring seal (28) to tube assembly (16), tube assembly (17), and tube assembly (18). Refer to Illustration 23.
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    Illustration 24	g06413849
    (W) Bolts

29. Remove the bolts (W) to assemble the auxiliary tubes on the boom.
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    Illustration 25	g06414737
    Right side view (14) 566-3153 Tube As (15) 515-8040 Tube As (16) 566-3152 Tube As (17) 551-0622 Tube As (19) 3E-6909 Clip (21) 8T-4121 Hard Washer (22) 8T-1887 Clip (23) 8T-1888 Clip (25) 091-9035 Spacer (29) 8T-4178 Bolt

30. Assemble tube assembly (15) with tube assembly (17) and tube assembly (14) with tube assembly (16) on the boom. Position the tube assembly (15) and tube assembly (14) on the boom using clip (22), clip (23), clip (19), and spacer (25). Refer to Illustration 25.

31. Use bolt (29) and washer (21) to attach the clips. Once all the clips are loosely clamped, tighten the bolt (29) to 55 ± 10 N·m (40 ± 7 lb ft) at all the three places. Refer to Illustration 25.

32. Tighten the tube assembly (14) and tube assembly (15) to 65 ± 10 N·m (48 ± 7 lb ft).
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    Illustration 26	g06413853
    Left side view (13) 515-8041 Tube As (18) 551-0621 Tube As (21) 8T-4121 Hard Washer (22) 8T-1887 Clip (23) 8T-1888 Clip (27) 8T-6466 Bolt

33. Assemble tube assembly (13) with tube assembly (18) on the boom. Position the tube assembly (13) on the boom using clip (22) and clip (23). Use bolt (27) and washer (21) to attach the clips. Once all the clips are loosely clamped, tighten the bolts (27) to 55 ± 10 N·m (41 ± 7 lb ft) at all the three places. Refer to Illustration 26.

34. Tighten the tube assembly (13) to 65 ± 10 N·m (48 ± 7 lb ft).
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    Illustration 27	g06414679
    (16) 566-3152 Tube As (17) 551-0622 Tube As (18) 551-0621 Tube As (28) 6V-8398 O-Ring Seal (30) 6V-8397 O-Ring Seal

35. Install O-Ring seal (28) to tube assembly (17) and tube assembly (18). Install O-Ring seal (30) to tube assembly (16). Refer to Illustration 27.
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    Illustration 28	g06413855
    (2) 551-0633 Hose As (3) 551-0634 Hose As (10) 556-4469 Hose As (16) 566-3152 Tube As (17) 551-0622 Tube As (18) 551-0621 Tube As

36. Attach hose assembly (10) with tube assembly (16), torque to 45 ± 5 N·m (33 ± 4 lb ft). Refer to Illustration 28.

37. Attach hose assembly (3) with tube assembly (18), torque to 65 ± 10 N·m (48 ± 7 lb ft). Refer to Illustration 28.

38. Attach hose assembly (2) with tube assembly (17), torque to 65 ± 10 N·m (48 ± 7 lb ft). Refer to Illustration 28.
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    Illustration 29	g06413856
    (13) 515-8041 Tube As (14) 566-3153 Tube As (15) 515-8040 Tube As (28) 6V-8398 O-Ring Seal (30) 6V-8397 O-Ring Seal

39. Install O-Ring seal (28) to tube assembly (13) and tube assembly (15). Install O-Ring seal (30) to tube assembly (14).
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    Illustration 30	g06414681
    Right side view (31) 169-5701 Connector As (32) 153-2997 Fitting As (33) 6V-9169 Nut (34) 153-2996 Fitting As (35) 161-2560 Dust Cap (36) 161-2561 Dust Cap (37) 568-5524 Film (38) 568-5522 Film

40. Install connector assembly (31), fitting assembly (32), fitting assembly (34), dust cap (35), and dust cap (36) on the bracket attached to the stick. Refer to Illustration 30

41. Install the film (37) and film (38) as shown in Illustration 30.
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    Illustration 31	g06414680
    Right side view (4) 7K-1181 Cable Strap (14) 566-3153 Tube As (15) 515-8040 Tube As (31) 169-5701 Connector As (39) 567-4459 Hose As (40) 515-8048 Hose As

42. Assemble hose assembly (39) with tube assembly (14), torque to 76 ± 4 N·m (56 ± 3 lb ft). Assemble the other end of hose assembly (39) to connector assembly (31), torque to 76 ± 4 N·m (56 ± 3 lb ft). Refer to Illustration 31.

43. Assemble hose assembly (40) with tube assembly (15), torque to 76 ± 4 N·m (56 ± 3 lb ft). Assemble the other end of hose assembly (40) to connector assembly (31), torque to 76 ± 4 N·m (56 ± 3 lb ft). Refer to Illustration 31.

44. Secure the hose assembly (39) and hose assembly (40) using cable strap (4). Refer to Illustration 31.
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    Illustration 32	g06414682
    Left side view (13) 515-8041 Tube As (31) 169-5701 Connector As (33) 6V-9169 Nut (34) 153-2996 Fitting As (36) 161-2561 Dust Cap (40) 515-8048 Hose As (41) 568-5523 Film

45. Install connector assembly (31), fitting assembly (34), and dust cap (36) to the bracket attached on the stick. Refer to Illustration 32.

46. Assemble the hose assembly (40) to tube assembly (13), torque to 76 ± 4 N·m (56 ± 3 lb ft). Attach the other end of tube assembly (13) to connector assembly (31). Refer to Illustration 32.

47. Install film (41) as shown in Illustration 32.