Procedure to Install Fixed Boom Secondary Auxiliary Lines for 307.5 Mini Hydraulic Excavators {5057}
- Mini Hydraulic Excavator
- 307.5 (S/N: GW71-UP)
Introduction
This special instruction will provide parts and procedures to install fixed boom secondary auxiliary lines for 307.5 Mini Hydraulic Excavators.
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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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
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| Required Parts for 561-8198 Auxiliary Lines Kit | |||
|---|---|---|---|
| Item | Qty | Part Number | Part Name |
| 1 | 2 | Cable Strap | |
| 2 | 2 | Bolt | |
| 3 | 1 | Bolt | |
| 4 | 3 | Spacer | |
| 5 | 1 | Cable Strap | |
| 6 | 2 | Connector As | |
| 7 | 1 | Connector As | |
| 8 | 2 | Fitting As | |
| 9 | 1 | Fitting As | |
| 10 | 2 | Dust Cap | |
| 11 | 1 | Dust Cap | |
| 12 | 3 | Connector As | |
| 13 | 3 | Strap | |
| 14 | 1 | Clip | |
| 15 | 1 | Clip | |
| 16 | 1 | Grommet | |
| 17 | 1 | Cable Strap | |
| 18 | 2 | Cable Strap | |
| 19 | 3 | Spacer | |
| 20 | 3 | Clip | |
| 21 | 1 | Tube As | |
| 22 | 1 | Tube As | |
| 23 | 2 | Hose As(1) | |
| 2 | Hose As(2) | ||
| 24 | 4 | Bolt | |
| 25 | 1 | Hose As | |
| 26 | 1 | Hose As | |
| 27 | 1 | Hose As | |
| 28 | 1 | Tube As | |
| 29 | 1 | Tube As | |
| 30 | 1 | Tube As | |
| 31 | 1 | Tube As | |
| 32 | 1 | Hose As(1) | |
| 1 | Hose As(2) | ||
| 33 | 4 | Bolt | |
| 34 | 1 | Film | |
| 35 | 1 | Film | |
| 36 | 1 | Film | |
| 37 | 2 | O-Ring Seal | |
| 38 | 7 | O-Ring Seal | |
| 39 | 3 | Nut | |
| 40 | 4 | Cable Strap | |
| 41 | 10 | Clip | |
| 42 | 10 | Clip | |
| 43 | 10 | Hard Washer | |
| 44 | 1 | Bolt | |
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| (1) | For machines with short stick |
| (2) | For machines with long stick |
Installation Procedure for Secondary Auxiliary Lines on Machine
- Unlatch the RH door (D) and remove RH door assembly (C) for access to the back of the hydraulic tank and save hardware. Remove the top cover assembly (A) and save hardware. Remove the center cover assembly (B) and save hardware. Refer to Illustration 1.
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Illustration 2 g06416370 (E) Cotter pin and washer combination
(F) Rod assembly - Remove the cotter pin and washer combination (E) and save hardware. Remove the rod assembly (F) and save hardware. Refer to Illustration 2.
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Illustration 3 g06416373 (G) Bolt
(H) Plug
(J) Battery disconnect switch
(K) Implement valve cover - Turn the battery disconnect switch (J) to the OFF position. Remove the four bolts (G) and the implement valve cover (K), save hardware. Remove the two plugs (H) at ports 2A and 2B from the implement valve. Refer to Illustration 3.
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Illustration 4 g06416609 (6) 148-8328 Connector As - Install 2 connector assemblies (6) in ports 2A and 2B on the implement valve and torques to
100 ± 15 N·m (74 ± 11 lb ft) . Refer to Illustration 4.Show/hide table
Illustration 5 g06416402 (25) 551-0633 Hose As - Install hose assembly (25) at port 2B on the implement valve on a 10° angle. Torque hose assembly (25) to
65 ± 10 N·m (48 ± 7 lb ft) . Refer to Illustration 5.Show/hide table
Illustration 6 g06416407 (26) 551-0634 Hose As - Install (26) at port 2A on the implement valve on a 10° angle. Torque (26) to
65 ± 10 N·m (48 ± 7 lb ft) . Refer to Illustration 6.Show/hide table
Illustration 7 g06416411 (25) 551-0633 Hose As
(26)551-0634 Hose As
(40)7K-1181 Cable Strap
(L) Implement valve
(M) Manifold - Route both hose assemblies (25) and (26) from the implement valve (L) towards the manifold (M). Install cable strap (40) at approximately
450 mm (17.75 inch) from the implement valve (L). Refer to Illustration 7.Show/hide table
Illustration 8 g06416415 (14) 275-1442 Clip
(15)275-1443 Clip
(16)275-1444 Grommet
(25)551-0633 Hose As
(26)551-0634 Hose As
(44)8T-4121 Hard Washer
(45)8T-4136 Bolt
(N) Manifold - Route hose assemblies (25) and (26) below the manifold (N). Secure hose assemblies (25) and (26) using a combination of clip (14), clip (15), grommet (16), hard washer (44), and bolt (45). Refer to Illustration 8.
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Illustration 9 g06416418 (25) 551-0633 Hose As
(26)551-0634 Hose As
(P) Manifold - Refer to Illustration 9 to show where to route hose assemblies (25) and (26) under the manifold (P).
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Illustration 10 g06416423 (Q) Plug assembly Show/hide table
Illustration 11 g06416451 (27) 556-4469 Hose As - For routing hose assembly (27), remove plug assembly (Q) from the back of the hydraulic oil tank and install hose assembly (27). Torque (27) to
45 ± 5 N·m (33 ± 4 lb ft) . Refer to Illustrations 10 and 11.Show/hide table
Illustration 12 g06416453 (13) 178-3620 Strap
(25)551-0633 Hose As
(26)551-0634 Hose As
(27)556-4469 Hose As
(40)7K-1181 Cable Strap
(R) Drain lines - Route hose assembly (27) from the back of the hydraulic tank and use cable strap (40) to secure hose assembly (27) to the other drain lines (R). Install 2 straps (13) to secure hose assembly (27). Refer to Illustration 12.
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Illustration 13 g06416490 (5) 136-0207 Cable Strap
(13)178-3620 Strap
(25)551-0633 Hose As
(26)551-0634 Hose As
(27)556-4469 Hose As
(S) Manifold - Install strap (13) after the manifold (S) to route hose assembly (27). Install cable strap (5) to hold hose assemblies (25), (26), and (27) together to the first auxiliary line. Connect hose assemblies (25), (26), and (27) to the correct tube assemblies on the boom. Refer to Illustration 13.
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Illustration 14 g06416494 (T) Port B on solenoid 09
(U) Port A on solenoid 08 - Ensure that harness connectors are connected to Port B on solenoid 09 (T) and Port A on solenoid 08 (U). Refer to Illustration 14.
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| Illustration 1 | g06416358 |
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(A) Top cover assembly
(B) Center cover assembly (C) RH door assembly (D) RH door | |
Installation Procedure for Secondary Auxiliary Tubes on Boom
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| Illustration 15 | g06416499 |
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(21) (22) (28) (29) (30) (31) | |
- Remove the bolt and washer combination (V) holding clamp. Refer to Illustration 16.
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Illustration 17 g06416790 (4) 091-9035 Spacer
(41)8T-1887 Clip
(42)8T-1888 Clip - Install spacer (4) on top of the holding clamp. Install clips (41) and (42) to hold the secondary auxiliary tubes temporarily. Refer to Illustration 17.
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Illustration 18 g06416791 (28) 556-4577 Tube As
(29)556-4578 Tube As
(41)8T-1887 Clip
(42)8T-1888 ClipShow/hide table
Illustration 19 g06416801 (D1) 120 ± 3 mm (4.75 ± 0.12 inch) - Install tube assembly (28) on the left side of the clips (41) and (42). Install tube assembly (29) on the right side of the clips (41) and (42). Install tube assemblies (28) and (29)
120 ± 3 mm (4.75 ± 0.12 inch) (D1) from the clips (41), and (42). Refer to Illustrations 18 and 19.Show/hide table
Illustration 20 g06416802 (19) 296-6980 Spacer
(41)8T-1887 Clip
(42)8T-1888 ClipShow/hide table
Illustration 21 g06416805 (3) 8T-6685 Bolt
(20)3E-6909 Clip
(30)566-3154 Tube As
(43)8T-4121 Hard Washer - Install spacer (19) on top of clips (41) and (42). Install tube assembly (30) using a combination of bolt (3), clip (20), and hard washer (43) on top of spacer (19). Refer to Illustrations 20 and 21.
Note: Do not torque bolt (3) during this step.
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Illustration 22 g06416816 (3) 8T-6685 Bolt
(30)566-3154 Tube As
(D2)56 ± 3 mm (2.20 ± 0.12 inch) - Install the end of the tube assembly (30) at
56 ± 3 mm (2.20 ± 0.12 inch) (D2) from the center of bolt (3). Refer to Illustration 22.Note: Do not torque bolt (3) during this step.
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Illustration 23 g06416828 (W) Combination of bolt and washer - Remove the two combinations of bolts and washers (W). Refer to Illustration 23.
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Illustration 24 g06417204 (28) 556-4577 Tube As
(33)8T-6466 Bolt
(41)8T-1887 Clip
(42)8T-1888 Clip
(43)8T-4121 Hard Washer - Secure tube assembly (28) on top of existing clamp on the left side of the boom using a combination of bolt (33), clip (41), clip (42), and hard washer (43). Refer to Illustration 24.
Note: Do not torque bolt (33) during this step.
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Illustration 25 g06416835 (2) 8T-4172 Bolt
(4)091-9035 Spacer
(20)3E-6909 Clip
(29)556-4578 Tube As
(30)566-3154 Tube As
(41)8T-1887 Clip
(42)8T-1888 Clip
(43)8T-4121 Hard Washer - Install tube assembly (29) on top of existing clamp on the right side of the boom using clips (41) and (42). Install spacer (4) on top of clips (41) and (42). Install tube assembly (30) on top of spacer (4). Secure all parts using a combination of bolt (2), clip (20), and hard washer (43). Refer to Illustration 25.
Note: Do not torque bolt (2) during this step.
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Illustration 26 g06416839 (X) Combination of bolt and washer - Remove the two combinations of bolts and washers (X). Refer to Illustration 26.
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Illustration 27 g06417206 (28) 556-4577 Tube As
(33)8T-6466 Bolt
(41)8T-1887 Clip
(42)8T-1888 Clip
(43)8T-4121 Hard Washer - Install tube assembly (28) on top of the existing clamp on the left side of the boom using a combination of bolt (33), clip (41), clip (42), and hard washer (43). Refer to Illustration 27.
Note: Do not torque bolt (33) during this step.
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Illustration 28 g06416843 (2) 8T-4172 Bolt
(4)091-9035 Spacer
(20)3E-6909 Clip
(29)556-4578 Tube As
(30)566-3154 Tube As
(41)8T-1887 Clip
(42)8T-1888 Clip
(43)8T-4121 Hard Washer - Install tube assembly (29) on top of the existing clamp on the right side of the boom using clips (41) and (42). Install spacer (4) on top of clips (41) and (42). Install tube assembly (30) on top of spacer (4) using a combination of bolt (2), clip (20), and hard washer (43). Refer to Illustration 28.
Note: Do not torque bolt (2) during this step.
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Illustration 29 g06417207 (2) 8T-4172 Bolt
(3)8T-6685 Bolt
(33)8T-6466 Bolt - Torque bolts (2), (3), and (33) to
55 ± 10 N·m (40.5 ± 7.5 lb ft) . Refer to Illustration 29.Show/hide table
Illustration 30 g06416847 (28) 556-4577 Tube As
(29)556-4578 Tube As
(30)566-3154 Tube As
(38)6V-8398 O-Ring Seal - Install o-ring seal (38) at the ends of tube assemblies (28), (29), and (30). Refer to Illustration 30.
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Illustration 31 g06416850 (y) Combination of bolt and washer - Remove the 4 combinations of bolts and washers (Y). Refer to Illustration 31.
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Illustration 32 g06417208 (22) 515-8012 Tube As
(28)556-4577 Tube As
(33)8T-6466 Bolt
(41)8T-1887 Clip
(42)8T-1888 Clip
(43)8T-4121 Hard WasherShow/hide table
Illustration 33 g06417211 (22) 515-8012 Tube As
(33)8T-6466 Bolt
(41)8T-1887 Clip
(42)8T-1888 Clip
(43)8T-4121 Hard Washer - Attach tube assembly (22) to tube assembly (28). Install tube assembly (22) to the left side of the boom using 2 combinations of bolts (33), clips (41), clips (42), and hard washers (43). Refer to Illustrations 32 and 33.
Note: Do not torque the two bolts (33) during this step.
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Illustration 34 g06416888 (21) 515-8009 Tube As
(29)556-4578 Tube As
(41)8T-1887 Clip
(42)8T-1888 Clip - Attach tube assembly (21) to tube assembly (29). Install clips (41) and (42) on to tube assembly (21) on the right side of the boom. Refer to Illustration 34.
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Illustration 35 g06417198 (19) 296-6980 Spacer
(20)3E-6909 Clip
(24)8T-4178 Bolt
(30)566-3154 Tube As
(31)566-3155 Tube As
(41)8T-1887 Clip
(42)8T-1888 Clip
(43)8T-4121 Hard WasherShow/hide table
Illustration 36 g06417196 (19) 296-6980 Spacer
(20)3E-6909 Clip
(24)8T-4178 Bolt
(43)8T-4121 Hard Washer - Install spacer (19) on top of the previously installed 8T-1887 Clip and 8T-1888 Clip. Attach tube assembly (31) to tube assembly (30) and install on the right side of the boom using a combination of clips (20), bolts (24), and hard washers (43). Refer to Illustrations 35 and 36.
Note: Do not torque the two bolts (24) during this step.
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Illustration 37 g06417199 (21) 515-8009 Tube As
(22)515-8012 Tube As
(24)8T-4178 Bolt
(31)566-3155 Tube As
(33)8T-6466 Bolt - Torque the tube assemblies (21), (22), and (31) to
65 ± 10 N·m (48 ± 7.5 lb ft) . Torque bolts (24) and (33) to55 ± 10 N·m (40.5 ± 7.5 lb ft) . Refer to Illustration 37.Show/hide table
Illustration 38 g06417030 (28) 556-4577 Tube As
(29)556-4578 Tube As
(30)566-3154 Tube As
(37)6V-8397 O-Ring Seal
(38)6V-8398 O-Ring Seal - Install o-ring seal (37) in to tube assembly (30). Install o-ring seals (38) in to tube assemblies (28) and (29). Refer to Illustration 38.
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Illustration 39 g06417072 (25) 551-0633 Hose As
(26)551-0634 Hose As
(27)556-4469 Hose As
(28)556-4577 Tube As
(29)556-4578 Tube As
(30)566-3154 Tube As - Attach hose assembly (27) to tube assembly (30) and torque to
45 ± 5 N·m (33 ± 4 lb ft) . Attach hose assembly (26) to tube assembly (28) and torque to65 ± 10 N·m (48 ± 7.5 lb ft) . Attach hose assembly (25) to tube assembly (29) and torque to65 ± 10 N·m (48 ± 7.5 lb ft) . Refer to Illustration 39.Show/hide table
Illustration 40 g06417116 (21) 515-8009 Tube As
(22)515-8012 Tube As
(31)566-3155 Tube As
(37)6V-8397 O-Ring Seal
(38)6V-8398 O-Ring Seal - Install o-ring seal (37) in to tube assembly (31). Install o-ring seals (38) in to tube assemblies (21) and (22). Refer to Illustration 40.
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Illustration 41 g06417220 (12) 169-5701 Connector As
(21)515-8009 Tube As
(23)515-8021 Hose As
(31)566-3155 Tube As
(32)567-4457 Hose As
(39)6V-9169 Nut
(40)7K-1181 Cable Strap
(Z) BracketShow/hide table
Illustration 42 g06417233 (12) 169-5701 Connector As
(23)515-8021 Hose As
(32)567-4457 Hose As
(39)6V-9169 Nut
(Z) Bracket - Attach strait end of hose assembly (23) to tube assembly (21) and torque to
76 ± 4 N·m (56 ± 3 lb ft) . Attach strait end of hose assembly (32) to tube assembly (31) and torque to76 ± 4 N·m (56 ± 3 lb ft) . Install two connector assemblies (12) and two nuts (39) to bracket (Z) on stick. Torque the two nuts (39) to100 ± 15 N·m (74 ± 11 lb ft) . Attach the other ends of the hose assemblies (23) and (32) to the corresponding connector assemblies (12) on the bracket (Z) and do not torque during this step. Install three cable straps (40) to hold the hose assemblies (23) and (32) together. Refer to Illustrations 41 and 42.Show/hide table
Illustration 43 g06417227 (8) 153-2996 Fitting As
(9)153-2997 Fitting As
(10)161-2560 Dust Cap
(11)161-2561 Dust Cap
(12)169-5701 Connector As
(23)515-8021 Hose As
(32)567-4457 Hose As
(34)568-5522 Film
(36)568-5524 Film
(39)6V-9169 Nut - Install fitting assembly (9) on to the right side connector assembly (12) and torque to
100 ± 15 N·m (74 ± 11 lb ft) Install dust cap (11) on to fitting assembly (9). Install fitting assembly (8) on to the left side connector assembly (12) and torque to100 ± 15 N·m (74 ± 11 lb ft) . Install dust cap (10) on to fitting assembly (8). Torque hose assemblies (23) and (32) to76 ± 4 N·m (56 ± 3 lb ft) . Install films (34) and (36) for hose assemblies (23) and (32) in the corresponding locations. Refer to Illustration 43.Show/hide table
Illustration 44 g06417719 (12) 169-5701 Connector As
(22)515-8012 Tube As
(23)515-8021 Hose As
(39)6V-9169 Nut
(AA) PlateShow/hide table
Illustration 45 g06417735 (12) 169-5701 Connector As
(23)515-8021 Hose As
(39)6V-9169 Nut
(AA) Plate - Attach strait end of hose assembly (23) to tube assembly (22) and torque to
76 ± 4 N·m (56 ± 3 lb ft) Install connector assembly (12) and nut (39) to plate (AA) and torque the nut (39) to100 ± 15 N·m (74 ± 11 lb ft) . Attach the other end of hose assembly (23) to the connector assembly (12), do not torque this end of the hose assembly during this step. Refer to Illustrations 44 and 45.Show/hide table
Illustration 46 g06417748 (8) 153-2996 Fitting As
(10)161-2560 Dust Cap
(12)169-5701 Connector As
(23)515-8021 Hose As
(35)568-5523 Film - Install connector assembly (12) onto fitting assembly (8) and torque to
100 ± 15 N·m (74 ± 11 lb ft) . Install dust cap (10) on to connector assembly (12). Torque hose assembly (23) attached to (12) to76 ± 4 N·m (56 ± 3 lb ft) . Install film (35) for hose assembly (23) in the corresponding location. Refer to Illustration 46.Show/hide table
Illustration 47 g06417772 (AB) Bolt
(AC) Implement valve cover - Reinstall the implement valve cover (AC) using the 4 bolts (AB) and torque the bolts (AB) to
6 ± 1 N·m (4.5 ± 1 lb ft) . Refer to Illustration 47.Show/hide table
Illustration 48 g06417774 (AD) Cotter pin and washer combination
(AE) Rod assembly - Reinstall the rod assembly (AE) and secure with the cotter pin and washer combination (AD). Refer to Illustration 48.
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Illustration 49 g06417838 (AF) Top cover assembly
(AG) Center cover assembly
(AH) RH door assembly - Reinstall the center cover assembly (AG) with existing hardware. Reinstall the top cover assembly (AF) with existing hardware. Reinstall the RH door assembly (AH) with the existing hardware. Refer to Illustration 49.
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Illustration 50 g06417847 (AJ) Battery disconnect switch - Turn the battery disconnect switch (AJ) to the ON position. Refer to Illustration 50.
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| Illustration 16 | g06416788 |
| (V) Bolt and washer combination | |
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