Procedure to Install a 455-6307 Gear Pump Group on Certain M318D MH and M322D MH Material Handlers {5073} Caterpillar

Introduction

This Special Instruction covers the installation procedure for the 455-6307 Gear Pump Gp on the models and applications listed above.

Safety Section

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by AVSpare is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

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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 Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any AVSpare dealer for replacement manuals. Proper care is your responsibility.

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Be sure all personnel are clear of the equipment while the equipment is being lowered. Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth and level location that is away from working machines and personnel. Ground all implements. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a "Do Not Operate" tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Illustration 1	g00037860

Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.

Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain a three-point contact with the step and with handholds.

Note: Three-point contact can be both feet and one hand or a single foot and two hands.

Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the machine when you carry tools or supplies. Do not try to dismount the machine when you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the cab or when you exit the cab.

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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 Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any AVSpare dealer for replacement manuals. Proper care is your responsibility.

In addition to the normal safety precautions that are taken in the day to day operation of heavy machinery, the following steps are recommended:

1. Move the machine to a suitable location. The location should be smooth, level, and out of direct sunlight.

2. Move away from other working machines and personnel.

3. Ground all implements.

4. Stop the engine.

5. Engage the machine brake. Put blocks in front of the wheels and behind the wheels.

6. Install steering frame lock in the LOCKED position so the machine cannot articulate. (If used on the specific machine work is being performed on)

   Note: Turn the engine start switch key to the ON position but do not start the engine before performing step 7.

7. Move the implement control levers through the full range of travel. This procedure will relieve any pressure that may be present in the implement hydraulic system.

8. Depress the brake pedal repeatedly. This procedure will relieve any pressure that may be present in the brake hydraulic system.

9. Turn the engine start switch key to the OFF position.

10. Allow several minutes for steering system pressure to release.

11. When possible, maintain ownership of the machine keys.

Consult the Machine Operation and Maintenance Manual for all safety procedures applicable to the specific machine being worked on before performing any repairs or diagnostics.

Required Parts

Fabricate Hose Assembly

Illustration 2	g06016681
465-0358 Hose As (A) 2270 ± 23 mm (89.4 ± 0.9 inch) (13) 122-6870 Hydraulic Hose (14) 124-2118 Permanent Coupling (15) 124-2148 Permanent Coupling

Manufacture the 465-0358 Hose Assembly as shown in Illustration 2.

Installation Procedure

Remove Existing Pump

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Illustration 3	g06017002
Left side view of engine (B) Existing 329-5736 Gear Pump Gp

1. Disconnect and cap the lines from existing pump (B).

2. Remove existing gear pump group (B) from the engine.

   Note: Retain the mounting bolts for later use.

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   Illustration 4	g06017023
   Gear pump group (B) ( C) Existing 148-8372 Elbow As (D) Existing 197-9995 Flange

3. Remove and retain existing elbow assembly (C) and flange (D).

Installing New Pump

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Illustration 5	g06017078
(C) Existing 148-8372 Elbow As (D) Existing 197-9995 Flange (1) 2M-9780 O-Ring Seal (2) 3K-0360 O-Ring Seal (3) 5K-9090 O-Ring Seal (5) 6V-8398 O-Ring Seal (10) 8T-0077 Connector (17) 455-6307 Gear Pump Gp

1. Install the previously removed elbow (C) on pump (17) using new O-ring seals (1) and (5).

2. Install the previously removed flange (D) on pump (17) with new O-ring seal (3).

3. Install connector (10) on pump (17) using O-ring seals (2) and (5).
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   Illustration 6	g06017147
   (C) Existing 148-8372 Elbow As (D) Existing 197-9995 Flange (9) 7J-9108 O-Ring Seal (10) 8T-0077 Connector (16) 157-2348 Elbow (17) 455-6307 Gear Pump Gp

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   Illustration 7	g06017138
   Rear view (C) Existing 148-8372 Elbow As (E) 141 degree angle (9) 7J-9108 O-Ring Seal (16) 157-2348 Elbow

4. Install elbow (16) on connector (10) at the angle shown using O-ring seal (9).

5. Mount gear pump group (17) on engine using previously removed mounting bolts.

6. Connect the previously removed lines to flange (D) and elbow (C).
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   Illustration 8	g06017230
   (F) Fabricated hose assembly - 465-0358 Hose As (16) 157-2348 Elbow

7. Connect the straight end of previously fabricated hose assembly (F) to elbow (16).
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   Illustration 9	g06017240
   (F) Fabricated hose assembly - 465-0358 Hose As

8. Route hose assembly (F) under the main control valve to the hydraulic oil tank as shown in Illustration 9.

   For machines equipped with a 358-9332 or 358-9322 Hydraulic Generator Arrangement (15 kW), skip to Step 12.

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   Illustration 10	g06017264
   Front view of hydraulic oil tank (G) Existing elbow - 148-8352 Elbow As

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   Illustration 11	g06017278
   Front view of hydraulic oil tank (F) Fabricated hose assembly - 465-0358 Hose As (3) 5K-9090 O-Ring Seal (7) 6V-8945 O-Ring Reducer (8) 6V-9840 Swivel Tee (9) 7J-9108 O-Ring Seal (11) 9X-6579 Orifice Nut

9. Replace existing elbow (G) with swivel tee (8) using two O-ring seals (3).

10. Add reducer (7) using orifice nut (11).

11. Using O-ring seal (9), connect fabricated hose assembly (F) to reducer (7).

    Note: This action completes the installation for machines not equipped with a 358-9332 or 358-9322 Hydraulic Generator Arrangement (15 kW).

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    Illustration 12	g06017338
    (H) Existing tee

12. Remove existing tee assembly (H).
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    Illustration 13	g06017785
    (F) Fabricated hose assembly - 465-0358 Hose As (J) Existing tee assembly - 148-8433 Tee As (1) 2M-9780 O-Ring Seal (3) 5K-9090 O-Ring Seal (5) 6V-8398 O-Ring Seal (6) 6V-8936 Reducer (7) 6V-8945 O-Ring Reducer (8) 6V-9840 Swivel Tee (9) 7J-9108 O-Ring Seal (11) 9X-6579 Orifice Nut (12) 115-8634 O-Ring Tee

13. Replace existing tee assembly (H) with swivel tee (8) using two O-ring seals (3).

14. Add reducer (7) using orifice nut (11).

15. Using O-ring seal (9), connect fabricated hose assembly (F) to reducer (7).

16. Disconnect existing tee assembly (J) and insert reducer (6) with tee (12) using one O-ring seal (1) and two O-ring seals (5).
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    Illustration 14	g06017856
    (K) Existing hose assembly - 138-7947 Hose As (6) 6V-8936 Reducer

17. Connect hose (K) to reducer (6).