Installation Procedure for 260-7986 Pilot Lines Gp {5057, 5059}
[GEHS0052]
HYDRAULIC SYSTEM
LINES GP-PILOT
Installation Procedure for 260-7986 Pilot Lines Gp {5057, 5059}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Hose Connection Chart
5.1. Installation Procedure
- Excavator:
- 320D (S/N: FNA1-UP; DFB1-UP)
- 320D (S/N: A6F1-UP)
- 320D (S/N: A8F1-UP)
- 320D (S/N: A9F1-UP)
- 320D (S/N: KGF1-UP; TDH1-UP; DHK1-UP; FAL1-UP; KLM1-UP; WJN1-UP; BWP1-UP; GDP1-UP; AZR1-UP; SNS1-UP; EBT1-UP; CXY1-UP; BWZ1-UP)
- 323D (S/N: LFL1-UP)
- 320D (S/N: A6F1-UP)
- Work Tool:
- HYDRAULIC KIT (S/N: HKD1-UP)
Introduction
This Special Instruction provides the information that is necessary to install the 260-7986 Pilot Lines Gp Revision -14on certain excavators.
Safety Section
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| Illustration 1 | g00104545 |
Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your AVSpare dealer.
Note: Drain the hydraulic fluid from the hydraulic tank before opening the hydraulic system. Remember to fill the hydraulic tank with hydraulic fluid once the installation is complete.
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before operating any compartment or disassembling any component containing fluids. After collecting all fluids in suitable containers, dispose of all fluids according to local regulations and mandates. |
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Check valves in the hydraulic system may allow pressure to exist in the hydraulic lines after the engine has been stopped. Pressure must be relieved prior to servicing the components of the hydraulic system. Failure to relieve pressure prior to servicing may result in personal injury. |
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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. |
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. |
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Required Parts
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| Required Parts 260-7986 Pilot Lines Gp Revision -14 |
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|---|---|---|---|
| Item | Qty | Part Number | Description |
| (1) | 1 | 4I-1878 | Hose As |
| (2) | 1 | 4I-3941 | Fitting As |
| (3) | 1 | 4I-3988 | Hose As |
| (4) | 2 | 4I-9521 | Marker Band (RED) |
| (5) | 2 | 4I-9522 | Marker Band (YELLOW) |
| (6) | 8 | 4I-9523 | Marker Band (BLUE) |
| (7) | 6 | 4I-9524 | Marker Band (BROWN) |
| (8) | 2 | 4I-9525 | Marker Band (ORANGE) |
| (9) | 8 | 4I-9527 | Marker Band (GREEN) |
| (10) | 4 | 4I-9528 | Marker Band (PURPLE) |
| (11) | 2 | 6V-0852 | Dust Cap |
| (12) | 1 | 7I-1105 | Hose As |
| (13) | 19 | 7K-1181 | Cable Strap |
| (14) | 1 | 7Y-4199 | Hose As |
| (15) | 1 | 7Y-8309 | Hose As |
| (16) | 1 | 087-5764 | Hose As |
| (17) | 1 | 087-5772 | Hose As |
| (18) | 2 | 108-7313 | Hose As |
| (19) | 1 | 111-0988 | Hose As |
| (20) | 1 | 118-9902 | Spacer |
| (21) | 1 | 124-1008 | Guard |
| (22) | 1 | 134-6921 | Hose As |
| (23) | 1 | 148-8443 | Tee |
| (24) | 1 | 165-9549 | Solenoid Valve Gp |
| (25) | 1 | 398-2282 | Solenoid Valve Gp |
| (26) | 1 | 179-7616 | Hose As |
| (27) | 2 | 199-1609 | Hose As |
| (28) | 2 | 204-2281 | Cable Strap |
| (29) | 1 | 212-5423 | Hose As |
| (30) | 1 | 266-1108 | Support As |
| (31) | 1 | 266-1133 | Hose As |
| (32) | 1 | 266-1179 | Hose As |
| (33) | 1 | 278-6470 | Hose As |
| (34) | 1 | 286-6561 | Support As |
| (35) | 1 | 309-5769 | Pressure Switch |
| (36) | 1 | 330-2384 | Hose As |
| (37) | 2 | 148-8336 | Connector As |
| (38) | 1 | 148-8338 | Connector As |
| (39) | 1 | 148-8342 | Connector As |
| (40) | 1 | 148-8353 | Elbow As |
| (41) | 17 | 148-8378 | Elbow As |
| (42) | 3 | 148-8393 | Elbow As |
| (43) | 2 | 148-8411 | Plug |
| (44) | 3 | 148-8433 | Tee As |
| (45) | 1 | 150-3036 | Elbow As |
| (46) | 2 | 150-4027 | Tee As |
| (47) | 1 | 150-4048 | Elbow As |
| (48) | 2 | 164-5567 | Quick Disconnect Coupler As |
| (49) | 2 | 6D-3479 | Clip |
| (50) | 1 | 6V-9829 | Cap As |
| (51) | 4 | 8T-4121 | Hard Washer |
| (52) | 2 | 8T-4136 | Bolt |
| (53) | 4 | 8T-4177 | Bolt |
| (54) | 1 | 8T-4191 | Bolt |
| (55) | 4 | 8T-4192 | Bolt |
| (56) | 4 | 8T-4223 | Hard Washer |
| (57) | 4 | 8T-4224 | Hard Washer |
| (58) | 1 | 8T-6466 | Bolt |
| (59) | 4 | 8T-6870 | Bolt |
| (60) | 1 | 363-6132 | Connector As |
| (61) | 2 | 363-6133 | Adapter As |
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| Illustration 2 | g02113835 |
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| Illustration 3 | g02113836 |
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| Illustration 4 | g02726586 |
Hose Connection Chart
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| Port Name | Band Color | Hose Number | Port Name | ||
| Pilot manifold | "DR2" | - | (16) | Check valve (Left) | "LD" |
| "DR6" | - | (18) | Check valve (right) | "RD" | |
| Control valve | "aR2" | RED (4) | (3) | Selector valve | "A3" |
| "bR2" | BROWN (7) | (14) | "A2" | ||
| Pedal | "L2" | BLUE (6) | (12) | F4 valve | "Pb2" |
| F2 valve | "Pa1" | GREEN (9) | (29) | Pedal | "R2" |
| YELLOW (5) | (26) | Selector valve | "P3" | ||
| "Pb1" | ORANGE (8) | (18) | "A1" | ||
| Negative control line flow control valve | "B2" | BLUE (6) | (31) | Pump | "Pn1" |
| "A2" | GREEN (9) | (33) | "Pn2" | ||
| "B1" | BLUE (6) | (36) | Control valve | "HR" | |
| "A1" | GREEN (9) | (32) | "HL" | ||
| "P" | - | (19) | Pilot manifold | "PSA2" | |
| Selector valve | "T2" | - | (1) | "DR6" | |
| Negative control line flow control valve | "T" | - | (17) | Selector valve | "T1" |
| Pedal | "L1" | BROWN (7) | (15) | F4 valve | "Pa2" |
| "R1" | PURPLE (10) | (22) | Selector valve | "P1" | |
| F4 valve | "RL1" | - | (27) | F4 valve | "RU2" |
| "RL2" | - | (27) | "RU1" | ||
Installation Procedure
- Assemble fittings onto Negative Flow Control (NFC) valve group (25) .
- Install the elbow (41) into ports "B1", and "A1".
- Install connector (38) into port "T".
- Install connector (60) into port "P".
- Install tee (46) into ports "A2" and "B2".
- Install Nipple As (48) and dust cap (11) to tee (46) .
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| Illustration 5 | g02726589 |
- Install support (30) in the pump compartment of the excavator. Use bolts (55), and washers (56) .
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| Illustration 6 | g02150099 |
- Mount the (NFC) valve group (25) to support (30). Use four bolts (53) and four hard washers (57) .
- Preassemble fittings on to the solenoid valve.
- Assemble fitting (61) into valve Gp (24) at ports "P1", "P3".
- Install elbow As (41) into ports "A1", "A2", and "A3" of valve (24) .
- Install elbow As (41) into ports "T1", and "T2" of valve Gp (24) .
- Attach support (34) to valve group (24). Use bolts (59) .
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| Illustration 7 | g02726590 |
- Mount the solenoid valve assembly to the existing threaded bosses inside the machine frame rail. Use two bolts (52), and washers (51) .
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| Illustration 8 | g02125741 |
- Attach the angled end of hose (17) to port "T" of the flow control valve.
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| Illustration 9 | g02125760 |
- Attach the straight end of hose (17) to port "T1" of the selector valve.
- Attach a blue hose band (6) to each end of hose (31) .
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| Illustration 10 | g02125824 |
- Attach the angled end of hose (31) to port "B2" of the flow control valve.
- Attach the straight end of hose (31) to port "Pn1" of the pump.
- Attach a green hose band (9) to each end of hose (33) .
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| Illustration 11 | g02142817 |
- Install elbow (45) into port "Pn2" of the pump.
- Attach the straight end of hose (33) to elbow (45) at port "Pn2" of the pump.
- Attach the angled end of hose (33) to port "A2" of the flow control valve.
- Install elbow fitting (41) into port "HL" of the control valve.
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| Illustration 12 | g02142835 |
- Attach a green hose band (9) to each end of hose (32) .
- Install the angled end of hose (32) to elbow fitting (41) at port "HL" on the control valve.
- Install the straight end of hose (32) to port "A1" of the flow control valve.
- Attach a blue hose band (6) to each end of hose (36) .
- Install one end of hose (36) onto port "HR" of the control valve.
- Install the other end of hose (36) onto port "B1" of the flow control valve.
- Attach the angled end of hose (19) to port "P" of the flow control valve.
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| Illustration 13 | g02142920 |
- Install connector (38) into port "PSA2" of the pilot manifold.
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| Illustration 14 | g02142938 |
- Install tee (44) onto connector (38) at port "PSA2".
- Install cap (50) onto tee (44) if no other hose assembly is installed at port "PSA2".
- Install the straight end of hose (19) to tee (44) at port "PSA2" of the pilot manifold.
- Install the straight end of hose (1) into port "T2" of the selector valve.
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| Illustration 15 | g02142949 |
- Install connector (37) into port "DR6" of the pilot manifold.
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| Illustration 16 | g02142953 |
- Connect tee (44) onto connector (37) at port "DR6".
- Attach the angled end of hose (1) to tee (44) at port "DR6" of the pilot manifold.
- Install the straight end of hose (18) to the tee at port "DR6" of the pilot manifold.
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| Illustration 17 | g02142954 |
- Install elbow (41) into port "RD" of the check valve.
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| Illustration 18 | g02143230 |
- Attach the angled end of hose (18) to elbow (41) at port "RD" of the check valve.
- Secure hose (18) the frame. Use spacer (20), washer (51), Bolt (58), and clip (49) .
- Install elbow (40) into port "DR2" of the pilot manifold.
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| Illustration 19 | g02143301 |
- Install tee (44) onto elbow (40) at port "DR2" of the pilot manifold.
- Attach the straight end of hose (16) to tee (44) .
- Install elbow (41) into port "LD" of the check valve.
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| Illustration 20 | g02143316 |
- Attach the angled end of hose (16) to elbow (41) at port "LD" of the check valve.
- Secure hose (16) the frame. Use washer (51), Bolt (54), and clip (49) .
- Install elbow (41) into port "aR2" of the control valve.
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| Illustration 21 | g02143333 |
- Attach a red band (4) to each end of hose (3) .
- Connect one end of hose (3) to fitting (41) at port "aR2" of the control valve.
- Install the other end of hose (3) to port "A3" of the selector valve.
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| Illustration 22 | g02143414 |
- Install elbow (41) into port "Pb1" of the "F2" valve.
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| Illustration 23 | g02143415 |
- Attach an orange band (8) to each end of hose (18) .
- Install the angled end of hose (18) to elbow (41) at port "Pb1" of the "F2" valve.
- Attach the straight end of hose (18) to port "A1" of the selector valve.
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| Illustration 24 | g02148288 |
- Install elbow (41) into port "bR2" of the control valve.
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| Illustration 25 | g02148293 |
- Attach a brown band (7) onto each end of hose (14) .
- Install the angled end of hose (14) to fitting (41) at port "bR2" of the control valve.
- Install the straight end of hose (14) to port "A2" of the selector valve.
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| Illustration 26 | g02148355 |
- Install elbow (41) into port "Pb2" of the "F4" valve.
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| Illustration 27 | g02148357 |
- Attach two blue bands (6) to each end of hose (12) .
- Attach the angled end of hose (12) to fitting (41) at port "Pb2" of the "F4" valve.
- Attach the straight end of hose (12) to port "L2" of the pedal.
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| Illustration 28 | g02148492 |
- Install elbow (41) into port "Pa2" of the "F4" valve.
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| Illustration 29 | g02148591 |
- Install two brown bands (7) onto each end of hose (15) .
- Attach one end of hose (15) to elbow (41) at port "Pa2" of the "F4" valve.
- Attach the other end of hose (15) to port "L1" of the pedal.
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| Illustration 30 | g02148606 |
- Install tee (23) into port "Pa1" of the "F2" valve.
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| Illustration 31 | g02148688 |
- Install elbow (41) onto tee (23) at port "Pa1" of the "F2" valve.
- Attach two green hose bands (9) onto each end of hose (29) .
- Install one end of hose (29) onto tee (23) at port "Pa1" of the "F2" valve.
- Install the other end of hose (29) to port "R2" of the pedal.
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| Illustration 32 | g02149092 |
- Attach two purple bands (10) to each end of hose (22) .
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| Illustration 33 | g02149102 |
- Attach one end of hose (22) to port "P1" of the selector valve.
- Attach the other end of hose (22) to port "R1" of the pedal.
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| Illustration 34 | g02149103 |
- Attach a yellow band (5) to each end of hose (26) .
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| Illustration 35 | g02149131 |
- Install the angled end of hose (26) to port "Pa1" of the "F2" valve.
- Install the straight end of hose (26) to port "P3" of the selector valve.
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| Illustration 36 | g02149189 |
- Install elbow (47) into port "RU1" of the "F4" valve.
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| Illustration 37 | g02149395 |
- Install elbow (42) into port "RL2" of the "F4" valve.
- Attach the straight end of hose (27) to port "RU1".
- Attach the angled end of hose (27) to port "RL2".
- Install connector (39) into port "RL1" of the "F4" valve.
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| Illustration 38 | g02149397 |
- Install elbow (42) into connector (39) at port "RL1".
- Install elbow (42) into port "RU2" of the "F4" valve.
- Attach the angled end of hose (27) to port "RU2".
- Attach the straight end of hose (27) to port "RL1".
- Install two plugs (43) into the "F4" valve.
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| Illustration 39 | g02149438 |
- Install fitting (2) at port "aL4" of the control valve.
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| Illustration 40 | g02149445 |
- Install switch (35) with connector (37) onto fitting (2) at port "aL4".
- Install guard (21) around the hoses in the pump compartment. Secure the guard with cable straps (13) .
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| Illustration 41 | g02150114 |
- Install cable straps (28) in the pump compartment.
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| Illustration 42 | g02150121 |
- Install cable straps (13) in order to secure hoses from damage.
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