New Grease Lines for Stick and Boom{7510} Caterpillar

New Grease Lines for Stick and Boom{7510}

Usage:

Track Feller Buncher:: TK741 (S/N:: 2021-UP); TK751 (S/N:: 3011-UP); TK752 (S/N:: 3021-UP); 1390 (S/N:: B3F1-UP)

Introduction

This Special Instruction provides the necessary procedures for installing new grease lines for the stick and the boom.

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Table 1
Required Parts
235-4038 Grease Lines Gp
Quantity	Part Number	Part Name
1	3B-8488	Grease Fitting
17	3B-8489	Grease Fitting
2	197-0527	Bracket As
2	240-0333	Hose As
1	241-3528	Hose As
1	267-2600	Hose As
2	267-2601	Hose As
2	267-2602	Hose As
1	267-2603	Hose As
5	2R-1939	Clip
2	3B-8822	Elbow
5	4D-6466	Clip
2	4M-8973	Elbow
2	6V-4245	Elbow
2	8L-5008	Pipe Elbow
12	8T-4121	Hard Washer
8	8T-4133	Nut
4	8T-4136	Bolt
2	9F-2247	Pipe Plug

Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this document.

Preparation of the Machine

Clean the machine. Cleaning the machine will help to prevent dirt from entering the components that are being installed.

Start the engine. Fully extend the stick. Lower the attachment to the ground.

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NOTICE

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 opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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Personal injury can result from contact with hot hydraulic oil and from contact with hydraulic oil that is under high pressure.
Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. The hydraulic oil pressure must be released before any service on the hydraulic system is performed or serious personal injury could occur.

Verify that all of the work tools have been completely lowered to the ground. Release the hydraulic oil pressure at the hydraulic tank through the breaker relief valve when the breaker relief valve is cool enough to touch with your bare hand. Verify that the hydraulic oil is cool before you begin to remove any hydraulic components or hydraulic lines.

Release the oil pressure in all of the implement circuits (the boom, the stick and the attachment) before any of the components are disconnected or removed. Procedure to release the pressure
1. Shut off the engine and turn the switch to the ON position. Put the hydraulic lockout control in the UNLOCK position.
1. Cycle all control levers through the full range of motion. This will release any pressure that might be present in the hydraulic system.
1. Turn the start switch to the OFF position.
1. Move the hydraulic lockout control to the LOCKED position.
  Note: When the hydraulic lockout control is in the LOCKED position no implements will function.

Removal Procedure

Remove existing grease lines and fittings.

Installation Procedure

Install Grease Lines to the Boom

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Table 2
Required Parts
235-4038 Grease Lines Gp
Quantity	Part Number	Part Name
7	3B-8489	Grease Fitting
2	197-0527	Bracket As
2	240-0333	Hose As
2	267-2602	Hose As
1	267-2603	Hose As
3	2R-1939	Clip
5	4D-6466	Clip
2	4M-8973	Elbow
2	6V-4245	Elbow
1	8L-5008	Pipe Elbow
10	8T-4121	Hard Washer
6	8T-4133	Nut
4	8T-4136	Bolt
1	9F-2247	Pipe Plug

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Illustration 1	g01232352
(1) Seven 3B-8489 Grease Fittings

Install the components that are listed in Illustration 1.

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Illustration 2	g01232347
(2) Two 4M-8973 Elbows (3) Two 267-2602 Hose As (4) Two 197-0527 Bracket As (5) Two 2R-1939 Clips , two 8T-4121 Hard Washers and two 8T-4133 Nuts (6) Two 4D-6466 Clips , two 8T-4121 Hard Washers and two 8T-4133 Nuts (7) Two 240-0333 Hose As (8) One 267-2603 Hose As

Install the components that are listed in Illustration 2.

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Illustration 3	g01232353
(4) One 197-0527 Bracket As (9) One 8T-4121 Hard Washer and one 8T-4136 Bolt (10) One 2R-1939 Clip , one 8T-4121 Hard Washer and one 8T-4136 Bolt

Install the components to the left tower plate of the upper frame. See Illustration 3.

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Illustration 4	g01232355
(4) One 197-0527 Bracket As (9) One 8T-4121 Hard Washer and one 8T-4136 Bolt (11) One 4D-6466 Clip , one 8T-4121 Hard Washer and one 8T-4136 Bolt

Install the components to the right tower plate of the upper frame. See Illustration 4.

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Illustration 5	g01232356
(6) One 4D-6466 Clip , one 8T-4121 Hard Washer and one 8T-4133 Nut (7) Two 240-0333 Hose As (8) One 267-2603 Hose As (12) One 8L-5008 Pipe Elbow (13) One 9F-2247 Pipe Plug

Install the components that are listed in Illustration 5.

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Illustration 6	g01232350
(6) One 4D-6466 Clip , one 8T-4121 Hard Washer and one 8T-4133 Nut (7) Two 240-0333 Hose As (14) Two 6V-4245 Elbows

Install the components that are listed in Illustration 6.

Install Grease Lines to the Stick

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Table 3
Required Parts
235-4038 Grease Lines Gp
Quantity	Part Number	Part Name
1	3B-8488	Grease Fitting
10	3B-8489	Grease Fitting
1	241-3528	Hose As
1	267-2600	Hose As
2	267-2601	Hose As
2	2R-1939	Clip
2	3B-8822	Elbow
1	8L-5008	Pipe Elbow
2	8T-4121	Hard Washer
2	8T-4133	Nut
1	9F-2247	Pipe Plug

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Illustration 7	g01232520
(5) Two 2R-1939 Clips , two 8T-4121 Hard Washers and two 8T-4133 Nuts (15) One 267-2600 Hose As (16) Two 267-2601 Hose As (17) One 241-3528 Hose As (1) Four 3B-8489 Grease Fittings

Install the components that are listed in Illustration 7.

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Illustration 8	g01232523
(5) One 2R-1939 Clip , one 8T-4121 Hard Washer and one 8T-4133 Nut (16) 267-2601 Hose As (17) 241-3528 Hose As (18) Two 3B-8822 Elbows