Instructions for Installing an Intermittent Saw Arrangement{6000, 6543} Caterpillar

Track Feller Buncher:

541 (S/N: 5411-UP)

551 (S/N: 5511-UP)

552 (S/N: 5521-UP)

Introduction

This Special Instruction provides the necessary guidelines for installing an Intermittent Saw arrangement.

Note: All fasteners should be tightened to standard torque specifications.

Note: Verify that the film inside the cab is for an Intermittent Saw and verify that the software in the monitoring system is for an Intermittent Saw.

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document. Perform the steps in the manual in order.

Preparation of the Machine

1. Clean the machine. Cleaning the machine will help to prevent dirt from entering the hydraulic system when hydraulic components are being installed.

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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.

2. Release the oil pressure in all of the implement circuits (the boom, the stick and the attachment) before any of the hydraulic lines or 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.

   2. Cycle all control levers through the full range of motion. This will release any pressure that might be present in the hydraulic system.

      Note: If the hydraulic circuit requires the activation of a switch for operation, activate the necessary switches for the hydraulic circuit.

   3. Open the hood for the engine compartment.

      Note: The switch for the hood is located underneath the right armrest on earlier models. The switch for the hood is located on the right hand console for the later models.

   4. Turn the start switch to the OFF position.

   5. Move the hydraulic lockout control to the LOCKED position.

      Note: When the hydraulic lockout control is in the LOCKED position no implements will function.

   6. Push down on the hydraulic tank breaker relief valve until all pressure is released.

   7. When the pressure in the hydraulic system has been released then the hydraulic oil lines and the components can be removed.

3. Drain the oil from the hydraulic oil tank in a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 318 L (84 US gal).

4. Drain the engine coolant into a suitable container for proper storage or disposal. Drain the coolant to a level below the water temperature regulator.

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Illustration 1	g01245354

5. Disconnect hose assemblies (1), (4), and (5). Remove fan guard (2). Remove three fan blades (8). Remove bolts (6) and lower shroud (7) .

   Note: Fan blades (8) can be individually removed.

Assemble the Boom

The following groups should be installed while the boom is on the ground.

• Grease lines

• Boom lines

• Saw lines

• Front lines

Install the Grease Lines to the Boom

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Illustration 2	g01247635

1. Install the grease lines and related components that are listed in Table 2. Refer to Illustration 2.

   Note: Install the grease lines and related components while the boom is on the ground.

   Note: Final installation of some of the components that are listed may need to wait for the installation of other components that will occur later. Illustration 2 shows a fully assembled front linkage.

Install the Boom Lines

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Illustration 3	g01247939

1. Install the components that are listed in Table 3. Refer to Illustration 3.

   Note: Install the components while the boom is on the ground.

2. Install an identification tag on both ends of the appropriate hoses.

Install the Saw Lines to the Boom

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Illustration 4	g01248201

1. Install the components that are listed in Table 4. Refer to Illustration 4.

   Note: Install the components while the boom is on the ground.

   Note: Illustration 4 also shows the saw lines for the stick. The lines for the stick will be installed later.

Install the Front Lines to the Boom

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Illustration 5	g01259316
Assembled boom

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Illustration 6	g01259318
View A-A Machine end of boom

1. Install the components that are listed in Table 5. Refer to Illustration 5 and Illustration 6.

   Note: Install the components while the boom is on the ground.

2. Install an identification tag on each end of the appropriate hoses.

Assemble the Stick

The following groups should be installed while the stick is on the ground.

• Grease lines

• Stick lines

• Saw lines

• Tilt cylinder and felling head linkage

Install the Grease Lines to the Stick

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Illustration 7	g01258078

1. Install the grease lines and related components that are listed in Table 6. Refer to Illustration 7.

   Note: Install the grease lines and related components while the stick is on the ground.

   Note: Final installation of some of the components that are listed may need to wait for the installation of other components that will occur later. Illustration 7 shows a fully assembled front linkage.

Install the Stick Lines

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Illustration 8	g01247685

1. Install the components that are listed in Table 7. Refer to Illustration 8.

   Note: Install the components while the stick is on the ground.

   Note: The stick must be pinned to the boom before some of the hoses can be connected.

2. Install an identification tag on both ends of the appropriate hoses.

Install the Saw Lines to the Stick

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Illustration 9	g01259529

1. Install the components that are listed in Table 8. Refer to Illustration 9.

   Note: Install the components while the stick is on the ground.

   Note: Illustration 9 also shows the saw lines for the boom. The lines for the boom were installed previously.

Install the Tilt Cylinder Group and the Felling Head Linkage

Illustration 10	g01247792

Illustration 11	g01247747

1. Install the components that are listed in Table 9. Refer to Illustration 10 and Illustration 11. Check the lateral clearance of the links. The maximum lateral clearance should be 1.6 mm (0.0630 inch).

   Note: Install the components while the stick is on the ground.

Install the Boom and the Stick

The following procedures will describe the installation of the boom and the stick to the machine. Once the boom and the stick have been installed onto the machine, connect the hoses from the stick to the boom. Also, connect the hoses from the boom to the stick cylinder. Finally, connect the hoses from the boom to the main control valve.

Install the Boom and the Cylinder Group

Illustration 12	g01247056
235-4041 Boom

Illustration 13	g01247067
284-8550 Hydraulic Cylinder Group

Install all of the components that are listed in Table 10. Refer to Illustration 12 and Illustration 13 for the final location of all the components. Perform the following procedure in order to install the components that are shown in Illustration 12 and Illustration 13.

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Illustration 14	g01247470

1. Attach a suitable lifting device to boom (14). Install 242-7946 Boom and Bearing As (14) into position. The weight of boom (14) is approximately 1633 kg (3600 lb).

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Illustration 15	g01247479

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Illustration 16	g01247481

2. Attach a suitable lifting device to pin assembly (59). Install pin assembly (59) through the frame and through boom (14). Install bolt (60). The weight of pin assembly (59) is approximately 57 kg (125 lb).

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Illustration 17	g01247491

3. Install Tooling (B) onto 234-5857 Hydraulic Cylinder Gp (STICK) (53). Install stick cylinder (53) into position. The weight of stick cylinder (53) is approximately 272 kg (600 lb).

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Illustration 18	g01247497

4. Position stick cylinder (53) into the pin boss.

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Illustration 19	g01247499

5. Install 246-2226 Pin (23) .

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Illustration 20	g01144999

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Illustration 21	g01247507

6. Install Tooling (B) to the boom and to stick cylinder (53) in order to support stick cylinder (53) .

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Illustration 22	g01247518

7. Attach a suitable lifting device to boom cylinder (61), as shown. Raise the rod end of the boom cylinder into position. Start the machine and extend the rod of the boom cylinder until the rod eye is in line with the bore of the boom. Install 246-2344 Pin (24) through the boom and into boom cylinder (61). Install 246-2165 Plate (22) and 8T-4139 Bolts (30) .

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Illustration 23	g01247523

8. Install three fan blades (69). Install shroud (68). Install bolts (67). Install guard (63). Connect hose assemblies (62), (65), and (66) .

   Note: These components were removed in ""Preparation of the Machine" ".

9. Fill the radiator to the proper level.

Install the Stick

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Illustration 24	g01247563

1. Install the components that are listed in Table 12. Refer to Illustration 24. Check the lateral clearance of the stick. The maximum lateral clearance should be 1.6 mm (0.0630 inch).

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Illustration 25	g01247587

2. Install lamps (21) and harness (22). Refer to Illustration 25.

Connect the Front Lines

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Illustration 26	g01247959

1. Install the components that are listed in Table 13 to the main control valve. Refer to Illustration 26.

   Note: The hoses and tags have already been installed onto the boom.