| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 504-9790 | Lift Gp (60Hz)(1) | 2 |
| OR | |||
| 504-9792 | Lift Gp (50Hz)(2) | 2 | |
| B | 1U-9200 | Lever Puller Hoist | 1 |
| C | 189-0863 | Shackle As | 2 |
| D | 208-8784 | Plate | 2 |
| E | 8S-7615 | Pin As | 2 |
| 283-1495 | Stand Assembly | 2 | |
| 8S-7611 | Handle As | 2 | |
| (1) | High-Voltage (480V) Low-Voltage (240V) |
| (2) | High-Voltage (400V) Low-Voltage (200V) |
Start By:
- Remove the body and canopy.
- Remove rear tires and rims.
| 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 opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
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The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this area. |
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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
| NOTICE |
|---|
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Put identification marks on all hose assemblies, on all tube assemblies and on all wire harnesses for installation purposes. Plug all hose assemblies and all tube assemblies to prevent fluid loss and this helps to prevent contaminants from entering the system.
- Drain the oil from the differential and final drive into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Differential and Final Drive Oil - Change".
- Drain the oil from the hoist/brake hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Hoist and Brake Tank Oil - Change".
- Drain the oil from the torque converter and the transmission into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Torque Converter and Transmission Oil - Change".
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Illustration 1 g06273514 - Position (A) as shown to support the front of the machine. Refer to Tool Operating Manual , NEHS1303, "Lift Group (Stand - 25 Ton)" for more information on Tooling (A).
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Illustration 2 g01759155 - Remove drive shaft guard (1).
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Illustration 3 g01759794 Show/hide table
Illustration 4 g01759838 - Install suitable blocking in the center tube to support the weight of the drive shaft.
- Attach a suitable lifting device onto drive shaft (2). The weight of drive shaft (2) is approximately
68 kg (150 lb) . - Remove bolts (3). Use a suitable prybar to retract drive shaft (2). Lower drive shaft (2) onto the suitable blocking.
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Illustration 5 g01759173 - Disconnect hose assemblies (4).
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Illustration 6 g01759213 - Disconnect hose assembly (5).
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Illustration 7 g01759874 - Remove step (6).
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Illustration 8 g01759876 - Disconnect harness assemblies (7) and remove the connecting hardware.
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Illustration 9 g01759894 - Disconnect hose assemblies (8).
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Illustration 10 g01760034 - Disconnect harness assembly (9). Disconnect hose assemblies (10).
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Illustration 11 g01760076 - Disconnect hose assemblies (11).
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Illustration 12 g01760085 - Disconnect hose assemblies (12).
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Illustration 13 g01760093 - Disconnect hose assemblies (13).
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Illustration 14 g01760254 - Disconnect hose assembly (14).
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Illustration 15 g01760258 - Remove clips (15).
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Illustration 16 g01760262 - Remove clips (16).
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Illustration 17 g01760358 - Remove clips (17).
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Illustration 18 g01760533 - Remove guard assembly (18).
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Illustration 19 g01760799 - Disconnect grease hose assembly (19).
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Illustration 20 g01760877 - Disconnect grease hose assembly (20).
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Illustration 21 g01760913 - Remove bolts (21). Remove plate (22).
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Illustration 22 g01760934 - Remove pin assembly (23).
- Repeat Step 22 through Step 26 for the remaining suspension cylinder.
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Illustration 23 g01760974 - Disconnect grease hose assembly (24).
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Illustration 24 g01761014 - Disconnect grease hose assembly (25).
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Illustration 25 g01761516 - Disconnect hose assembly (26). Remove bolts (27). Position lubrication group (28) out of the way.
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Illustration 26 g01761514 Show/hide table
Illustration 27 g01761598 - Remove bolt (29). Remove retainer plates (30).
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Illustration 28 g01761558 Show/hide table
Illustration 29 g01761601 - Attach a suitable lifting device onto lateral control rod (31). The weight of lateral control rod (31) is approximately
113 kg (250 lb) . Remove pin assembly (32). Lower lateral control rod (31) onto the rear axle housing.Show/hide table
Illustration 30 g01761605 Show/hide table
Illustration 31 g01761615 - Attach Tooling (B), Tooling (C), and Tooling (D) onto rear axle housing (33) and transmission (34). The weight of rear axle housing (33) and transmission (34) is approximately
16783 kg (37000 lb) .Show/hide table
Illustration 32 g01762136 Show/hide table
Illustration 33 g01762196 - Disconnect tube assembly (35). Disconnect hose (36). Remove clips (37). Remove tube assembly (35).
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Illustration 34 g01762256 Show/hide table
Illustration 35 g01762433 - Disconnect tube assembly (38). Disconnect hose (39). Remove clips (40). Remove tube assembly (38).
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Illustration 36 g06273577 - Use Tooling (E) to support axle housing support (41). Repeat this step for the opposite side.
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Illustration 37 g01762453 - Remove bolts (42).
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Illustration 38 g01762495 - Remove bolts (43).
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Illustration 39 g06273516 - Remove Tooling (A).
- Remove rear axle housing (33).
