M0074900: 509-7382 Locomotive Tooling Lifting Group C175-20 {0374, 0599, 0629, 0632, 0700, 0701} Caterpillar

Engine

C175 Engines

Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

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.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate, perform lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as “DANGER”,“WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety Section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. This section provides useful information on individual parts, extra tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.

Safety Section

General Hazard

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Information

Wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment. Make sure that all protective guards and all covers are secured in place on the equipment.

Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only.

Obey all local regulations for the disposal of liquids.

Do not allow unauthorized personnel on the equipment.

Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position. Refer to the Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position.

Crushing Prevention and Cutting Prevention

Support the equipment properly before you perform any work or maintenance beneath that equipment.

Stay clear of all rotating and moving parts.

Safety Icon Nomenclature

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

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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To avoid injury do not stand on or between implement and machine while operating lift control.

Personal Protection/Important Information

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Personal Protection/Important Information

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

Contact Information

For product support questions concerning this tool, contact the Dealer Service Tools hotline at:

USA: 800-542-8665, Option 1

International: 1-309-578-7372

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

General Information Section

Introduction

Illustration 4	g06167348
Assembled view of Lifting Group 509-7382 (Items 11 - 17 not shown) per Table 2

The 509-7382 Lifting Group is designed to lift C175-20 engine components for removal, service, and installation while the C175-20 engine is in the chassis of a F125 locomotive. The Lifting Group is used with suitable straps, ratchets, and tooling, as compatible with particular engine components.

Note: Refer to the appropriate Disassembly and Assembly Manual for mounting and lifting hardware and correct location of the lifting point in various engine components.

Specifications

Bill of Material

The Bill of Material in Lifting Group 509-7382 (per Illustration 4) is as follows:

Operation Section

Setup

1. Inspect the part of the 509-7382 Lifting Group before each use. Do not use any tool that is damaged, altered, or in poor condition.

2. If necessary, disassemble 509-7382 Lifting Group and transport piece parts inside the locomotive carbody one by one.

3. In the locomotive carbody, where the aftertreatment module is bolted, measure the distance between the two bolt holes where each of the Lift Brackets (Item 9) will be mounted. (If bolts are closer than desired, leave 1 or 2 bolt spaces in the middle, so the distance is close to 1m (3.3 ft). See Illustrations 5 and 6.
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   Illustration 5	g06139706
   Bolting locations on the locomotive inside F125 carbody.

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   Illustration 6	g06139723
   Bolting locations inside F125 carbody on either side of the engine.

4. Once suitable locations are identified, bolt two (2) Lift Brackets (Item 9) using 3/4" bolts to the Locomotive. (See Illustration 5)

5. Connect the Clevis Pins (Item 5) to Chain (Item 19) and attach to each of the Lift Brackets.
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   Illustration 7	g06139731
   Rooftop lift brackets and rooftop adapter bolted to the locomotive (some components of the locomotive carbody are hidden for clarity).

6. To the bottom Clevis Pins, attach another set of Lift Brackets (Item 9) and bolt the 1m (3.3 ft.) long Unistrut Channel (Item 18) using 1/2" bolts. The Unistrut Channel will act as Rooftop adapter (See Illustration 7).

7. Repeat Steps 4, 5 and 6 on the opposite side of the locomotive. Location of the Lift Brackets and Rooftop adapter on the other side will be based on which engine component is being serviced.

8. Measure the distance between locomotive left-hand side bolt holes and locomotive right-hand side bolt holes (being used for installing the Rooftop adapters), over the top of the engine, under the Aftertreatment module (See Illustration 8).
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   Illustration 8	g06167359
   Bolting locations on either side of the engine inside F125 carbody.

9. Compare this distance with 3m (9.8 ft.) length and shorten the 3m (9.8 ft.) long Unistrut Channel (Item 20) as needed.
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   Illustration 9	g06140624
   Piece parts to install the double Unistrut Channel.

   Note: Perform steps 8 and 9 only when installing the Lifting Group Tooling for the first time.

10. Now on either side of the engine, connect second set of Lift Brackets (Item 8). Using Spring Nuts (Item 11), Clevis, and Chains (Items 5 and 19), lower Bracket (Item 1), to position the layout of double Unistrut Channel (Item 20). See Illustration 9.
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    Illustration 10	g06140677
    Spring Nuts used for bolting lift plates to the double uni-strut channel.

11. Before installation of Item 20, prepare Lifting assembly by adding 12 Spring Nuts in each slot of the double Unistrut Channel (Item 20). See Illustration 10.
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    Illustration 11	g06143499
    Bolting lift plates to double unistrut channel

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    Illustration 12	g06143310
    Bolting lift plates to double unistrut channel

12. Bolt the supporting Lift Plates (Items 2, 3, 4, 6) as shown in Illustration 8 and 9, keeping the bolts loose enough to slide the Lift Plates.
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    Illustration 13	g06141060
    Lifting Assembly bolted to L-shaped brackets

13. Now with the Spring Nuts and Lift Plates in place, the Lifting Assembly is ready to be installed inside the locomotive carbody. Bolt the Lifting Assembly to the L-shaped end brackets (Item 1) at both ends. At this point the Lifting Assembly is connected to the Rooftop adapters.

Illustration 14	g06141107
Lifting Assembly Spreader bar setup.

Lifting Operation

1. Based on which component on the C175 engine is to be serviced, determine the best location for installing the Lift Brackets (Item 9) on both sides of the engine / Aftertreatment module.

2. Orient the Lifting assembly (assembled in Step 12 above) such that Items 4 and 6 are on the side requiring the lift, seen in Illustration 12.

3. Assemble all items in the Bill of Material given in Table 2 to complete the setup of the Lifting Group inside the locomotive carbody. See Illustration 15.

4. Adjust Lift Plates on the Lifting Group to ideal locations.

5. Tighten all bolts on the Lifting Group to specification.

6. Adjust the length of the chains for desired reach. Chains should be adjusted so that Item 20 sits flush to the bottom of the aftertreatment module.

7. Attach straps (suitable nylon lifting slings can be found in Dealer Service Tools catalog).

8. Connect ratchets / hand winch to Lift Plates-Items 2 and 3. Reference Dealer Service Tools catalog for Cat part number 456-4371 (1/4 Ton lever hoist) or 386-6030 (3/4 Ton lever hoist).

9. Run lifting sling or strap between ratchet and Pin Assembly, Item 7, and down to lifting location (on the component to be lifted on the engine).

Illustration 15	g06143504
Showing Lifting Group after complete assembly.

Note: Refer to Illustration 16, Items 2 and 3, lift brackets can overlap Item 1 lift bracket, if needed, using 4 bolts only, through both brackets. Also, Item 4 lift plate may be placed next to Item 1 lift bracket, if needed, and items 2 and 3 lift brackets bolted on top of both items 4 and 1.

Illustration 16	g06177916
Lifting Group Load Anchor Functionality

Illustration 17	g06167911
Lifting sling/strap going over the pin

Illustration 18	g06167913
Attachment of Lifting sling/strap

Illustration 19	g06167914
Attachment of Lifting sling/strap

Illustration 20	g06141139
Lifting Group Tooling inside the locomotive carbody

Illustration 21	g06143354
Lifting Group Tooling inside locomotive carbody

Illustration 22	g06167928
Lifting Group Tooling inside locomotive carbody

Disassembly of Lifting Group

1. Unhook ratchet strap from Lifting Assembly.

2. Unhook Lifting Assembly from chains.

3. Remove Lifting Assembly from locomotive.

4. Unhook chains from Rooftop Adapter Assemblies.

5. Unbolt and remove Rooftop Adapter Assemblies.

6. Put bolts removed in Step 5 back into locomotive roof, torque to spec.

Inspection and Maintenance

1. Have tools inspected annually by an Approved dealership inspector. Maintain a written record of all inspections.

2. Do not use Spring Nuts if damaged.

3. Replace the hardware pieces as needed, using information from Table 3.

Service Parts

Cleaning

Clean the tooling after each use, using a non-solvent based cleaner.

Storage

1. Store the tooling in a clean, dry location to prevent rust or corrosion. Tooling can be damaged by moisture or high humidity.

2. The tool should be stored in the most stable position.

Tool Disposal

At the end of the operational life of the tool, destroy the tool and dispose of as scrap.