Usage:
Start By:
a. remove counterweight
b. remove boom cylinders
c. remove boom
1. Position drain plug (2) for each final drive in the position shown. Drain the oil from each final drive into a suitable container. The capacity of each final drive is 13 liters (3.4 U.S. gal).
2. Put wood blocks in front of and behind each track assembly.
3. Remove two cover bolts (1) from the final drive.
4. Install two suitable size threaded rods (3) in the final drive, in place of two bolts (1). The threaded rods will prevent the ring gear and carrier assemblies from falling out of position when cover (5) is removed.
5. Remove remaining bolts (4) that hold cover (5) in position.
6. It may be necessary to use a soft faced hammer to break the seal between the cover and ring gear of the final drive. Using two persons, remove cover (5) from the final drive. Using two persons, remove cover (5) from the final drive. The weight of the cover is 30 kg (66 lb).
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When ring gear (7) is removed from cover (5) in each final drive, and the covers are reinstalled on the machine, the brakes for the machine are inoperable. The machine is free to move. To prevent movement of the machine, be sure wood blocks have been installed in front of and behind each track assembly. |
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7. Remove twelve socket head bolts (6) and ring gear (7) from cover (5).
8. Temporarily reinstall cover (5) back on the final drive. Remove the two threaded rods from the final drive.
9. Repeat Steps 3 through 8 for the other final drive.
10. Remove the swivel joint from the machine. See the topic "Remove & Install Swivel Joint" in this module.
Typical Example
| NOTICE |
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To prevent damage to the boom cylinder mounting pins, wrap them with tape after reinstalling them in the upper structure and prior to fastening a hoist to them. |
11. Reinstall two boom cylinder mounting pins (8) in the upper structure. Install the retaining bolts that hold the mounting pins in place. Wrap the pins with tape to prevent possible damage to them.
Typical Example
12. Fasten a hoist to the boom cylinder mounting pins at the front of the upper structure as shown.
13. Fasten a hoist to the main frame at the rear of the upper structure.
NOTE: A total of forty bolts hold the upper structure to the undercarriage frame assembly.
14. Remove forty bolts (9) that hold the upper structure to the undercarriage frame assembly.
Typical Example
15. Fasten a chain to undercarriage frame assembly (10) as shown.
Typical Example
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During removal or installation, the upper structure must be kept in a level position at all times. |
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16. Slowly raise upper structure (11) off of undercarriage frame assembly (10). Raise the upper structure until the pinion shaft in the swing drive is clear of the swing gear and bearing in the undercarriage frame assembly. The weight of the upper structure is approximately 10433 kg (23000 lb).
17. Pull undercarriage frame assembly (10) clear of upper structure (11) with the lift truck.
Typical Example
18. Put tooling (A) in position under the upper structure at the front and rear of the main frame and under the sub frames as shown. Lower the upper structure onto tool (A).
NOTE: The following steps are for the installation of the undercarriage frame assembly.
19. Be sure the mating surfaces of the upper structure and the undercarriage frame assembly are thoroughly clean and free of dirt and debris.
20. Put a coat of 1U8846 Gasket Maker on the mating surface of the upper structure and the undercarriage frame assembly.
21. Raise the upper structure off of tool (A) with hoists. Remove tool (A) from under the upper structure.
22. Using a lift truck move undercarriage frame assembly (10) in position under upper structure (11). Block the undercarriage so it can not move.
| NOTICE |
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When the upper structure is installed, do not damage the tooth surfaces of the pinion shaft and the swing gear and bearing. |
23. Put 5P3931 Anti-Seize Compound on the dowels in the upper structure.
24. Lower the upper structure down slowly. Align the dowel pins in the upper structure with the dowel holes in the swing gear and bearing. Also, check the alignment of the pinion shaft with the swing gear and bearing as the upper structure is being lowered into position.
25. Put 5P3931 Anti-Seize Compound on the threads of forty bolts (9) that hold the upper structure to the undercarriage frame assembly. Install bolts (9) and the spacers, and tighten them to a torque of 785 ± 78 N·m (580 ± 58 lb ft).
26. Remove the hoists and the boom cylinder mounting pins from the upper structure.
27. Install the swivel joint. See the topic "Remove & Install Swivel Joint" in this module.
28. Reinstall the two covers under the swivel joint.
29. Fill the hydraulic tank with oil to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.
30. Reinstall two threaded rods (3) in the final drive.
31. Remove cover (5) from each final drive.
32. Put ring gear (7) in position in cover (5). Be sure all of the mounting bolt holes in both components are in alignment with each other. Put 9S3263 Thread Lock on the threads of twelve socket head bolts (6) that hold the ring gear in place. Install the socket head bolts, and tighten them evenly.
33. Be sure the mating surface of the ring gear on the final drive is thoroughly clean, free of dirt and debris, and is dry. Put 1U8846 Gasket Maker around the machined surface of the ring gear. Using two persons, put cover (5) in its original position on the ring gear. It will be necessary to rotate the cover back and forth to engage the planetary gears of the outer carrier assembly with the ring gear in cover (5).
34. Put a thin coat of 9S3263 Thread Lock on the threads of twenty bolts (4) that hold cover (5) in position. Install the twenty washers and bolts. Tighten the bolts evenly.
35. Repeat Steps 30 through 34 for the other final drive.
36. Fill each final drive with oil to the correct level. See the Operation & Maintenance Manual for the correct filling procedure.
End By:
a. install boom
b. install boom cylinder
c. install counterweight