Usage:
Start By:
a. remove bucket
Fluid Spillage Containment
Care must be taken to ensure that the fluids are contained during performance of the inspection, the maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and mandates.
1. Start the machine, and move it on a level hard surface. Position drain plug (2) for each final drive in the position shown. Drain the oil from each final drive in a suitable container for storage or disposal. The capacity of each final drive is 16 liters (4.2 U.S. gal).
2. Remove two cover bolts (1) and the washers from the final drive.
3. Install two M20 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 (4) is removed.
4. Remove remaining bolts (1) and the washers that hold cover (4) in position.
5. It may be necessary to use a soft faced hammer to break the seal between the cover and the ring gear of the final drive. Remove cover (4) from the final drive.
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When sun gear (5) is removed from each final drive, the brakes for the machine are inoperable. The machine is free to move. To prevent movement of the machine, put wood blocks in front of and behind each track assembly. |
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6. Put wood blocks in front of and behind each track assembly so the machine can not move.
7. Remove sun gear (5) from the final drive.
8. Temporarily reinstall cover (4) back on the final drive using bolts (1) and the washers. Remove the two threaded rods from the final drive.
9. Repeat Steps 2 through 8 for the other drive.
10. Use Tooling (E) to loosen 30 bolts (6) that hold the upper structure to the undercarriage frame assembly. Do Not remove the 30 bolts at this time.
Typical Example
11. Remove right hand boom cylinder (7) from the machine. Refer to the topic "Remove & Install Boom Cylinders" in this module. Put caps on the ends of the hose assemblies, in order to keep dirt and debris from entering the hydraulic system, that connect to the right hand boom cylinder.
12. Start the machine, and rotate the upper structure 90 degrees to the right or to the left. Raise the boom, and fully extend the stick cylinder.
Typical Example
13. With the engine still running, position the end of the stick so the distance between the end of the stick and the floor is the same distance between the floor and the bottom of the counterweight. This distance is approximately 1075 mm (42.5 in).
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Do Not lower the boom after Tool (A) has been installed in place of the right hand boom cylinder. |
14. Adjust the length of Tool (A), and install it in place of the right hand boom cylinder. Make sure to use the five bolts, the washers and the nuts to hold the link group [Tool (A)] together.
15. Adjust the height of Tooling (B) so it can be installed under the end of the stick as shown. Make sure Tooling (B) is centered.
16. Install Tooling (C) under the main frame at the rear of the machine as shown.
17. Disconnect lubrication tube assembly (8) from the block on the front of the main frame.
18. Remove all bolts (6) and the spacers that hold the upper structure to the undercarriage frame assembly.
19. Install four M24 guide bolts (9), 90 degrees apart, in the upper structure.
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At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the hydraulic system in all of the implement hydraulic circuits (the boom, the stick and the bucket) before any of the hydraulic lines or any of the components are disconnected or removed. |
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20. Release the pressure in all of the implement hydraulic circuits (the boom, the stick, and the bucket) before any of the hydraulic lines or the components are disconnected or removed as follows:
a. Place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.
b. Move the control levers for the boom, the stick and the swing to all full stroke positions. This will release any pressure that might be present in the pilot system.
c. Return the key to "OFF" position.
d. Slowly loosen the fill plug on the hydraulic tank and release the pressure.
e. Tighten the fill plug on the hydraulic tank to a torque of 68 ± 7 N*m (50 ± 5 lb ft).
21. Drain the oil from the hydraulic oil tank in a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 130 liters (34 U.S. gal).
View From Under Machine
22. Remove bolts (11) and two cover assemblies (10) and (12) from the underside of the undercarriage frame assembly.
View From Under Machine
23. Put identification marks on four tube assemblies (14), two hose assemblies (17) and two hose assemblies (13) as to their location on the bottom of the swivel joint. Disconnect the four hose assemblies and the four tube assemblies from the bottom of the swivel joint. Put plugs in the hose assemblies and the tube assemblies to keep dirt and debris out of the hydraulic system.
24. Remove tee (15) from the swivel joint.
25. Remove six bolts (16) from the swivel joint.
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It is important to keep the upper structure level when it is being removed or installed from the undercarriage frame assembly. If the upper structure is not kept level, binding of the pinion shaft in the swing drive with the swing gear and bearing, will result. The clearance between the gears is minimal. |
NOTE: The weight of the upper structure and the undercarriage frame assembly will vary depending on the attachments. The weights which are listed below are only approximate weights.
26. Carefully raise upper structure (18) off of the undercarriage frame assembly with Tooling (B) and (C) in 13 mm (.50 in) increments. Raise the upper structure until pinion shaft (19) is clear of swing gear and bearing (20). The weight of the upper structure is approximately 14 515 kg (32,000 lb).
Typical Example
27. Check the clearance between the pinion shaft and the swing gear and bearing. Make sure the components will not interfere with each other during the removal of the undercarriage frame assembly.
NOTE: The weight of the upper structure should only be concentrated on Tooling (C) and (B). Tooling (D) is only used as additional support.
28. Install Tooling (D) under the rear of the machine as shown.
Typical Example
29. Remove the wood blocks from the front and rear of the track assemblies.
30. Fasten a suitable chain to the undercarriage frame assembly as shown. Slowly pull undercarriage frame assembly (21) out from under the upper structure with a lift truck. The weight of the undercarriage frame assembly can range approximately 6154 to 7665 kg (13,567 to 16,898 lb).
31. If the undercarriage frame assembly is to be serviced, use wood blocks to support the upper structure of the machine. Support the upper structure under the main frame and sub frame.
NOTE: The following steps are for the installation of the undercarriage frame assembly.
32. Make sure the mating surfaces of the upper structure and the undercarriage frame assembly are thoroughly clean and free of dirt and debris.
33. Make sure four guide bolts (9) in the upper structure are in position and are not bent.
NOTE: Two locating dowels are used to align the upper structure with the undercarriage frame assembly. Be sure these dowels are in position.
34. Apply 4C-5593 Anti-Seize Compound in the bores of the swing gear and bearing for the locating dowels in the upper structure.
35. Apply 1U-8846 Gasket Maker on the mating surfaces of the upper structure and the undercarriage frame assembly.
36. Remove the wood blocks from under the main frame and the sub frame of the upper structure.
37. Using a lift truck, move undercarriage framer assembly (21) in position under the upper structure.
| NOTICE |
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Because of the minimal amount of clearance between pinion shaft (19) and swing gear and bearing (20), careful alignment of the upper structure and the undercarriage frame assembly is required. Be sure guide bolts (9) Do Not bend during the installation of the upper structure. If the guide bolts bend, it is an indication that correct alignment between the upper structure and the undercarriage frame assembly has not been obtained. Keep the upper structure level during the installation. |
38. Remove Tooling (D) from under the rear of the machine. Slowly lower upper structure (18) down with Tooling (B) and (C) in 13 mm (.50 In) increments. As the upper structure is being lowered, be sure four guide bolts (9) in the upper structure are in align with their respective bolt holes in the undercarriage frame assembly.
39. Apply 4C-5593 Anti-Seize Compound on the threads of some of the bolts (6) that hold the upper structure to the undercarriage frame assembly together. At this time, only install the bolts that have easy access. Tighten the bolts evenly. Remove four guide bolts (9) from the upper structure.
View From Under Machine
40. Install six bolts (16) in the bottom of the swivel joint.
41. Install tee (15) in the swivel joint.
42. Check the condition of the O-ring seals used in the ends of the hose assemblies and the tube assemblies that connect to the swivel joint. If any of the O-ring seals are damaged, use new parts for replacement.
43. Connect two hose assemblies (13) to the tee. Tighten the hose assemblies to a torque of 40 ± 5 N*m (30 ± 4 lb ft).
44. Connect four tube assemblies (14) to the swivel joint.
45. Connect two hose assemblies (17) to the swivel joint. Tighten the hose assemblies to a torque of 80 ± 7 N*m (60 ± 5 lb ft).
View From Under Machine
46. Reinstall cover assemblies (10) and (12) under the undercarriage frame assembly.
47. Connect lubrication tube assembly (8) to the block on the main frame.
Typical Example
48. Remove Tool (A) from the machine.
NOTE: Refer to the topic (Lubricant Viscosities and Refill Capacities" in the "Operation & Maintenance Manual" for the proper filling procedure and the proper levels for the hydraulic system.
49. Fill the hydraulic oil tank with oil to the correct level.
| NOTICE |
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When the main hydraulic pump has been serviced or the hydraulic oil has been replaced, the air in the hydraulic system must be removed. No attempt should be made to start the engine until the main hydraulic pump has been filled with oil, or serious damage can be caused to the hydraulic components. To release the pressure from the main hydraulic pump, refer to the topic "Release Of Air From Main Pumps" in the appropriate "320B, 320B L and 320B N Hydraulic Excavators, Hydraulic Systems Testing & Adjusting Manual". |
50. Start the machine, and straighten it out.
Typical Example
51. Reinstall the right hand boom cylinder. Refer to the topic "Remove & Install Boom Cylinders" in this module.
52. Remove Tooling (C) from under the rear of the machine.
53. Remove Tooling (B) from under the stick.
54. Apply 4C-5593 Anti-Seize Compound on the threads of the remainder of bolts (6) that hold the upper structure and the undercarriage frame assembly together. Install the remainder of the bolts and the washers, and tighten them. The machine can be rotated to the left or right to gain access to all bolts (6) easier. Using Tooling (E), tighten 30 bolts (6) to a torque of 568 ± 59 N*m (418 ± 43 lb ft).
55. Reinstall two M20 threaded rods (3) in each of the final drives.
56. Remove cover (4) from each final drive.
57. Install sun gear (5) in each final drive.
58. Make sure the machined surface of the final drive ring gear is thoroughly clean, free of dirt and debris and is dry.
59. Apply 1U-8846 Gasket Maker around the machined surface of the ring gear. Put cover (4) in its original position on the ring gear.
60. Apply 9S-3263 Thread Lock on the threads of 16 bolts (1) that hold cover (4) in position. Install bolts (1) and the washers that hold the cover.
NOTE: Refer to the topic "Lubricant Viscosities and Refill Capacities" in the "Operation & Maintenance Manual" for the proper filling procedure and the proper levels for the final drive.
61. Fill each final drive with oil to the correct level.
End By:
a. install bucket