Connection Procedure
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Table 1
| Required Tools |
| Tool |
Part Number |
Part Description |
Qty |
| A |
5P-0306 |
Vacuum Transducer |
1 |
| FT-1115 |
Vacuum Cap |
1 |
| 6V-4142 |
Fitting |
1 |
| 5K-5068 |
Fitting |
1 |
| B |
4C-6486 |
Stand |
2 |
| 8S-7621 |
Tube |
2 |
| 8S-7625 |
Collar |
2 |
| 8S-8048 |
Saddle |
2 |
| 8S-7615 |
Pin |
4 |
| 8S-7650 |
Cylinder As |
2 |
| 4C-5809 |
Electric Hydraulic Pump Gp |
1 |
| 8F-0024 |
Hose As |
2 |
| C |
228-4532 |
Link |
1 |
| D |
4C-6486 |
Stand |
2 |
| 8S-7621 |
Tube |
2 |
| 8S-7625 |
Collar |
2 |
| 8S-7615 |
Pin |
4 |
| 8S-7650 |
Cylinder As |
2 |
| 4C-5809 |
Electric Hydraulic Pump Gp |
1 |
| 6D-7726 |
Hose As |
2 |
| FT-2765 |
Support Beam As |
1 |
| E |
1U-6228 |
Reaction Arm |
1 |
| 1U-6221 |
Hydraulic Torque Wrench Gp |
1 |
| G |
4C-5593 |
Anti-Seize Compound |
1 |
| H |
1U-8846 |
Gasket Sealant |
1 |
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.
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| 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, "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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At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Before installation or removal of any hydraulic test equipment, relieve the pressure in the hydraulic tank by slowly loosening the filler cap. |
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- Make sure that the mating surfaces of the upper structure and of the undercarriage frame are thoroughly clean and free of dirt and debris prior to the installation.
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| Illustration 1 | g01181758 |
- Attach a suitable towing device to the undercarriage frame (23), as shown. Use the suitable towing device and slowly position undercarriage frame (23) under the upper structure.
Note: A locating dowel is used to align the upper structure with the undercarriage frame. Make sure that the dowel is in position in the undercarriage frame prior to installation.
- Apply Tooling (G) in the bores of the swing gear and the bearing that are for the locating dowels in the upper frame.
- Apply Tooling (H) on the mating surfaces of the upper frame and the undercarriage frame.
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| Illustration 2 | g01190420 |
- Use Tooling (B) and Tooling (C) to carefully lower upper frame (20) onto the undercarriage frame in increments of 6.4 mm (0.25 inch). Lower the upper frame until swing pinion (21) is in position on swing gear (22) .
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| Illustration 3 | g01167540 |
- Use Tooling (D) and Tooling (B) in order to lower the machine onto the swing bearing.
- Remove Tooling (D) that is under the rear of the machine, as shown.
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| Illustration 4 | g01181607 |
- Use Tooling (E) in order to install bolts (19). Install the clips and connect grease hose assembly (17) to swing bearing (18) .
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| Illustration 5 | g01181591 |
- Install bolts (16) and fittings (15) onto the swivel. Connect hose assemblies (14) .
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| Illustration 6 | g01181757 |
- Position upper cover (13) and lower cover (12) and install bolts (11) .
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| Illustration 7 | g01181267 |
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| Illustration 8 | g01190560 |
- Attach a suitable lifting device to Tooling (C). Apply a slight pressure on Tooling (B) (not shown) in order to support the machine. Remove bolts (4), plate (5), bolt (8), and pin (9). Reposition pin (6). Remove Tooling (C). The weight of Tooling (C) is approximately 249 kg (550 lb).
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| Illustration 9 | g01190330 |
- Attach a suitable lifting device (not shown) to boom cylinder (7). The weight of boom cylinder (7) is approximately 254 kg (560 lb). Position boom cylinder (7). Install pin (8) and bolt (9). Connect hose assemblies (10) .
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| Illustration 10 | g01181268 |
- Reposition pin (6) in order to install boom cylinder (7). Install plate (5) and bolts (4). Connect grease hose assembly (3). Remove the suitable lifting device from boom cylinder (7) .
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| Illustration 11 | g00944947 |
- Remove Tooling (A). Install the cap onto the hydraulic tank.
- Fill the hydraulic system. Refer to Operation and Maintenance Manual, "Hydraulic System Oil Level - Check". Refer to Operation and Maintenance Manual, "Lubricant Viscosities and Refill Capacities".
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| Illustration 12 | g01167520 |
- Retract stick (2) in order to raise the boom and stick (2) from Tooling (B), as shown. Remove bucket pin (1) .
- Tighten the track tension. Refer to Operation and Maintenance Manual, "Track - Adjust".
End By:
- Install the travel motors. Refer to Disassembly and Assembly, "Travel Motor- Install".
- Install the bucket. Refer to Disassembly and Assembly, "Bucket - Install".
