Machine Installation Procedure for Certain 390F Excavators {7000, 7960} Caterpillar

Excavator

390F (S/N: HJD1-UP; TYE1-UP; MGF1-UP; HNG1-UP; FEH1-UP; HSM1-UP; YHT1-UP; GAY1-UP)

Introduction

Table 1

Revision History
Revision	Summary of Changes
02	Updated Illustration 136.

This Special Instruction contains the assembly procedure and the installation information that is required to assemble 390F Excavators when the machine is shipped to the field. The items that need to be assembled may be different depends on the shipping style.

Note: Clean all surfaces before you install any parts.

Note: Verifying all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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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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NOTICE
Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

Do not perform any procedures in this publication or order any parts until you understand the information that is contained in this publication.

Torque Specifications

English (SAE) Fasteners

The following table has the recommended standard torque values.

Table 2

Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 5 N·m (18 ± 5 lb ft)
3/8	47 ± 10 N·m (35 ± 5 lb ft)
7/16	70 ± 15 N·m (50 ± 10 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 20 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Table 3

Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	30 ± 5 N·m (20 ± 5 lb ft)
M10	55 ± 10 N·m (40 ± 5 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 20 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 45 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Hydraulic Four Bolt Flange

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Illustration 1	g02724217

1. Position the flanges parallel over the port.

2. Evenly install bolts hand-tight, keeping the gap between flanges at a minimum.

3. Put the hose in a position so that the hose does not contact the machine or with another hose.

4. Tighten using one of the assembly torque values for bolts, used in Illustration 1 for proper torque sequence of various flange fittings.

   Note: The maximum gap permitted after final tightening is 4 mm (0.16 inch) for the combined total of both sides.

Straight Thread O-ring Fittings

The following tables have the recommended standard torque values.

Note: Straight Thread O-Ring fittings for medium pressure usage will have shorter threaded ends than high-pressure fittings. The torque value for medium pressure Straight Thread O-Ring fittings will be lower than the torque values that are required for Straight Thread O-Ring fittings for high-pressure fittings.

Table 4

Ferrous Straight Thread O-Ring Fitting Torques for Mating with Ferrous Materials Medium Pressure use Fittings
Nominal Outer Diameter of the Tube	Thread Size Inch	Standard Torque
3.18 mm (.125 inch)	5/16 - 24	10 ± 2 N·m (7 ± 1. lb ft)
4.76 mm (.188 inch)	3/8 - 24	17 ± 3 N·m (13 ± 2 lb ft)
6.35 mm (.250 inch)	7/16 - 20	35 ± 5 N·m (26 ± 4 lb ft)
7.94 mm (.312 inch)	1/2 - 20	45 ± 7 N·m (33 ± 5 lb ft)
9.52 mm (.375 inch)	9/16 - 18	45 ± 7 N·m (33 ± 5 lb ft)
12.70 mm (.500 inch)	3/4 - 16	80 ± 12 N·m (59 ± 9 lb ft)
15.88 mm (.625 inch)	7/8 - 14	110 ± 17 N·m (81 ± 13 lb ft)
19.05 mm (.750 inch)	1 1/16 - 12	130 ± 20 N·m (96 ± 15 lb ft)
22.22 mm (.875 inch)	1 3/16 - 12	200 ± 30 N·m (148 ± 22 lb ft)
25.40 mm (1.000 inch)	1 5/16 - 12	220 ± 33 N·m (162 ± 24 lb ft)
31.75 mm (1.250 inch)	1 5/8 - 12	300 ± 45 N·m (221 ± 33 lb ft)
38.10 mm (1.500 inch)	1 7/8 - 12	350 ± 53 N·m (258 ± 39 lb ft)
50.80 mm (2.000 inch)	2 1/2 - 12	420 ± 63 N·m (310 ± 46 lb ft)

Note: Straight Thread O-Ring fittings for high-pressure usage will have longer threaded ends than medium pressure fittings. The torque value for high-pressure Straight Thread O-Ring fittings will be higher than the torque values that are required for Straight Thread O-Ring fittings for medium pressure fittings.

Table 5

Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials High Pressure use with O-Ring Face Seal Fittings
Nominal Outer Diameter of the Tube	Thread Size Inch	Standard Torque
4.76 mm (0.188 inch)	3/8 - 24	25 ± 4 N·m (18 ± 3 lb ft)
6.35 mm (0.250 inch)	7/16 - 20	35 ± 5 N·m (26 ± 4 lb ft)
7.94 mm (0.312 inch)	1/2 - 20	50 ± 8 N·m (37 ± 6 lb ft)
9.52 mm (0.375 inch)	9/16 - 18	70 ± 11 N·m (52 ± 8 lb ft)
12.7 mm (0.500 inch)	3/4 - 16	110 ± 17 N·m (81 ± 13 lb ft)
15.88 mm (0.625 inch)	7/8 - 14	140 ± 21 N·m (103 ± 15 lb ft)
19.05 mm (0.750 inch)	1 1/16 - 12	220 ± 33 N·m (162 ± 24 lb ft)
22.22 mm (0.875 inch)	1 3/16 - 12	260 ± 39 N·m (192 ± 29 lb ft)
25.40 mm (1.000 inch)	1 5/16 - 12	350 ± 53 N·m (258 ± 39 lb ft)
31.75 mm (1.250 inch)	1 5/8 -12	400 ± 60 mm (16 ± 2 inch)
38.10 mm (1.500 inch)	1 7/8 - 12	420 ± 63 N·m (3100 ± 46 lb ft)
63.50 mm (2.500 inch)	21/2 - 12	600 ± 90 N·m (443 ± 66 lb ft)

Table 6

Metric Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials Medium Pressure use Fittings
Ref Nominal Outer Diameter of the Tube	Thread Size	Standard Torque Tolerance
4 mm	M8 X 1	10 ± 2 N·m (7 ± 1. lb ft)
5 mm	M10 X 1	17 ± 3 N·m (13 ± 2 lb ft)
6 mm	M12 X 1.5	35 ± 5 N·m (26 ± 4 lb ft)
8 mm	M14 X 1.5	45 ± 7 N·m (33 ± 5 lb ft)
10 mm	M16 X 1.5	45 ± 7 N·m (33 ± 5 lb ft)
12 mm	M18 X 1.5	80 ± 12 N·m (59 ± 9 lb ft)
16 mm	M22 X 1.5	110 ± 17 N·m (81 ± 13 lb ft)
20 mm	M27 X 2	130 ± 20 N·m (96 ± 15 lb ft)
22 mm	M30 X 2	200 ± 30 N·m (148 ± 22 lb ft)
25 mm	M33 X 2	220 ± 33 N·m (162 ± 24 lb ft)
30 mm	M42 X 2	300 ± 45 N·m (221 ± 33 lb ft)
38 mm	M48 X 2	350 ± 53 N·m (258 ± 39 lb ft)
50 mm	M60 X 2	420 ± 63 N·m (310 ± 46 lb ft)

Table 7

Metric Ferrous Straight Thread O-Ring Fittings Torques for Mating with Ferrous Materials High Pressure use with O-Ring Face Seal Fittings
Ref Nominal Outer Diameter of the Tube	Thread Size	Standard Torque Tolerance
5 mm	M10 X 1	25 ± 4 N·m (18 ± 3 lb ft)
6 mm	M12 X 1.5	35 ± 5 N·m (26 ± 4 lb ft)
8 mm	M14 X 1.5	50 ± 8 N·m (37 ± 6 lb ft)
10 mm	M16 X 1.5	70 ± 11 N·m (52 ± 8 lb ft)
12 mm	M18 X 1.5	110 ± 17 N·m (81 ± 13 lb ft)
16 mm	M22 X 1.5	140 ± 21 N·m (103 ± 15 lb ft)
20 mm	M27 X 2	220 ± 33 N·m (162 ± 24 lb ft)
22 mm	M30 X 2	260 ± 39 N·m (192 ± 29 lb ft)
25 mm	M33 X 2	350 ± 53 N·m (258 ± 39 lb ft)
30 mm	M42 X 2	400 ± 60 mm (16 ± 2 inch)
38 mm	M48 X 2	420 ± 63 N·m (3100 ± 46 lb ft)
50 mm	M60 X 2	600 ± 90 N·m (443 ± 66 lb ft)

O-ring Faced Seal Fittings

The following table has the recommended standard torque values.

Table 8

Ferrous ORFS Fitting
Thread Size Inch	Standard Torque for Nut (3)
9/16 - 18	30 ± 5 N·m (266 ± 44 lb in)
11/16 - 16	50 ± 8 N·m (37 ± 6 lb ft)
13/16 - 16	70 ± 11 N·m (52 ± 8 lb ft)
1 - 14	110 ± 17 N·m (81 ± 13 lb ft)
1 13/16 - 12	160 ± 24 N·m (118 ± 18 lb ft)
1 7/16 - 12	260 ± 39 N·m (192 ± 29 lb ft)
1 11/16 - 12	300 ± 45 N·m (221 ± 33 lb ft)
2 - 12	350 ± 53 N·m (258 ± 39 lb ft)

Tapered Pipe Thread Fittings

The following table has the recommended standard torque values.

Table 9

Tapered Pipe Thread Fittings
Diameter of the Pipe Thread (Inch)	Standard Torque
	Assembly Turns after Hand Tight	Torque
1/16	3	10 ± 2 N·m (89 ± 18 lb in)
1/8	3	20 ± 3 N·m (177 ± 27 lb in)
1/4	3	35 ± 5 N·m (26 ± 4 lb ft)
3/8	3	60 ± 9 N·m (44 ± 7 lb ft)
1/2	2.5	80 ± 12 N·m (60 ± 9 lb ft)
3/4	2.5	100 ± 15 N·m (74 ± 11 lb ft)
1	2.5	120 ± 18 N·m (89 ± 13 lb ft)
1 1/4	2.5	140 ± 21 N·m (103 ± 15 lb ft)
1 1/2	2.5	160 ± 24 N·m (118 ± 18 lb ft)
2	2.5	180 ± 27 N·m (132 ± 20 lb ft)

Hose Clamps

The following tables have the recommended standard torque values.

Table 10

Worm Drive Band Type Hose Clamps
Width of Clamp	Torque for New Hose
7.5 mm (0.3 inch) or smaller	1.4 ± 0.3 N·m (12 ± 3 lb in)
12 mm (0.5 inch) or smaller	4.5 ± 0.7 N·m (40 ± 6 lb in)
14 mm (0.6 inch) or smaller	7.5 ± 1 N·m (66 ± 9 lb in)
Width of Clamp	Torque for Reused Hose(1)
7.5 mm (0.3 inch) or smaller	0.8 ± 0.3 N·m (7 ± 3 lb in)
12 mm (0.5 inch) or smaller	3.0 ± 0.5 N·m (27 ± 4 lb in)
14 mm (0.6 inch) or smaller	4.5 ± 0.7 N·m (40 ± 6 lb in)

(1)	Use this value when the hose is reused. The clamp may be new or reused.

Table 11

Constant Torque Hose Clamps Belleville Washer
Diameter of Hose Clamp	Standard Torque
Up to 50.8 mm (2 inch)	7.5 ± 1 N·m (65 ± 10 lb in)
Greater than 50.8 mm (2 inch)	11 ± 1 N·m (95 ± 10 lb in)

Table 12

Constant Torque Hose Clamps Tee Bolt and Spring
Diameter of Hose Clamp	Standard Torque
All	7.5 ± 1 N·m (65 ± 10 lb in)

Specification Data

Illustration 2	g00838585

Table 13

390F L Excavator
	Mass Boom (1)		General Boom (2)
	2925 mm (9 ft 6 inch)Stick	3400 mm (11 ft 2 inch)Stick	2925 mm (9 ft 6 inch)Stick	3400 mm (11 ft 2 inch)Stick	3700 mm (12 ft 1 inch)Stick	4400 mm (14 ft 4 inch)Stick
Overall Length (A)	13830 mm (45 ft 4 inch)	13550 mm (44 ft 5 inch)	14930 mm (48 ft 10 inch)	14720 mm (48 ft 3 inch)	14710 mm (48 ft 3 inch)	14690 mm (48 ft 2 inch)
Boom Height (B)	5310 mm (17 ft 4 inch)		5000 mm (16 ft 4 inch)	5160 mm (16 ft 9 inch)	5080 mm (16 ft 7 inch)	5290 mm (17 ft 4 inch)
Height of Cab (C)	3650 mm (11 ft 10 inch)
Overall Width (D)	4510 mm (14 ft 8 inch)
Width of Track (E)	4260 mm (13 ft 10 inch)
Track Shoe Width (F)	750 mm (30 inch)
Ground Clearance (G)	910 mm (2 ft 10 inch)
Swing Radius (H)	4700 mm (15 ft 4 inch)
Length of Track (I)	6360 mm (20 ft 9 inch)
Length to Center of Rollers (J)	5120 mm (16 ft 8 inch)

(1)	7250 mm (23 ft 8 inch) mass boom, equipped with a 6.0 m3 (7.8 yd3) bucket, and a 10 percent full fuel tank.
(2)	8400 mm (27 ft 6 inch) general boom, equipped with a 4.6 m3 (6.0 yd3) bucket, and a 10 percent full fuel tank.

Basic Machine with Counterweight

Illustration 3	g03539104

Table 14

390F Excavator(1)
Weight (900 mm Shoe)	68140 kg (150223 lb)
Weight (650 mm Shoe)	66152kg (145840 lb)
Width	3500 mm (11 ft 6 inch)
Length (A)	7880 mm (25 ft 10 inch)
Height (B)	3790 mm (12 ft 5 inch)
Center of Gravity (C)	1530 mm (5 ft 0 inch)
Center of Gravity (D)	1230 mm (4 ft 0 inch)

(1)	These specifications are for machines that have a fully retracted track, and a 10 percent full fuel tank.

Basic Machine without Counterweight

Illustration 4	g06362840

Table 15

390F Excavator
Weight	53381 kg (117684.8 lb)
Width	4508 mm (14 ft 9 inch) ()
Length (A)	7258 mm (23 ft 10 inch)
Height (B)	3834 mm (12 ft 7 inch)
Center of Gravity (C)	1329 mm (4 ft 4 inch)
Center of Gravity (D)	562 mm (1 ft 10 inch)

Carbody

Illustration 5	g03509961

Table 16

390F Excavator
Weight	27930 kg (61575 lb)(1)	27860 kg (61421 lb)(2)
Length (A)	6100 mm (20 ft 0 inch)(1)	6020 mm (19 ft 9 inch)(2)
Height (B)	2880 mm (9 ft 5 inch)
Height (C)	2680 mm (8 ft 9 inch)
Height (D)	2960 mm (9 ft 8 inch)
Length (E)	3350 mm (11 ft 0 inch)

(1)	The specification is for a machine with a front guard.
(2)	The specification is for a machine without a front guard.

Track Frame

Illustration 6	g02571599

Table 17

Track Frame	390F Excavator
Weight (650 mm)	13630 mm (30049 lb)
Weight (900 mm)	14624 mm (32240 lb)
Length (A)	6360 mm (20 ft 10inch)
Height (B)	1450 mm (4 ft 9 inch)
Width (C)	1070 mm (3 ft 6 inch)
Center of Gravity (D)	109 mm (4 inch)
Center of Gravity (E)	771 mm (2 ft 6 inch)

Counterweight

Illustration 7	g02571600

Table 18

Standard Counterweight
Weight	12350 kg (27227 lb)
Length (A)	640 mm (2 ft 1inch)
Height (B)	1930 mm (6 ft 4 inch)
Width (C)	3470 mm (11 ft 5 inch)
Center of Gravity (D)	0
Center of Gravity (E)	2524 mm (8 ft 3 inch)

Boom with Stick Cylinder

Illustration 8	g02765979

Table 19

	General Boom 8.4 m (27 ft 7 inch)	Mass Boom 7.25 m (23 ft 9 inch)	Reach Boom 10.0 m (32 ft 10 inch)
Weight	8280 kg (18254 lb)	8430 kg (18585 lb)	0
Width	1330 mm (4 ft 4 inch)	1330 mm (4 ft 4 inch)	0
Length (A)	8730 mm (28 ft 8 inch)	7580 mm (24 ft 10 inch)	0
Height (B)	2260 mm (7 ft 5 inch)	2390 mm (7 ft 10 inch)	0
Center of Gravity (C)	1070 mm (3 ft 6 inch)	1020 mm (3 ft 4 inch)	0
Center of Gravity (D)	4420 mm (14 ft 6 inch)	3640 mm (11 ft 11 inch)	0

Stick with Bucket Cylinder

Illustration 9	g02765978

Table 20

General Boom	General Boom 2.92 m (9 ft 7 inch)	General Boom 3.4 m (11 ft 2 inch)	Boom 4.4 m (14 ft 4 inch)
Weight	4849 kg (10690 lb)	5158 kg (11371 lb)	4970 kg (10957 lb)
Width	890 mm (2 ft 11 inch)	890 mm (2 ft 11 inch)	770 mm (2 ft 6 inch)
Length (A)	4420 mm (14 ft 6 inch)	4890 mm (16 ft 0 inch)	5930 mm (19 ft 5 inch)
Height (B)	1630 mm (5 ft 4 inch)	1570 mm (5 ft 2 inch)	1340 mm (4 ft 5 inch)
Center of Gravity (C)	490 mm (1 ft 7 inch)	480 mm (1 ft 7 inch)	410 mm (1 ft 4 inch)
Center of Gravity (D)	890 mm (2 ft 11 inch)	1210 mm (4 ft 0 inch)	1740 mm (5 ft 8 inch)

Table 21

Mass Boom	2.92 m (9 ft 7 inch)	3.4 m (11 ft 2 inch)
Weight	5123kg (11294 lb)	5384 kg (11870 lb)
Width	890 mm (2 ft 11 inch)	890 mm (2 ft 11 inch)
Length (A)	4420 mm (14 ft 6 inch)	4890 mm (16 ft 0 inch)
Height (B)	1660 mm (5 ft 5 inch)	1600 mm (5 ft 3 inch)
Center of Gravity (C)	470 mm (1 ft 7 inch)	470 mm (1 ft 7 inch)
Center of Gravity (D)	890 mm (2 ft 11 inch)	1200 mm (3 ft 11 inch)

Bucket

Refer to this Operation and Maintenance Manual, "Boom/Stick/Bucket Combinations" for bucket specifications.

Boom Cylinders

Illustration 10	g00589456

Table 22

Weight (Each Boom Cylinder)	1790 kg (3946 lb)
Length (A)	3110 mm (5 ft 10 inch)
Height (B)	1220 mm (4 ft 0 inch)

Walkway

Illustration 11	g01131465

Table 23

	Walkway (1)	Walkway (2)
Weight	22 kg (49 lb)	36 kg (82 lb)
Length (A)	1450 mm (4 ft 10 inch)	2480 mm (8 ft 1 inch)
Width (B)	500 mm (1 ft 8 inch)	500 mm (1 ft 8 inch)
Height (C)	210 mm (8 inch)	210 mm (8 inch)

Miscellaneous

Illustration 12	g03539101
Right side of the machine (1) Hand rail (2) Hand rail (3) Hand rail

Illustration 13	g03539103
Left side of the machine (4) Hand rail (5) Hand rail (6) Hand rail (7) Hand rail (8) Hand rail

Table 24

	Exhaust Pipe	Rear View Mirror on Storage Box	Hand rail (1)	Hand rail (2)	Hand rail (3)	Hand rail (4)	Hand rail (5)	Hand rail (6)
Weight	7 kg (15.4 lb)	8 kg (18.0 lb)	3 kg (6.6 lb)	8 kg (17.6 lb)	23 kg (50.8 lb)	10 kg (22.0 lb)	4 kg (8.8 lb)	3 kg (6.6 lb)
Length	295 mm (11.6 inch)	380 mm (15.0 inch)	1260 mm (49.6 inch)	300 mm (11.8 inch)	720 mm (28.3 inch)	1010 mm (39.8 inch)	390 mm (15.4 inch)	1260 mm (49.6 inch)
Width	255 mm (10.0 inch)	160 mm (6.3 inch)	40 mm (1.6 inch)	270 mm (10.6 inch)	310 mm (12.2 inch)	390 mm (15.4 inch)	50 mm (2.0 inch)	40 mm (1.6 inch)
Height	640 mm (25.2 inch)	670 mm (26.4 inch)	90 mm (3.5 inch)	1390 mm (54.7 inch)	1700 mm (66.9 inch)	850 mm (33.5 inch)	610 mm (24.0 inch)	90 mm (3.5 inch)

Track Roller Frame - Install

Illustration 14	g06292472

Table 25

Required Tools
A	-	Suitable lifting cable
B	-	Suitable shackle
C	6V-6080	Torque Multiplier Gp

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Illustration 15	g06268867

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Illustration 16	g06268868

1. Lift the track roller frame by the suitable lifting cable. The weight of the track roller frame is approximately 13630 kg (30049 lb) for 650 mm (2.1 ft) shoe or 14624 kg (32240 lb) for 900 mm (3 ft) shoe. Position the track roller frame for installation.

   Note: Put the suitable guard on the wire contact point as shown in Illustration 16.

2. Prepare the proper hoist.

   Note: Static weights for each lifting point is 11.8 t (26015 lb) in the rear and 15.8 t (34833 lb) in the front ( 7.9 t (17416 lb) for each front lifting point).

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   Illustration 17	g06268869

3. In front side, put the suitable lifting device on PT12 pin as shown in Illustration 17. (PT1 is also acceptable)

   Note: Make sure there is no interference with the lifting device.

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   Illustration 18	g06268870

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   Illustration 19	g06268872
   541-9325 Bracket As

4. In back side, we recommend to use the hole on the upper frame. Attach the suitable shackle on the hole on the upper frame and put the cable.

   Another option is to put the 541-9325 Bracket As on the upper frame to lift the car body. Attach the two suitable jig like below on the upper frame and hook the suitable cable as shown in Illustration 19.

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   Illustration 20	g06293096

5. Lift the upper car body and move towards the one of track roller frame. Position the upper chassis onto the track roller frames for the installation of the bolts. The weight of the upper car body without the front structure and counterweight is 27600 kg (60848 lb).
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   Illustration 21	g06268903

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   Illustration 22	g02556638
   (1) Carbody (2) Track frame (3) Bolts (4) Spacers (5) Bolts (6) Corks

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   NOTICE
   Do not use oil on the threads. Do not use antiseize on the threads. Do not use any other lubricant on the threads.

6. Secure the track roller to the upper car body by twelve spacers and twelve bolts. Use the tooling (C) to tighten the bolts to a torque of 2800 ± 350 N·m (2065 ± 258 lb ft).

   Note: Seven bolts and seven spacers needs to be installed on the side with the idler and seven bolts and seven spacers need to be installed on the side with the final drive.

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   Illustration 23	g06275644

7. Use suitable cribbing to support the other side of the upper chassis. Remove suitable lifting device from the upper car body.
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   Illustration 24	g06268867

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   Illustration 25	g06268868

8. Use suitable lifting devices and lift the other track roller frame. The weight of the track roller frame is approximately 13630 kg (30049 lb) for 650 mm (2.1 ft) shoe or 14624 kg (32240 lb) for 900 mm (3 ft) shoe.

   Note: Put the suitable guard on the wire contact point as shown in Illustration 16.

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   Illustration 26	g06268923

9. Position the track roller frame onto the car body for the installation of the bolts.
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   Illustration 27	g06268903

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   Illustration 28	g02564758
   (1) Car body (2) Track frame (3) Bolts (4) Spacers (5) Bolts (6) Bolts (7) Washer (8) Plate

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   NOTICE
   Do not use oil on the threads. Do not use antiseize on the threads. Do not use any other lubricant on the threads.

10. Secure the track roller to the upper car body by twelve spacers and twelve bolts. Use the tooling (C) to tighten the bolts to a torque of 2800 ± 350 N·m (2065 ± 258 lb ft).

    Note: Seven bolts and seven spacers needs to be installed on the side with the idler and seven bolts and seven spacers need to be installed on the side with the final drive.

Travel Motor Lines - Install

Illustration 29	g06292473

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Illustration 30	g06360126
Supply lines (typical example)

1. Install the lines for forward travel (upper) and reverse travel (lower). Make sure to connect to the correct ports. Install eight bolts, eight hard washers, one seal and four split flanges. Follow the same procedure for the other side.
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   Illustration 31	g06360187
   Drain line (typical example)

2. Install the drain line to the port on the top of the travel motor. Follow the same procedure for the other side.
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   Illustration 32	g06360185
   Pilot lines (A) Left hand side (B) Right hand side

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   Illustration 33	g06270367

3. Install the pilot line to the port on the top of the travel motor. Follow the same procedure for the other side.

   Note: Make sure that there is no interference with the other hardware such as the ports, frame, hoses,etc, at the red circle location. Reroute the hoses, if any interference is found.

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   Illustration 34	g06362896
   479-5616 Travel Motor Guard Gp left side (1) 398-5906 Support As (2) 426-4920 Cover As (3) 451-5687 Cover As (4) 451-5689 Cover As (5) 451-5691 Cover As (6) 479-5618 Cover As (7) 453-2835 Bolt (8) 453-2865 Hard Washer (9) 453-2836 Bolt (10) 135-8575 Bolt As

4. Install cover assembly (6) and cover assembly (2) with bolts (9) and (7) and hard washers (8). Install cover assembly (3) then cover assembly (4) with bolts (7) and hard washers (8). Install cover assembly (5) with support assembly (1) and bolt assembly (10). Refer to Illustration 34 for installing the left side travel motor guard.
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   Illustration 35	g06363289
   479-5616 Travel Motor Guard Gp right side (1) 398-5906 Support As (7) 453-2835 Bolt (8) 453-2865 Hard Washer (9) 453-2836 Bolt (10) 135-8575 Bolt As (11) 426-4915 Cover As (12) 451-5688 Cover As (13) 451-5690 Cover As (14) 451-5692 Cover As (15) 479-5617 Cover As

5. Install cover assembly (15) and cover assembly (11) with bolts (9) and (7) and hard washers (8). Install cover assembly (12) then cover assembly (13) with bolts (7) and hard washers (8). Install cover assembly (14) with support assembly (1) and bolt assembly (10). Refer to Illustration 35 for installing the right side travel motor guard.

Counterweight - Install (Standard Machines)

Illustration 36	g06292474

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Unexpected machine movement can cause injury or death. In order to avoid possible machine movement, move the hydraulic lockout control to the LOCKED position and attach a Special Instruction, SEHS7332, "Do Not Operate" or similar warning tag to the hydraulic lockout control.

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Personal injury or death can occur from a counterweight falling during removal or installation. Do not allow personnel under or around the counterweight during removal or installation. Make sure that the lifting device is in good condition and is capable of handling the weight of the counterweight.

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Make certain personnel are clear of cable when there is a load on it. Cable can break and cause personal injury.

Table 26

Required Tools
Tool	Part Number	Part Description	Qty
A	4C-8217	55 mm Socket	1
	6V-6080	Torque Multiplier	1
	8T-9293	Torque Wrench	1
	-	Reaction Bar	1
B	5P-3931	Anti-Seize Compound	-
C	384-9666(1)	Lifting Eye Assembly	2

(1)	This Tooling is to be used with a suitable lifting device to move the counterweight for installation.

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Illustration 37	g03485178

1. Attach a suitable lifting device and a hoist to counterweight.

   Note: The counterweight weighs approximately 11040 kg (24339 lb).

2. Position counterweight on the swing frame.
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   Illustration 38	g03437997

3. Install six counterweight mounting bolts and washers.

   Note: Temporarily tighten the six counterweight mounting bolts. Decrease the tension on the lifting cable. Make sure that the counterweight is correctly positioned on the retaining pins. Tighten the bolts to a torque of 2800 ± 350 N·m (1990 ± 220 lb ft).

Counterweight - Install (Machines Equipped with a Counterweight Removal System)

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Unexpected machine movement can cause injury or death. In order to avoid possible machine movement, move the hydraulic lockout control to the LOCKED position and attach a Special Instruction, SEHS7332, "Do Not Operate" or similar warning tag to the hydraulic lockout control.

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Personal injury or death can occur from a counterweight falling during removal or installation. Do not allow personnel under or around the counterweight during removal or installation. Make sure that the lifting device is in good condition and is capable of handling the weight of the counterweight.

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Make certain personnel are clear of cable when there is a load on it. Cable can break and cause personal injury.

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Personal injury or death can occur from a counterweight falling during removal or installation. Before you begin the Removal Procedure make sure that the support blocks are in the horizontal position.

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IMPROPER OPERATION OF THE COUNTERWEIGHT REMOVAL SYSTEM CAN RESULT IN SERIOUS INJURY OR DEATH. DO NOT OPERATE THIS SYSTEM UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUAL.

Table 27

Required Tools
Tool	Part Number	Part Description	Qty
A	4C-8217	55 mm Socket	1
	6V-6080	Torque Multiplier	1
	8T-9293	Torque Wrench	1
	-	Reaction Bar	1
B	5P-3931	Anti-Seize Compound	-
C	384-9666(1)	Lifting Eye Assembly	2

(1)	This Tooling is to be used with a suitable lifting device to move the counterweight for installation.

1. Place the machine on a surface that is hard and level.
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   Illustration 39	g06324642

2. Use an appropriate lifting device and a proper rated wire cable with shackles in order to put the counterweight on a surface that is hard and level near the machine. The weight of the counterweight is approximately 11100 kg (24470 lb).
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   Illustration 40	g03485485
   (7) Chain (11) Bracket (12) Washer (13) Bolt (14) Pin (15) Bolt (16) Washer

3. At the end of pin (14), remove washer (12) and bolt (13).

4. Remove bolts (15) and washers (16) in order to remove pin (14) from bracket (11).

5. Remove pin (14) from chains (7).

6. Place pin (14) to the storage box.
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   Illustration 41	g03485456
   (4) Counterweight (7) Chains (8) Pins (9) Nuts (10) Cotter pins

7. Install pins (8) in order to connect chains (7) to counterweight (4).

8. Install cotter pins (10). Tighten the nuts (9) to a torque of 15 ± 3 N·m (11 ± 2 lb ft).

9. Open the rear access door on the right side of the machine.
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   Illustration 42	g03485316
   (1) Switch (2) Control lever (3) Stop valves (A) CLOSED position (B) OPEN position

10. Place stop valves (3) in OPEN position.

11. Move switch (1) upwards to the ON position.
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    Illustration 43	g06274061
    (4) Counterweight

12. Move control lever (2) upward in order to raise counterweight (4) onto lift from the ground.
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    Illustration 44	g06274040
    (5) Retaining pin (6) Extension

13. Use a ratchet wrench and an extension (6) in order to rotate each retaining pin (5). Retaining pins (5) require ninety degrees of rotation. The retaining pins (5) are now in the LOCKED position.
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    Illustration 45	g03485336
    (4) Counterweight (5) Retaining pin

14. Move control lever (2) downward in order to lower the counterweight (4) until the retaining pins (5).
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    Illustration 46	g03437997

15. Apply Anti-Seize Compound (B) on the counterweight mounting bolts. Install the six counterweight mounting bolts and washers to the frame of the machine. First, tighten the bolts by hand until the washers contact the counterweight. Move control lever (2) downward to allow the counterweight to settle on the support blocks. Use Tooling (A) to tighten the counterweight bolts.

    Note: Make sure that you remove pin (14), bolt (13), washer (12), bolt (15), and washer (16). Return these parts to the storage box.

    Note: Before you install the counterweight mounting bolts, make sure that the retaining pins are in the LOCKED position and that the counterweight is securely held on the retaining pins. There should be a slight amount of slack on the chains. Tighten the counterweight mounting bolts to a torque of 2800 ± 350 N·m (2065.2 ± 258.1 lb ft).

16. Move switch (1) downward to the OFF position.

17. Place stop valves (3) in CLOSED position (A).

18. Remove the wire cable from the counterweight.

19. Close the rear access door on the right side of the machine.
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    Illustration 47	g03640796

20. Install two bolts from the top of the counterweight cover plate.

Steps - Install

Illustration 48	g06292475

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Illustration 49	g06274359
Steps (1) 346-7268 Step (2) 447-1719 Bolt (3) 451-2176 Hard Washer

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Illustration 50	g06274363
(2) 447-1719 Bolt (3) 451-2176 Hard Washer (4) 346-7269 Step As

1. Install three steps (1) with bolts (2) and hard washers (3).

2. Install step assembly (4) with bolts (2) and hard washers (3).

Walkways - Install

Illustration 51	g06292476

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Illustration 52	g06362858
Walkway (1) 385-2148 Walkway As (2) 385-2147 Walkway As (3) 447-1730 Bolt (4) 453-2865 Hard Washer (5) 8T-4192 Bolt (6) 8T-4223 Hard Washer (7) 450-3429 Handrail As

1. Install five walkway assemblies (1) by using bolts (3) and hard washers (4).

2. Install walkway assembly (2) by using bolts (3) and hard washers (4).

3. Install handrail assembly (7) by using bolts (5) and hard washers (6).

Handrails and Mirrors - Install

Illustration 53	g06292477

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Illustration 54	g06363375
Handrail (1) 148-4977 Handrail As (2) 382-8468 Handrail As (3) 385-2410 Handrail As (4) 385-2424 Handrail As (5) 135-8578 Bolt As (6) 5P-1076 Hard Washer (7) 8T-4194 Bolt

1. Install three handrail assembly (2) with bolt assemblies (5).

2. Install handrail assembly (3) by using bolts (7) and hard washers (6).

3. Install handrail assembly (4) by using bolts (7) and hard washers (6).

4. Install handrail assembly (1) with bolt assemblies (5).
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   Illustration 55	g06363388
   Handrail (1) 8T-4223 (2) 133-5795 (3) 135-8577 (4) 135-8578 (5) 141-6518 (6) 379-7669 (7) 396-8473 (8) 8T-4244 (9) 8T-4956 (A) 225 ± 5 mm (8.9 ± 0.2 inch)

5. Install handrail assembly (6) by using bolt assemblies (3), spacers (5), and bolt assemblies (4).

6. Install clips (7) and grommets (2) with dimension (A) by using bolts (9), nuts (8), and hard washers (1).

Mirrors - Install

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Adjust all mirrors as specified in the Operation and Maintenance Manual. Failure to heed this warning can lead to personal injury or death.

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Slips and falls can result in personal injury. Use the machine's access systems when adjusting the mirrors. If the mirrors cannot be reached using the machine access systems follow the instructions found within the Operation and Maintenance Manual, "Mirror" in order to access the mirrors.

Illustration 56	g06274696
(A) Right side rear view mirror (B) Left side rear view mirror

Mirrors provide additional visibility around your machine. Make sure that the mirrors are in proper working condition and that the mirrors are clean. Adjust all mirrors at the beginning of each work period and adjust the mirrors when you change operators.

An appropriate job site organization is also recommended in order to minimize visibility hazards. For more information regarding job site organization refer to this Operation and Maintenance Manual, "Visibility Information"

Modified Machines or machines that have additional equipment or attachments may influence your visibility.

Mirror Adjustment

• Park the machine on a level surface.

• Lower the work tool to the ground.

• Move the hydraulic lockout control to the LOCKED position. For further details on this procedure, refer to Operation and Maintenance Manual, "Operator Controls"

• Stop the engine.

Note: You may need to use hand tools in order to adjust certain types of mirrors.

Illustration 57	g06361788
Right side rear view mirror (1) 392-7316 Plate (2) 135-8575 Bolt As (3) 5P-6879 Mirror (4) 8T-4195 Bolt (5) 8T-4121 Hard Washer (6) 8T-4183 Bolt (7) 5P-1076 Hard Washer (8) 8T-4244 Nut (9) 5P-8112 Grommet (10) 262-2292 Clip (11) 262-2293 Clip (12) 262-2357 Support As

Install mirror (3) by using plate (1), bolt assemblies (2), bolts (4), hard washers (5), bolts (6), hard washers (7), nuts (8), grommet (9), clip (10), clip (11), and support assembly (12).

Note: Adjust the side mirror (A) on the storage box so that the right side access door and the right side track can be seen from the operator seat. Additionally, provide as much visibility to the rear of the machine as possible.

Illustration 58	g06274711
Left Side Rear View Mirror (1) 316-8989 Support As (2) 447-1711 Bolt (3) 451-2175 Hard Washer (4) 394-9460 Mirror Gp

Install mirror group (4) by using support assembly (1), bolt (2), and hard washer (3).

Note: Adjust the left mirror (B) on the cab so that the left access door and the left side track can be seen from the operator seat. Additionally, provide as much visibility to the rear of the machine as possible.

Boom Cylinder and Lines - Install

Illustration 59	g06292432

Table 28

Required Tools
Tool	Part Number	Part Description	Qty
A	4C-6486	Stand	2
	8S-8048	Saddle	2
	8S-7641	Tube	2
	8S-7615	Pin	2
B	5P-0960	Grease Cartridge	1

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Illustration 60	g00581741

1. Fasten two properly rated wire cables to the boom cylinder and secure the piston rod to the cylinder tube. The weight of boom cylinder is approximately 1790 kg (3946 lb).

2. Slowly lift the boom cylinder.
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   Illustration 61	g06276118
   (1) Boom cylinder

3. Support the boom cylinder (1) onto tooling (A). Position the boom cylinder (1) into the upper frame.
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   Illustration 62	g06276200
   (X) Boom cylinder (Y) Support pin (Z) Upper frame (2) 453-2852 Bolt

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   Illustration 63	g06357595
   Location : PT12 (3) 208-1974 Shim (4) 208-1973 Shim (5) 208-1972 Shim (A) Spacer (B) Pin assembly

4. Slide the boom cylinder to one side until the boom cylinder contacts the frame. Measure the total clearance between the boom cylinder and the frame at the pin bore. The total clearance of (a) and (b) may not be more than 1.0 mm (0.04 inch). If the total clearance is less than 1.0 mm (0.04 inch), the addition of shims between the boom cylinder and frame will not be required. If the total clearance is more than 1.0 mm (0.04 inch), add the correct thickness of shims in order to obtain the necessary clearance.
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   Table 29

   Shim	Part Number	Outside Diameter in (mm)	Inside Diameter in (mm)	Thickness in (mm)
   PT12- (3)	208-1974	260 mm (10.2 inch)	142 mm (5.6 inch)	2.0 mm (0.08 inch)
   PT12- (4)	208-1973	260 mm (10.2 inch)	142 mm (5.6 inch)	1.0 mm (0.04 inch)
   PT12- (5)	208-1972	260 mm (10.2 inch)	142 mm (5.6 inch)	0.5 mm (0.02 inch)

   Note: Shims should be installed on the cab side for the left cylinder and storage box side for the right cylinder.

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   Illustration 64	g06276145
   (2) 453-2852 Bolt (6) 367-1450 Pin As (7) 451-2177 Hard Washer (8) 201-2771 Washer (9) 123-5574 Spacer

5. Install piston end of the boom cylinder (1) into upper frame by using pin assembly (6) with bolt (2), hard washer (7), washer (8), and spacer (9).
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   Illustration 65	g06276172
   (15) Bolt (16) Tube assembly (17) Bolt (18) Tube assembly (19) Bolt (20) Support assembly

6. Install support assemblies (20) and bolts (19).

7. Install bolts (17) and tube assembly (18).

8. Install bolts (15) and tube assembly (16).
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   Illustration 66	g06276178
   (21) Bolt (22) Clamp

9. Install clamp (22) with bolts (21).
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   Illustration 67	g06276187
   (23) Hose assembly (24) Hose assembly

10. Connect hose assemblies (23) and (24).
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    Illustration 68	g06276189
    (25) Hose assembly

11. Connect hose assemblies (25).

12. Repeat Steps 1 through Steps 7 in order to install the boom cylinder on the other side.

Boom - Install

Illustration 69	g06292435

Table 30

Required Tools
Tool	Part Number	Part Description
A	-	Suitable lifting cable
B	-	Suitable shackle

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Illustration 70	g06276060

1. Clean the bores of the boom and of the upper frame. Lubricate all the bores.
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   Illustration 71	g06362448
   Typical example (1) Boom (C) Tube (D) Boom (E) Wood block (F) Shackles (G) Wire cable

2. Use the two lifting eyes that are provided in the brackets on the top of the boom. Install shackles through the lifting eyes and fasten properly rated wire cable to the front section of the boom (1). Use a cloth in order to protect the lifting cable from being damaged by the edges of the boom (1). Refer to Illustration 71.

   Note: In case, if there are any interference between the wire and hardware such as the tubes, hoses, etc. when lifting the boom (1), use the wooden block as shown in 71.

   The weight of the boom (1) and the stick cylinder is approximately 8280 kg (18254 lb) for general boom and 8430 kg (18585 lb) for mass boom.

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   Illustration 72	g00879638
   (X) Upper frame (Y) Boom

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   Illustration 73	g06357593
   Location : PT1 (2) 364-4975 Shim (3) 364-4974 Shim (4) 364-4976 Shim (F) Pin assembly

3. Slide the boom to one side until the boom makes contact with the frame. Measure clearance (Z) between the boom and the frame at the mounting pin bore. The clearance must not be more than 1.0 mm (0.04 inch). If the clearance is less than 1.0 mm (0.04 inch), the addition of shims will not be required. If the clearance is more than 1.0 mm (0.04 inch), add the correct thickness of shims in order to obtain the necessary clearance.
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   Table 31

   Shim	Part Number	Outside Diameter in (mm)	Inside Diameter in (mm)	Thickness in (mm)
   PT1- (2)	364-4975	300 mm (11.8 inch)	142 mm (5.6 inch)	2.0 mm (0.08 inch)
   PT1- (3)	364-4974	300 mm (11.8 inch)	142 mm (5.6 inch)	1.0 mm (0.04 inch)
   PT1- (4)	364-4976	300 mm (11.8 inch)	142 mm (5.6 inch)	0.5 mm (0.02 inch)

   Note: Shims should be installed on the cab side.

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   Illustration 74	g06362740
   (5) 436-0247 Pin As (6) 363-1159 Plate (7) 447-1709 Bolt (8) 451-2175 Hard Washer

4. Lubricate pin assembly (5). Install pin assembly (5) by using plate (6), two bolts (7), and two hard washers (8).
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   Illustration 75	g06370606
   (9) Boom cylinder (10) 172-3052 Pin

5. Install rod end of the boom cylinder (9) into boom. Install pin (10) through boom cylinder and boom.
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   Illustration 76	g06370600
   (9) Boom cylinder (11) 123-5574 Spacer (12) 172-3051 Plate (13) 451-2177 Bolt (14) 453-2854 Hard Washer

6. Install pin (10) by using spacer (11), plate (12), bolt (13), and hard washers (14).
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   Illustration 77	g06370609
   (15) Grease hose assembly

7. Connect grease hose assembly (15).
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   Illustration 78	g06370610
   (16) Harness assembly (17) Clip (18) Hose assembly

8. Connect the hose assemblies (18).

9. Connect the harness assembly (16) and install clip (17).

10. Lower the boom. Place the other end of the boom on the wood blocks.

If CPM is installed, Rotary Position Sensor needs to be Installed

Installation Procedure for Boom Rotary Position Sensor

The boom rotary position sensor is found at the base of the boom attachment, where the boom and the machine body meet.

Note: The center of Rotary Position Sensor (RPS) must be aligned with the center of the boom and stick pins by using the special tools.

Table 32

Required Tools
Tool	Part Number	Part Description
G	376-3072	Alignment Tool

Reference: Special Instruction, REHS7312, "Instructions for Installing Rotary Position Sensor for Cat^® Grade Control on Certain Series E and Series F Excavators"

Mounting sensor must be required for Installing the Rotary Position Sensor.

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Illustration 79	g06363455
(1) Pin (2) 451-1817 Plate As (3) Rotary position sensor (4) Alignment tool (jig)

1. Attach the alignment tool (4) and mount plate (2) to pin (1). Refer to the Illustration 79.
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   Illustration 80	g06363457
   (2) 451-1817 Plate As (5) 8T-6868 Bolt (6) 8T-4223 Hard Washer

2. Attach the mount plate (2) and hand tighten the two bolts (5). Torque the bolts evenly, taking care that the plate does not rotate. Refer to the Illustration 80.

   Note: The mount plate must be mounted using the special alignment tool (jig).

3. Remove alignment tool (4) from pin (1). Mount rotary position sensor (3) over the mount plate (2). Refer to Illustration 79.
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   Illustration 81	g06363460
   (7) 345-1948 Position Sensor Gp (8) 131-3983 Bolt (9) 8T-4224 Hard Washer

4. Install position sensor group (7) by using four bolts (8) and four hard washers (9).
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   Illustration 82	g06363464
   (10) 451-1816 Lever (11) 5C-9553 Bolt (12) 9X-8256 Washer

5. Install lever assembly (10) by using two bolts (11) and two washers (12).
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   Illustration 83	g06363465
   Install the rod assembly for the boom section of the front linkage for 390F (13) 308-5695 Hose As (14) 9X-2040 Screw (15) 8T-4121 Hard Washer

6. Install hose assembly (13) by using two screw (14) and four hard washers (15). (Two hard washers for each bolt).

Stick - Install

Illustration 84	g06292437

Table 33

Required Tools
Tool	Part Number	Part Description	Qty
A	8S-7615	Pin	1
	4C-6486	Stand	1
	8S-7641	Tube Assembly	1
B	5P-0960	Grease Cartridge	1

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Illustration 85	g00581738

Note: Clean and lubricate all the bores of the stick.

1. Use the two lifting eyes that are provided in the brackets on the top of the stick. Install shackles through the lifting eyes and fasten properly rated wire cable to the front section of the stick. Use a cloth in order to protect the lifting cable from being damaged by the edges of the stick. The combined weight of the stick, the bucket cylinder, and the bucket control linkage varies from 3629 to 4082 kg (8000 to 9000 lb).

2. Slowly lift the stick with the bucket cylinder.
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   Illustration 86	g06370341

3. Install tooling (A) under the front of the boom in order to support the boom.
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   Illustration 87	g06276470

4. Position the stick (1) into the boom.
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   Illustration 88	g00877718

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   Illustration 89	g06357590
   Location : PT4 (B) Pin assembly (2) 093-0108 Shim (3) 093-0076 Shim (4) 151-0653 Shim

5. Slide the stick to one side until the stick contacts the boom. Measure total Clearance (Y) between the stick and the boom at the pin bore. The total clearance must not be more than 0.8 mm (0.03 inch). If the total clearance is less than 0.8 mm (0.03 inch), the addition of shims between the stick and the boom will not be required. If the total clearance is more than 0.8 mm (0.03 inch), add the correct thickness of shims in order to obtain the necessary clearance.
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   Table 34

   For Reach
   Shim	Part Number	Outside Diameter in (mm)	Inside Diameter in (mm)	Thickness in (mm)
   PT4- (2)	093-0108	260 mm (10.2 inch)	132 mm (5.2 inch)	2.0 mm (0.08 inch)
   PT4- (3)	093-0076	260 mm (10.2 inch)	132 mm (5.2 inch)	1.0 mm (0.04 inch)
   PT4- (4)	151-0653	260 mm (10.2 inch)	132 mm (5.2 inch)	0.5 mm (0.02 inch)

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   Table 35

   For Mass
   Shim	Part Number	Outside Diameter in (mm)	Inside Diameter in (mm)	Thickness in (mm)
   PT4- (2)	093-0109	280 mm (11.0 inch)	142 mm (5.6 inch)	2.0 mm (0.08 inch)
   PT4- (3)	093-0077	280 mm (11.0 inch)	142 mm (5.6 inch)	1.0 mm (0.04 inch)
   PT4- (4)	158-3852	280 mm (11.0 inch)	142 mm (5.6 inch)	0.5 mm (0.02 inch)

   Note: Shims should be installed on the right side.

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   Illustration 90	g06276474
   (5) 364-4923 Pin As (6) 363-1159 Plate (7) 447-1709 Bolt (8) 451-2175 Hard Washer

6. Lubricate pin assembly (5). Install pin assembly (5) by using plate (6), two bolts (7), and two hard washers (8).
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   Illustration 91	g06294223

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   Illustration 92	g06357588
   Location : PT5 (C) Pin assembly (9) 093-0108 Shim (10) 093-0076 Shim (11) 151-0653 Shim

7. Slide the stick cylinder to one side until the stick cylinder contacts the frame. Measure the total clearance between the stick cylinder and the frame at the pin bore. The total clearance of (a) and (b) may not be more than 1.0 mm (0.04 inch). If the total clearance is less than 1.0 mm (0.04 inch), the addition of shims between the stick cylinder and frame will not be required. If the total clearance is more than 1.0 mm (0.04 inch), add the correct thickness of shims in order to obtain the necessary clearance.
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   Table 36

   Shim	Part Number	Outside Diameter in (mm)	Inside Diameter in (mm)	Thickness in (mm)
   PT5- (9)	093-0108	260 mm (10.2 inch)	132 mm (5.2 inch)	2.0 mm (0.08 inch)
   PT5- (10)	093-0076	260 mm (10.2 inch)	132 mm (5.2 inch)	1.0 mm (0.04 inch)
   PT5- (11)	151-0653	260 mm (10.2 inch)	132 mm (5.2 inch)	0.5 mm (0.02 inch)

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   Illustration 93	g06276487
   (12) Grease hose assembly (13) 7Y-9267 Spacer (14) 367-1455 Pin As (15) 453-2853 Bolt (16) 201-2771 Washer (17) 451-2177 Hard Washer

8. Attach rod end of the stick cylinder group to stick assembly by using spacer (13), pin assembly (14), bolt (15), washer (16), and hard washer (17).

9. Connect grease hose assembly (12).
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   Illustration 94	g06276519
   (18) Hose assembly

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   Illustration 95	g06244824
   Type of sticks (A) Clearance between the hose and top Plate (B) Clearance between the hose and side plate (C) Clearance between the hose and bottom plate

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

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   Hot hydraulic oil under high pressure can remain in the components of the hydraulic system or the power train system after the engine has been stopped. The uncontrolled release of the hydraulic oil can cause sudden machine movement and can also result in the following conditions: Burns The penetration of body tissue Other personal injury Death If hydraulic oil penetrates body tissue, the injury must be treated immediately by a doctor who is familiar with this type of injury. Use a board or a piece of cardboard to check for a hydraulic oil leak. Make sure that all of the attachments have been lowered to the ground and that all trapped pressure has been released from the hydraulic system and the power train system. Also, make sure that the hydraulic oil is cool before the removal of any components or lines. Remove the hydraulic oil filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand.

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   NOTICE
   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, PERJ1017, "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.

10. The hose assemblies (18) should be adjusted based on the adjustment procedure below:

    Adjust the hose routing by keeping the clearance between hose and structure. Refer to Table 37 for the required clearance on each portion.

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    Table 37

    Model	Stick Length	Part Number	Type	A		B		C
    				RH	LH	RH	LH	RH	LH
    390F	5.5 m (18.04 ft)	357-4766, 506-0429	1	-	-	-	-	54 mm (2.1 inch)	56 mm (2.2 inch)
    	4.4 m (14.43 ft)	357-4767, 506-0430	2	-	-	47 mm (1.8 inch)	53 mm (2.1 inch)	-	-
    	3.7 m (12.14 ft)	382-7326, 527-1952	3	26 mm (1.0 inch)	35 mm (1.4 inch)	-	-	-	-
    	2.92 m (9.580 ft)	384-2102, 527-1953	3	85 mm (3.3 inch)	85 mm (3.3 inch)	-	-	-	-
    	M 2.92 m (9.580 ft)	366-6288, 384-2102, 504-6350	3	63 mm (2.5 inch)	51 mm (2.0 inch)	-	-	-	-
    	3.4 m (11.15 ft)	384-2101, 384-2103, 504-6349, 527-1954	4	-	-	61 mm (2.4 inch)	62 mm (2.4 inch)	-	-

If CPM is installed, Rotary Position Sensor needs to be Installed

Installation Procedure for Stick Rotary Position Sensor

Note: The center of Rotary Position Sensor (RPS) must be aligned with the center of the boom and stick pins by using the special tools.

Table 38

Required Tools
Tool	Part Number	Part Description
G	376-3072	Alignment Tool

Reference: Special Instruction, REHS7312, "Instructions for Installing Rotary Position Sensor for Cat^® Grade Control on Certain Series E and Series F Excavators"

Mounting sensor must be required for Installing the Rotary Position Sensor.

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Illustration 96	g06370399
(1) Pin (2) 415-7074 Plate As (3) Rotary position sensor (4) Alignment tool (jig)

1. Attach alignment tool (4) and mount plate (2) to pin (1). Refer to the Illustration 96.
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   Illustration 97	g06370408
   (2) 415-7074 Plate As (5) Bolt

2. Attach the mount plate (2) and hand tighten the two bolts (5). Torque the bolts evenly, taking care that the plate does not rotate. Refer to the Illustration 97.

   Note: The mount plate must be mounted using the special alignment tool (jig).

3. Remove alignment tool (4) from pin (1). Mount rotary position sensor (3) over the mount plate (2). Refer to Illustration 96.
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   Illustration 98	g06370412
   (7) 345-1948 Position Sensor Gp (8) 131-3983 Bolt (9) 8T-4224 Hard Washer

4. Install position sensor group (7) by using four bolts (8) and four hard washers (9).
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   Illustration 99	g06325912
   Stick rotary sensor group and lever assembly (10) 415-7071 Lever As (11) 5C-9553 Bolt (12) 9X-8256 Washer

5. Install lever assembly (10) by using two bolts (11) and two washers (12).
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   Illustration 100	g06325915
   Stick rotary position sensor rod assembly (13) 309-5695 Rod As (14) 9X-2039 Screw (15) 8T-4121 Hard Washer

6. Install rod assembly (13) by using two screws (14) and four hard washers (15). (Two hard washers for each bolt).
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   Illustration 101	g06325919
   Illustration of the guard covering the stick rotary position sensor (13 16) 349-2294 Guard As (14 17) 135-8572 Bolt As (15 18) 9D-3769 Grommet

7. Install guard assembly (16) by using grommet (18) (back of cover, not shown) and two bolt assembly (17).

Bucket Install

Reference: Disassembly and Assembly , UENR0165 , "Bucket - Remove and Install"

Illustration 102	g06292439

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Failure to follow the instruction below for the installation of a work tool may result in personal injury or death. Special care must be taken if more than one person is installing the work tool. Confirm the verbal communication and the hand signals that will be used during the installation. Be alert for sudden movement of the front linkage and the work tool. Do not insert fingers into the bores of the support pins when the support pins and the bores are being aligned.

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NOTICE
To facilitate removal of the bucket pins without causing damage to the pins, the bearings, and/or the O-ring seals put the bucket on the floor and the stick in a vertical position, as shown.

Required Parts

Table 39

Required Parts for 390F Excavators
		When raising retaining plate by 3.5 mm (0.14 inch)	When raising retaining plate by 6 mm (0.24 inch)
Bucket linkage pin assembly (1)	New Bolt to be installed	166-1880	166-1880
	Spacer	451-2176	453-2866
Bucket linkage cylinder pin assembly (2)	New Bolt to be installed	166-1880	166-1880
	Spacer	451-2175	453-2865

Inspection

Illustration 103	g06325961
(1) Bucket linkage pin assembly (2) Bucket linkage cylinder pin assembly

Illustration 104	g06311334
Bucket linkage pin assembly (D1) Dimension 1 (D2) Dimension 2 (A) Retaining Plate (B) Bucket (C) Stick (D) Pin (E) Bucket (F) Pin Flag

Illustration 105	g06311343
Bucket linkage cylinder pin assembly (D1) Dimension 1 (D2) Dimension 2 (A) Retaining Plate (B) Bucket (C) Power Link (D) Pin (E) Bucket (F) Pin Flag

Inspect the Bucket linkage pin retaining plate. Note the total clearance (D1) between bucket (or idler link) and retaining plate and (D2) between bucket (or idler link) and pin flag. Refer to Illustrations 104 through 105.

Procedure

Reinstallation of the Retaining Plate and Replacement of the Bolts

When the retaining plate of bucket linkage pin (1) and (2) is reinstalled, ensure the total clearances of (D1) and (D2), is 2 mm (0.08 inch) or more. Refer to Illustrations 104 through 105.

If the total clearance is less than 2 mm (0.08 inch), follow the rework procedure below.

1. Select the appropriate set of "New Bolts to be installed" and "Spacer" to keep the total clearance over 2 mm (0.08 inch). Refer to Tables 39.
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   Illustration 106	g06311365
   (A) "New Bolt to be installed" (B) Washer (C) Retaining Plate (D) Pin (E) "Spacer"

2. Install three "Spacer" between the retainer plate and the pin assembly face, and install three "New Bolts to be installed". Refer to Illustration 106. When installing the bolts, apply the following torques:

   • 166-1880 Bolt 460 ± 60 N·m (339 ± 44 lb ft)

The Clearance Check at Regular Maintenance or Bucket Reinstallation

If bucket linkage pin (1) and (2) has less than 2 mm (0.08 inch) total clearance at (D1) and (D2), refer to Steps 1 and 2. Ensure a clearance of 2 mm (0.08 inch) or more to prevent damage or loosening of retaining plate bolts.

The Additional Procedure of Installing a Bucket on a New Machine

Install the bucket referring to Disassembly and Assembly , UENR0165 , "Bucket - Remove and Install". After that, check the total clearances of (D1) and (D2) in Illustrations 104 and 105 are 2 mm (0.08 inch) or more.

If the total clearance is less than 2 mm (0.08 inch), ensure that proper procedures were taken when installing the bucket.

If the customer wants to install Non-CAT bucket, Non-CAT quick coupler or Non-CAT attachment, check the total clearances of (D1) and (D2) in Illustrations 104 and 105. Ensure that the dimensions are 2 mm (0.08 inch) or more after installation. Installation without verification of this check, can result in the retaining plate bolts breaking or loosening and the claim will not be accepted.

Bucket Install Procedure

1. Clean each pin and each pin bore. Lubricate each pin bore with molybdenum grease.
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   Illustration 107	g03822729

2. Position the O-ring seals (1) onto the flanges of the bucket.
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   Illustration 108	g06276630

3. Start the engine and lower the stick into the bucket until the pin bores are in alignment with each other. Stop the engine.
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   Illustration 109	g06276631
   Typical example (2) 441-0038 Pin As (3) 212-3088 Pin As

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   Illustration 110	g06276636
   Typical example (2) 441-0038 Pin As (3) 212-3088 Pin As (4) 480-9882 Plate (5) 480-9885 Plate (6) 447-1707 Bolt (7) 453-5032 Hard Washer (8) 447-1720 Bolt (9) 453-2866 Hard Washer

4. Insert support pin assembly (2) into the bore. Make sure that the flange of the support pin rest inside the support on the side of the bucket.

5. Install retaining plate (4) by using three bolt (8) and three hard washers (9). Tighten the bolts (8) evenly.

6. Slide O-ring seals (1) in position over the pin joints between the bucket and the stick.

7. Insert support pin assembly (3) into the bore. Make sure that the flange of the support pin rest inside the support on the side of the bucket.

8. Install retaining plate (5) by using three bolt (6) and three hard washers (7). Tighten the bolts (6) evenly.

9. Slide O-ring seals (1) in position over the pin joints between the bucket and the link assembly.

10. Lubricate the bucket pins. Refer to Operation and Maintenance Manual, "Bucket Linkage - Lubricate" or Operation and Maintenance Manual, "Boom, Stick, and Bucket Linkage - Lubricate".

Hydraulic System Oil Level - Check/Fill

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NOTICE
Never remove the fill/vent plug from the hydraulic tank if the oil is hot. Air can enter the system and cause pump damage.

1. Park the machine on level ground. Place the machine in the servicing position.
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   Illustration 111	g01137399
   (A) High temperature range (B) Low temperature range

2. For a cold machine, maintain the hydraulic oil level in the low temperature range. For a machine that is at normal operating temperature, maintain the hydraulic oil level in the high temperature range.

3. The hydraulic fill cap is located on top of the Hydraulic tank.
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   Illustration 112	g03241858

   Note: Refer to Operation and Maintenance Manual, "General Hazard Information" for information on containing fluid spillage.

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   Pressurized system! The hydraulic tank contains hot oil under pressure. To prevent burns from the sudden release of hot oil, relieve the tank pressure with the engine off by slowly turning the cap approximately 1/8 of a turn until the cap reaches the secondary stop.

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   Illustration 113	g02275615
   Filler cap (A) LOCK position (B) PRESSURE RELEASE - START position (C) PRESSURE RELEASE - END position (D) OPEN position

4. Release the pressure that may be present in the return hydraulic circuit with the following procedure. Refer to Illustration 113 for filler cap positions.

   1. Turn the filler cap counterclockwise, with no downward force applied, and move the arrow from position (A) to position (B).

   2. Release the pressure for a minimum of 45 seconds by moving the arrow from position (B) to position (C).

   3. Push the center of the filler cap down. Without tilting the filler cap, move the arrow from position (C) to position (D).

   4. The hydraulic tank pressure is relieved. The filler cap can now be removed if needed.

5. Fill the hydraulic system oil tank.

6. Tighten the filler cap on the hydraulic tank to position (A).

7. After the pressure is relieved, tighten the filler cap.

Lubrication - Boom/Stick/Bucket

Note: Before greasing, ensure all grease lines are connected correctly.

Note: Caterpillar recommends the use of 5% molybdenum grease for lubricating the boom, stick, and bucket linkage. Refer to Special Publication, SEBU6250, "Caterpillar Machine Fluids Recommendations" for more information on molybdenum grease.

Illustration 114	g06368759

Wipe all fittings before you apply lubricant.

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Illustration 115	g01122104

1. Apply lubricant through the fitting at the base of each boom cylinder.
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   Illustration 116	g00685798

2. The fittings are at the base of the boom. The fittings can be serviced from the platform on the storage box. To lubricate the lower boom bearings, apply lubricant through fittings (1) and (2). To lubricate the boom cylinder rod, apply lubricant through fittings (3) and (4). To lubricate the stick cylinder head, apply lubricant through fitting (5).

   Note: To ensure proper lubrication of the lower boom bearings and of the boom cylinder rod end bearings, lubricant should be applied through fittings (1), (2), (3), and (4). Apply lubricant first when the boom is raised and any work tool is suspended. Then apply lubricant when the boom is lowered and the work tool is rested on the ground with a slight downward pressure.

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   Illustration 117	g01396856

3. Apply lubricant through fittings (6) and (7). These fittings are on the bucket.

4. Apply lubricant through fittings (8) and (9). These fittings are on the stick.

5. Apply lubricant through fittings (10), (11), and (12). These fittings are on the link.

Grease Block on the Stick

Illustration 118	g01396894
(13) Left side connection point of boom and stick (14) Stick cylinder rod (15) Right side connection point of boom and stick (16) Bucket cylinder head end

Some machines may be equipped with a grease block that is located on the stick. Apply lubricant through the fittings.

Air Bleed

The cylinders and hydraulic lines that were assembled may contain the air.  The following step shows the procedure of air bleed from the hydraulic circuit.

1. Start the engine.

2. Place the hydraulic activation control lever in the UNLOCKED position.

3. Place the machine controls at the following settings: engine speed dial “1” and AEC switch OFF.

4. Move the joystick slowly to each direction several times for bleeding air from the circuit.

5. Return the joystick to the NEUTRAL position.

6. Stop the engine.

7. Check hydraulic system oil level and fill if needed. Refer to Section "Hydraulic System Oil Level - Check/Fill".

Operational Check/Test

Visual Inspection

A visual inspection of the system is the first step. Check all cylinders / lines / components / harnesses / etc, if there is no oil leakage, bolt loosening, interference, etc.

Hydraulic System Warm-Up

Engine and Machine Warm-Up

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NOTICE
Keep engine speed low and do not operate until the message 'Warm-Up Mode Power Derate" on the monitor goes out. If it does not go out within thirty seconds, stop the engine and investigate the cause before starting again. Failure to do so, can cause engine damage.

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NOTICE
Always run the engine at low idle for at least ten minutes before performing any other operations in cold conditions or each time the engine oil and oil filter are changed in order to protect your engine and hydraulic components.

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NOTICE
Depending on the ambient temperature, in order to prevent the machine operation with high speed without sufficient lubrication at the turbo bearing, the engine speed may be set to low speed and the hydraulic power minimized for a pre-determined time after the engine starts. Refer to turbo protection feature.

The engine may automatically change speeds when the machine is stationary and idling in cold ambient temperature for an extended time. This is to:

• Maintain desired coolant temperature.

• Maintain desired operation of engine systems.

• Maintain desired operation of the regeneration system.

During extended idling in cold ambient conditions, engine speed may operate between 900 rpm and 1000 rpm. Operation at 1000 rpm is minimal and will only last for up to 20 minutes. The regeneration active indicator may also illuminate during extended idling conditions to signal that a regeneration is in progress.

Hydraulic System

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When you cycle the machine controls, the machine can move suddenly. Contact between the machine and external objects or ground personnel can result in serious injury or death. Before you cycle the machine controls, the machine should be located in an unobstructed, hazard-free work area that is away from external objects and ground personnel.

1. Make sure that the area is clear of personnel and equipment.

   Note: The hydraulic lockout control must be in the UNLOCKED position before the hydraulic controls will function.

2. Allow the engine to warm up at low idle for at least 5 minutes. Engage the work tool controls and disengage the work tool controls. This will speed up the warm-up of the hydraulic components.

   When you idle the machine for warm-up, observe the following recommendations:

   • If the temperature is greater than 0°C (32°F), warm up the engine for approximately 15 minutes.

   • If the temperature is less than 0°C (32°F), warm up the engine for approximately 30 minutes.

   • If the temperature is less than − 18°C (0°F) or if hydraulic functions are sluggish, additional time may be required.
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   NOTICE
   The hydraulic oil temperature should be higher than 25 °C (77 °F) before performing work with the machine. Make sure that the warm-up procedure is performed. If the hydraulic oil temperature is less than 25 °C (77 °F) and the machine is operated abruptly, serious damage to the hydraulic components may occur.

   Note: The recommended operating temperature of the hydraulic fluid for this machine is 55 °C (131 °F).

3. To warm up the hydraulic oil, turn the engine speed dial to the medium engine speed. Run the engine for approximately 5 minutes and move the joystick intermittently from the BUCKET DUMP position to the HOLD position. Do not hold the joystick in the BUCKET DUMP position with the bucket cylinder fully extended for more than 10 seconds.

   This allows the oil to attain relief pressure, which causes the oil to warm up more rapidly.

   Note: If the joysticks are held for more than 30 seconds, the machine ECM will go into a "Warm-Up Mode Power Derate" setting. "Warm-Up Mode Power Derate" will be shown on the monitor screen. When "Warm-Up Mode Power Derate" is active, the machine ECM limits the hydraulic pump torque to 50 percent. Release the joysticks in order to cancel the "Warm-Up Mode Power Derate" setting.

4. Turn the engine speed dial to the maximum engine speed and repeat step 3.

5. Cycle all controls in order to circulate warm oil through all hydraulic cylinders and all hydraulic lines, and through the swing motor and travel motors.

6. Observe the gauges and the indicators frequently during the operation.

Turbo Protection Power Derate - After an engine start, the engine speed will be set to dial one position and the hydraulic power limited for a time period . During this period, the monitor displays the message "Warm -Up Mode Power Derate". (Maximum is around 30 seconds). After the turbo bearing lubrication is sufficient, the engine speed goes to the setting dial speed and the monitor stops to display the message.

Hydraulic System Automatic Warm-up

Hydraulic System Automatic Warm-up - When the hydraulic oil is below operating temperature, the automatic warm-up function will automatically circulate hydraulic oil through the hydraulic circuits. Circulating the hydraulic oil through the hydraulic circuits will accelerate the warm-up of the hydraulic oil.

Note: The automatic warm-up feature can be enabled or disabled through the monitoring system. consult your Cat dealer for additional information.

The following conditions must be met in order for the automatic warm-up to operate after the machine has been started:

• Automatic Hydraulic System Warm-up function must be enabled

• Hydraulic Lockout Control is in the LOCKED position

• Hydraulic oil temperature is below operating temperature.

When conditions are met, a "START AUTO WARMING UP?" message will appear on the monitor and a hydraulic warm-up icon will appear as a selection on the monitor.

1. Lower the work tools to the ground and place the hydraulic lockout control in the LOCKED position.

2. Press the automatic warm-up key on the monitor.

3. Press the automatic warm-up key again in order to start the automatic warm-up function.

   Note: A "AUTO WARMING UP STARTING" message will appear on the monitor when the automatic warm-up function is active.

The automatic warm-up will stop once the temperature of the hydraulic oil has reached operating temperature or when the hydraulic lockout control is moved to the UNLOCKED position.

Note: If any warning message or system event message are active on the monitor, "AUTO WARMING UP" cannot be active. If any event occurred during "AUTO WARMING UP", the system is stopped.

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Always make sure that the work tool is lowered to the ground and deactivate all work tools before activating the Hydraulic System Automatic Warm-up. Activating the system with the work tool not on the ground could result in unexpected machine movement which could result in personal injury or death.

Dynamic Cool Engine Elevated Idle (DCEEI)

The Dynamic Cool Engine Elevated Idle (DCEEI) feature will temporarily increase the low idle engine speed when the engine coolant is below normal operating temperature. Increasing the low idle speed will accelerate the warm-up of the engine and fluids. When the engine coolant reaches normal operating temperature, the engine speed returns to the low idle speed.

Extended periods of low engine idle can also result in lower coolant temperatures. During extended periods of low engine idle, the engine idle speed will automatically increase if the engine coolant drops below the operating temperature. This increase in the engine idle speed will prevent overcooling of the engine.

Improve Cold Weather Performance

Covers installed over the vents in the radiator compartment door will help to control overcooling in ambient temperatures below −15° C (5° F).

The materials used for the covers and the method used to install the covers is at the installers discretion.

Install the covers if overcooling is observed while the machine is idling in ambient temperatures below −15° C (5° F).

Stop the machine, and remove the covers under the following conditions:

• The ambient temperature is above −15° C (5° F).

• The engine temperature gauge indicates overheating.

• The hydraulic oil temperature gauge indicates overheating.

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Illustration 119	g03707408
Typical example of cover location on the radiator compartment door (1) Covers

1. Clean the surface of the radiator compartment door.

2. Install the covers in the location shown in Illustration 119. The covers should fully cover the door vents.

Operational Check / Test

The operational checks can be used to find leakage in the system and components that are not functioning correctly. The speed of rod movement or the torque on a motor can be used to check the condition of the cylinders, motors, and the pumps. Perform the following operational checks in order to troubleshoot problems concerning the hydraulic circuits and components on the machine. The following operational checks should be performed under the following conditions:

• Engine Speed Dial "10"

• AEC switch OFF

• High Power (HP) Mode

Note: The following operational checks should be performed with the hydraulic oil temperature at 55° ± 5°C (131° ± 9°F).

• Testing and Adjusting, "Cylinder Drift - Check (Empty Bucket)"

• Testing and Adjusting, "Cylinder Drift - Check (Loaded Bucket)"

• Testing and Adjusting, "Cylinder Speed - Check"

Cylinder Drift - Check (Empty Bucket)

Table 40

"Cylinder Drift - Check (Empty Bucket)"
Item	Cylinder Position	Factory Inspection Standard	Actual
Boom Cylinder	Extended	6.0 mm (0.24 inch) or less
Stick Cylinder	Retracted	10.0 mm (0.39 inch) or less
	Extended	25.0 mm (0.98 inch) or less
Bucket Cylinder	Extended	10.0 mm (0.39 inch) or less
	Retracted	20.0 mm (0.79 inch) or less

The performance level of the cylinder, the cylinder seals, and the overload relief valves for the implements can be determined with the following procedure.

Note: The machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Table 41

Description	Qty
Measuring Tape	1
Stopwatch	1

Illustration 120	g00298378

Position the machine on level ground. Empty the bucket. Refer to Illustration 120.

1. Fully extend the bucket cylinder.

2. Fully retract the stick cylinder.

3. Extend the stick cylinder rod 70 mm (2.8 inch) from the fully retracted position.
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   Illustration 121	g01402004

4. Raise the boom until the stick to bucket pin is the same height as the boom foot pin. Refer to Illustration 121.

5. Measure each cylinder length from cylinder pin to cylinder pin.

6. Stop the engine.

7. Leave the machine in this position for 5 minutes. Measure each cylinder length from cylinder pin to cylinder pin for drift.

1. Start the engine.

2. Fully extend the bucket cylinder.

3. Fully extend the stick cylinder.

4. Retract the stick cylinder rod 60 mm (2.4 inch) from the fully extended position.
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   Illustration 122	g01401745

5. Raise the boom until the stick to bucket pin is 600.0 mm (23.6 inch) high from ground level. Refer to Illustration 122.

6. Measure the stick cylinder length from cylinder pin to cylinder pin.

7. Stop the engine.

8. Leave the machine in this position for 5 minutes. Measure the stick cylinder length from cylinder pin to cylinder pin for drift.

1. Start the engine.

2. Fully retract the bucket cylinder.

3. Fully retract the stick cylinder.
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   Illustration 123	g01401747

4. Raise the boom until the stick to bucket pin is 600.0 mm (23.6 inch) high from ground level. Refer to Illustration 123.

5. Measure the bucket cylinder length from cylinder pin to cylinder pin.

6. Stop the engine.

7. Leave the machine in this position for 5 minutes. Measure the bucket cylinder length from cylinder pin to cylinder pin for drift.

Cylinder Speed - Check

Table 42

"Cylinder Speed - Check"
Item	Cylinder Position	Cylinder Operating Speed (seconds)
		Factory Inspection Standard	Actual
Boom(1)	Extension	5.8 ± 0.5
	Retraction	3.0 ± 0.3
Boom(2)	Extension	6.0 ± 0.5
	Retraction	3.1± 0.3
Stick	Extension	4.7 ± 0.3
	Retraction	3.7 ± 0.3
Bucket(3)	Extension	4.2 ± 0.3
	Retraction	2.5 ± 0.3
Bucket(4)	Extension	4.9 ± 0.3
	Retraction	3.1 ± 0.3

(1)	Reach / General
(2)	Mass
(3)	HB2 - Family
(4)	JC - Family

The performance level of the cylinders and the hydraulic oil flow through the system to the implements can be determined by the following procedure.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Table 43

Description	Qty
Stopwatch	1

1. Perform the following steps in order to test the operating speed of the boom cylinders.
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   Illustration 124	g00298498
   (A) Extension test (B) Retraction test

   1. Place the machine on level ground.

   2. The bucket should be empty.

   3. Fully retract the bucket cylinder and the stick cylinder.

   4. Position the bucket on the ground. With a stopwatch, measure the time that is required to extend the boom cylinders to full extension.

   5. Position the boom cylinders at full extension. With a stopwatch, measure the time that is required for the bucket to come in contact with the ground.

   6. Refer to the specifications in Table 42 for the operating speed of the boom cylinders.

2. Perform the following steps in order to test the operating speed of the stick cylinder.
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   Illustration 125	g03649253
   (A) Extension test (B) Retraction test

   1. Place the machine on level ground.

   2. The bucket should be empty.

   3. Position the upper surface of the boom parallel to the ground.

   4. Fully retract the bucket cylinder.

   5. Retract the stick cylinder. With a stopwatch, measure the time that is required to extend the stick cylinder to full extension.

   6. Extend the stick cylinder. With a stopwatch, measure the time that is required to retract the stick cylinder to full retraction.

   7. Refer to the specifications in Table 42 for the operating speed of the stick cylinder.

3. Perform the following steps in order to test the operating speed of the bucket cylinder.
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   Illustration 126	g00298598
   (A) Extension test (B) Retraction test

   1. Place the machine on level ground.

   2. The bucket should be empty.

   3. Position the upper surface of the boom parallel to the ground.

   4. Position the stick so that the stick is perpendicular to the ground.

   5. Fully retract the bucket cylinder.

   6. With a stopwatch, measure the time that is required to extend the bucket cylinder to full extension.

   7. Position the bucket cylinder at full extension. With a stopwatch, measure the time that is required to retract the bucket cylinder to full retraction.

   8. Refer to the specifications in Table 42 for the operating speed of the bucket cylinder.

Swing Speed and Overswing on Level Ground - Check

Table 44

"Swing Speed and Overswing on Level Ground - Check"
Item	New	Rebuild	Service Limit	Actual
Swing Speed (three Revolutions) (seconds)
Right Swing	29.3 ±1.0	35.0 or less	38.0 or less
Left Swing
Swing Acceleration on Level Ground (seconds)
Right Swing	6.8 or less	7.9 or less	8.9 or less
Left Swing
Overswing mm (inch)
Right Swing	1000 mm (39.4 inch) or less	1150 mm (45.3 inch) or less	1300 mm (51.2 inch) or less
Left Swing

Measuring the swing speed and the overswing of the machine will determine if there is a need to check the swing motor. The fine swing control switch (if equipped) must be in the OFF position.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Table 45

Required Tools
Description	Qty
Measuring Tape	1
Stopwatch	1

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Illustration 127	g00297618

1. Position the machine on level ground. Refer to Illustration 127.

   Note: The bucket should be empty.

2. Swing the machine in either direction. Use a stopwatch to count the swing time for three revolutions.

   Note: Begin counting swing time after one full revolution has been completed.

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Illustration 128	g00297618

1. Position the machine on level ground. Refer to Illustration 127.

   Note: The bucket should be empty.

2. Stop the engine.
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   Illustration 129	g00293972
   (A) Upper frame (B) Undercarriage frame (C) Marking

3. To indicate the relationship of the two positions, put a mark (C) on the inner race and the outer race of the swing bearing. The mark will be used as a target to stop the swing operation. Refer to Illustration 129.

4. Start the engine.

5. Move the swing joystick in either direction until the machine completes a 180 degree swing operation away from the target.

6. Move the swing joystick in either direction until the machine completes a 180 degree swing operation toward the target. Return the swing joystick to the NEUTRAL position at the target.

7. Measure the amount of overswing by measuring the distance between the marks on the swing bearing. Refer to Illustration 129.

   Note: Use a point that is visible from the operator seat as a reference point for the target.

Swing Speed and Swing Drift on a Slope - Check

Table 46

"Swing Speed and Swing Drift on a Slope"
Swing Time (seconds)
Item	New	Rebuild	Service Limit	Actual
Right Swing	5.2 or less	6.0 or less	6.8 or less
Left Swing
Swing Drift mm (inch)
Item	New	Rebuild	Service Limit	Actual
Right Swing	0	0	0
Left Swing

Measuring the swing speed on a slope will determine if there is a need to check the swing motor. Measuring the swing drift on a slope will determine if there is a need to check the swing parking brake.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Table 47

Description	Qty
Measuring Tape	1
Stopwatch	1

Illustration 130	g00298078

1. Complete the following steps in order to measure the swing speed on a slope.

   1. The work tool should be empty.

   2. Position the machine on a slope of 12 degrees. Refer to Illustration 130.

   3. Position the implements at maximum reach and close the work tool. Position the work tool above the ground so that the work tool will not come in contact with any obstacles.
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      Illustration 131	g00298079

   4. Position the upper structure at position (A). The upper structure should be at a 90 degree angle to the lower structure. Refer to Illustration 131.

   5. Measure the time that is required to swing the upper structure from position (A) to position (B).

   6. Position the upper structure at position (C). The upper structure should be at a 90 degree angle to the lower structure.

   7. Measure the time that is required to swing the upper structure from position (C) to position (B).

1. Complete the following steps in order to measure the swing drift on a slope.
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   Illustration 132	g00298079

   1. Position the upper structure at position (A). The upper structure should be at a 90 degree angle to the lower structure. Refer to Illustration 132.
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      Illustration 133	g00293972
      (A) Upper frame (B) Undercarriage frame (C) Marking

   2. To indicate the relationship of the two positions, put a mark (C) on the inner race and the outer race of the swing bearing. Refer to Illustration 133.

   3. Stop the engine.

   4. Leave the machine in this position for 3 minutes. Measure the swing drift on the circumference of the swing bearing.

   5. Start the engine.

   6. Position the upper structure at position (C). The upper structure should be at a 90 degree angle to the lower structure. Refer to Illustration 132.

   7. Repeat Steps 1b through 1d.

Travel on Level Ground - Test (Optional Test)

Table 48

"Travel on Level Ground - Test (Optional Test)"
Time For Three Revolutions (time in seconds)
Undercarriage	Travel Speed		New	Rebuild	Service Limit	Actual
						Right	Left
Long	HIGH	Forward	30.3 ± 2.5	35.4 or less	39.0 or less
		Reverse
	LOW	Forward	49.2 ± 2.5	55.4 or less	64.0 or less
		Reverse

When the procedure for the Travel on Level Ground cannot be performed, this test may be used as a substitute.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Table 49

Description	Qty
Stopwatch	1

1. Start the engine.

2. Position the machine on level ground.

3. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).
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   Illustration 134	g00297292

4. Raise a track off the ground. Refer to Illustration 134.

5. Put a mark on a shoe of the raised track.

6. Place the machine controls at the following settings: Engine speed dial "10" and AEC switch OFF.

7. Place the travel speed control switch in HIGH position.

8. Move the travel lever of the raised track to full travel position.

9. Measure the time that is required for the raised track to make three complete revolutions. Measure the time that is required in each direction.

   Note: The difference in times between forward and reverse should not exceed 0.5 seconds for HIGH travel speed and 1.0 seconds for LOW travel speed.

10. Place the travel speed control switch in the LOW position and repeat Steps 8 through 9.

BLCV and SLCV - Calibrate (If Equipped)

Introduction

Use the following procedure to calibrate the Boom Lowering Control Valves and Stick Lowering Control Valve.

Note: Front structures must be installed before completing calibration.

Preliminary Test

• Testing and Adjusting, "Swashplate - Calibrate"

Machine Preparation

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Illustration 135	g03345286

1. Position the machine on level ground. Fully retract the stick cylinder and the bucket cylinder. Retract the boom cylinders until the bucket tip is flat on the ground. Refer to Illustration 135.

Calibration Procedure

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

Note: Machine movement is possible during calibration procedures. The calibration may be aborted by releasing all control levers.

Monitor Procedure

Table 50

Lowering Check Valves

BLCV

SLCV

1. Start the engine.

2. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F). Refer to Testing and Adjusting, "Hydraulic System Warm-up".

3. To perform calibration enter the monitor.

   1. Enter the "Service" menu.

   2. Enter password "9992".

   3. Select "Configurations".

   4. Select "Work Mode".

   5. Set "Hydraulic Power Mode" to "STD".

4. Enter the Service Menu.

   1. Enter service password "9992".

5. Select "Calibration" menu.

6. Select "Lowering Check Valves" from the "Calibrations" menu. Refer to Table 50 for appropriate calibration.

7. Follow the instructions on the monitor to complete the calibration.

8. If the calibration was successful and no errors occurred, the display will indicate the calibration is complete.

   Note: The "Error" screen will be displayed on the monitor if an error occurs. The process of the calibration will not be saved and the process must be restarted.

ET Procedure

Table 51

ACS Valve Calibrations

Boom Lowering Check Valve

Stick Lowering Check Valve Calibration

1. Start the engine.

2. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F). Refer to Testing and Adjusting, "Hydraulic System Warm-up".

3. Select the ECM for "Machine Control".

4. Select "Calibrations" from the "Service" menu.

5. Select appropriate calibrations to complete. Refer to Table 51.

6. Select "Start".

7. Follow the instructions on the screen to complete the calibration.

8. If no error occurs, the calibration was completed successfully.

Calibration/Accuracy Check (If CPM is Equipped)

If the machines have CPM, CGC / CPM calibration and accuracy check are required.

Refer to Special Instruction , M0069506 , "Procedure to Remove and Install Front Structure, Remove and Install Stick and Boom Rotary Position Sensors, and Calibrate Cat ^® Grade Control, for 374F and 390F".

Grade Control Calibration

Note: Only the front linkage calibration and the individual linkage sensor calibrations are required. Body sensor calibration is not required.

1) Perform the front linkage calibration procedure

Refer to Testing and Adjusting , UENR1725 , "Cat ^® Grade Control Depth & Slope for E-Series and F-Series Excavators" , System - Calibrate "Front Linkage Calibration".

Note: The purpose of this calibration is to provide an initial calibration for the system to calculate linkage angles by mapping sensor output signals to default boom angles, stick angles, and cylinder lengths based on nominal print dimensions.

2) Perform the individual linkage sensor calibration procedure. Calibrate the boom sensor, stick sensor, and bucket sensor

Refer to Testing and Adjusting , UENR1725 , "Cat ^® Grade Control Depth & Slope for E-Series and F-Series Excavators" , System - Calibrate "Individual Linkage Sensor Calibration".

3) Perform the Bucket measure-up

Refer to Testing and Adjusting , UENR1725 , "Cat ^® Grade Control Depth & Slope for E-Series and F-Series Excavators" , Machine Dimensions - Configure "Configuring Cat ^® Grade Control with New Simplified Bucket Measure-Up Software Released April 2014and Later".

4) Perform the Accuracy Check

Refer to Testing and Adjusting , UENR1725 , "Cat ^® Grade Control Depth & Slope for E-Series and F-Series Excavators" , System - Calibrate "Accuracy Verification and Troubleshooting Procedures".

System Accuracy - Test

Testing System Accuracy. Multiple methods exist to test the accuracy of the Cat Grade Control system.

Refer to Testing and Adjusting , UENR1725 , "Cat ^® Grade Control Depth & Slope for E-Series and F-Series Excavators" , System Accuracy - Test.

Production Measurement Calibration

Perform the calibration for Cat Production Measurement.

Refer to Operation and Maintenance Manual , SEBU8588 , Production Measurement Application Calibration.

Note: CPM auto calibration tooling is available. Refer to Special Instruction , M0076968 , "Cat Production Measurement System (CPM) Auto Calibration Procedure for certain 336F XE, 349F XE, 374F, and 390F Excavator".

Pre-Delivery Inspection

Perform Pre-Delivery Inspection before shipping the machine to the customer job site.

Caterpillar Excavators, Loggers, Front Shovels, Forestry Swings

Predelivery Inspection (PDI) / Revisit Checklist

Table 52

Type	Dealer Code	Work Order No.	Date	Employee ID	Model	Serial No.
Hours	Inspector Name

1. If the machine was in storage, engine needs pressure lubrication before it is started.

2. For cold weather starts, see Cold Weather Operation Form SEBU5898.

3. All Safety Product Improvement Programs (PIP) must be completed.

4. Explanation for this form are in Special Instructions Form , SEHS8298.

Table 53

"Cylinder Drift - Check (Empty Bucket)"
Item	Cylinder Position	Factory Inspection Standard	Actual
Boom Cylinder	Extended	6.0 mm (0.24 inch) or less
Stick Cylinder	Retracted	10.0 mm (0.39 inch) or less
	Extended	25.0 mm (0.98 inch) or less
Bucket Cylinder	Extended	10.0 mm (0.39 inch) or less
	Retracted	20.0 mm (0.79 inch) or less

Table 54

"Cylinder Speed - Check"
Item	Cylinder Position	Cylinder Operating Speed (seconds)
		Factory Inspection Standard	Actual
Boom(1)	Extension	5.8 ± 0.5
	Retraction	3.0 ± 0.3
Boom(2)	Extension	6.0 ± 0.5
	Retraction	3.1± 0.3
Stick	Extension	4.7 ± 0.3
	Retraction	3.7 ± 0.3
Bucket(3)	Extension	4.2 ± 0.3
	Retraction	2.5 ± 0.3
Bucket(4)	Extension	4.9 ± 0.3
	Retraction	3.1 ± 0.3

(1)	Reach / General
(2)	Mass
(3)	HB2 - Family
(4)	JC - Family

Table 55

"Swing Speed and Overswing on Level Ground - Check"
Item	New	Rebuild	Service Limit	Actual
Swing Speed (three Revolutions) (seconds)
Right Swing	29.3 ±1.0	35.0 or less	38.0 or less
Left Swing
Swing Acceleration on Level Ground (seconds)
Right Swing	6.8 or less	7.9 or less	8.9 or less
Left Swing
Overswing mm (inch)
Right Swing	1000 mm (39.4 inch) or less	1150 mm (45.3 inch) or less	1300 mm (51.2 inch) or less
Left Swing

Table 56

"Swing Speed and Swing Drift on a Slope"
Swing Time (seconds)
Item	New	Rebuild	Service Limit	Actual
Right Swing	5.2 or less	6.0 or less	6.8 or less
Left Swing
Swing Drift mm (inch)
Item	New	Rebuild	Service Limit	Actual
Right Swing	0	0	0
Left Swing

Table 57

"Travel on Level Ground - Test (Optional Test)"
Time For Three Revolutions (time in seconds)
Undercarriage	Travel Speed		New	Rebuild	Service Limit	Actual
						Right	Left
Long	HIGH	Forward	30.3 ± 2.5	35.4 or less	39.0 or less
		Reverse
	LOW	Forward	49.2 ± 2.5	55.4 or less	64.0 or less
		Reverse

Table 58

System	Visual Inspection	Service Points & Fluid Levels	Operation	After Operation
Engine	__ Paint __ Outside Damage	__ Oil __ Coolant __ Fuel __ Batteries OCV > (12.45)_____ VDC1 _____ VDC2 __ Air Filter __ Drain Water from Fuel Tank __ Drain Water Separator __ Open Coolant Conditioner Valves __ Grease Fittings	__ Priming Pump __ Governor Control __ Smoke Color __ Unusual Noise	__ Air Cleaner Indicator __ Clean Pre-cleaner Bowl __ V-Belt Tension __ Leaks - Oil, Fuel, Coolant __ Friction on Hoses __ Friction on Wires __ Loose Wire Connections __ Loose or Lost Fasteners
Power Train	__ Paint __ Outside Damage __ Tires- Cuts, Gouges	__ Final Drive __ Pump Drive __ Swing Gear Grease __ Swing Drive __ Tire Pressure (1) __ Differentials (1) __ Drive Shafts (1) __ Stabilizers (1) __ 90° Drive Boxes (1) __ Grease Fittings	__ Transmission __ Travel Alarm and Shutoff __ Steering __ Hydraulic Lever Lock __ Parking Brake __ Swing __ Swing Brake __ Swing Lock __ Unusual Noise/Vibration	__ Leaks - Oil __ Loose or Lost Fasteners __ Tires - Cuts, Gouges (1)
Chassis & Undercarriage	__ Sheet Metal __ Paint __ Damage	__ Adjust Track Tension (2) __ Grease Fittings __ Torque on Track Roller Frame Bolts (245 Re-assembly) (2)	__ Enclosure Door - Locks & Latches	__ Track Tension (2) __ Leaks - Oil __ Loose or Lost Fasteners __ Welds
Hydraulic	__ Cylinder Rods	__ Hydraulic Tank __ Grease Fittings	__ Controls __ Too Much Drift __ Unusual Noise	__ Leaks - Oil __ Friction on Hoses __ Loose or Lost Fasteners
Boom, Stick, Linkage, Bucket	__ Paint __ Damage __ Ground Engaging Tools	__ Clam Shell Rotator Gear Drive __ Grease Fittings __ All Pins Installed and Lubricated (245 Re-assembly) (2)	__ Boom and Stick __ Shovel, Bucket or Logger	__ Welds __ Loose or Lost Fasteners __ Damage __ Ground Engaging Tools
Cab	__ Sheet Metal __ Paint __ Glass	__ Windshield Washer __ Air Filters	__ Disconnect Switch __ Electronic Monitoring System __ Horn __ Seat Belts __ Seat Adjustments __ All Switches & Controls __ Doors & Windows __ Locks & Latches __ Mirrors Adjustment __ Windshield Wipers __ Windshield Washers __ Heater __ Air Conditioner/Pressurizer __ Lights - Outside & Cab __ Gauges __ Unusual Noise	__ Operation Guide __ Maintenance Guide __ Parts Book __ Seat Cover __ Steps & Grab Irons __ Loose or Lost Fasteners __ Leaks - Water
Misc & Attachments	__Special Assembly Parts __ S/N Plates __ Correct Attachments __ Hand Tools __ Paint	__ Attachment Fluid Levels __ Charge on Fire Suppression System __ Grease Fittings	__ Attachments __ Fire Suppression Test Switch __ Unusual Noise	__ Warning Plates __ Decals __ Leaks __ Loose or Lost Fasteners
Product Link (If Applicable)	__Antenna Installed Correctly __Configuration Reviewed __PL Harness Plugged on PL ECM Correctly		__PL Unit Registered __PL Unit Registration Confirmed

(1)	Pneumatic Tired Units
(2)	Track Type Units

Table 59

390F Machine (series number _____________) conduct and pass all the required performance check.
Date:	Signature:
	Name:

After checking the machine performance and inspecting the machine, report the inspection data through SIMSi.

1. Go to SIMSi at the following address.
   https://sims.cat.com/sims/simsi/index.jsp
   

   Note: CWS ID is required for SIMSi.

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   Illustration 136	g06417701

2. Click "Service Reporting" on the top menu.

3. Click "Report Service" on the left side menu.

4. Input all of the following required information as shown in Illustration 136.

   • Part Causing Failures: 7588 (Non-Cat)

   • Qty: 1

   • Group number: 7588 (Non-Cat)

   • Check on check box for "Service is predelivery?"

   • Check on check box for "Non-Failure service (informational)?"

   • Comments: PERFORM - PRE-DELIVE

5. Upload the inspection sheets listed below through "Add Image", refer to Illustration 136.

   • Cylinder Drift check sheet

   • Cylinder Speed check sheet

   • Pre-Delivery Inspection Sheet

6. Submit the inspection data.

Special Instruction for Assembly

Make sure to apply the following “Manufacturing Best Practice” for all installation procedure.

Seal Inspection

Illustration 137	g06230209
(A) Cracking (B) Hardened lubricant (C) Cracking (D) Lip seal - damaged spring (E) Lip seal - dirt lip folded under (F) Lip seal - distorted (does not lay flat on surface)

Complete a visual inspection to the seal looking for damage and contamination. Do not use the seal, if it has obvious signs of deterioration, deformation, and/or contamination like the example Damaged / Degraded as shown in Illustration 137.

Recommended Seal Cleaning

• Chemtool CT Clean 15861 Wipe With Cleaner - Crib Identification 3-0124698, Caterpillar Part Number 169-5420 Cleaner.

• Chemtool Lint-Free Wipes - Crib Identification 3-0080298, Caterpillar Part Number 265-2256 Lint Free Wipes.

• Kimtex Lint-Free Polypropylene Towels - Crib Identification 3-0039125.

• New Pig Low-Lint wipes, Part Number WIP230 or WIP232 from New Pig Corporation.

Seal Assembly / Installation for STOR / ORFS

O-ring sealing depends on proper seating of the seal in the groove, maintaining this condition during assembly of the joint, and proper torque on the connection. Improper assembly practices increase the likelihood of leaking joints.

Best practices should be followed when applying final torque to the seal connections. When necessary, utilize a backup wrench to maintain the orientation of the fitting and/or hose. In some operations, it may be necessary to also include a fixture or bracket to help hold orientation or prevent hose twisting while securing the connections.

When tightening, make the best effort to keep wrench at a 90° angle to the coupling for the most consistent and accurate torque application.

In the event the connection must be re-orientated or re-torqued outside of the initial assembly station, the O-ring should be replaced with a new seal and applied with the proper assembly tools while executing a contaminant free process; this is a recommended best practice

It is NOT recommended to utilize high RPM powered tooling to secure connectors with seals. High RPM tooling procedures increase the likelihood of seals becoming dislodged or damaged during the securing process, therefore it is recommended to utilize reduced RPM tools or manual tools when assembling components with seals.

O-rings may be installed into a fitting/adapter without the use of a tool however; installing a seal without the use of a tool places the seal at extreme risk of damage. It is recommended that appropriate tooling be used for the installation of O-rings.

STOR (Straight Threaded O-Rings)

Illustration 138	g06230224
STOR installation tools (A) Tooling head (B) Head edge

Illustration 139	g06230225
Anatomy of an STOR/ORFS fitting (C) Nut (D) STOR O-ring (E) Washer (F) ORFS O-ring

When installing an O-ring over a threaded fitting, it is critical to protect the seal from damage from threads. To assist the assembly and protect the seal, an installation tool must be used. Refer to Illustration 138 and Illustration 139. The seal protector slides over the threads and allows for an O-ring to be installed, reducing the risk of a leak due to nicks, cuts, gouges, and twisting of the seal.

Table 60

STOR Installation Tool Part Numbers
Fitting Size	CAT Part Numbers
(-3)	336-0739
(-4)	336-0740
(-6)	336-0741
(-8)	336-0742
(-10)	336-0744
(-12)	336-0750
(-14)	336-0767
(-16)	336-0784
(-20)	336-0787

Assembly tool must be used to protect the seal from damage due to thread contact. Threads may cut or tear the seal during installation.

Follow the steps below for proper tool use and assembly of an O-ring onto the STOR end of a fitting/adapter :

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Illustration 140	g06230231
STOR locknut position (G) O-ring must be positioned next to the washer (H) Fitting body (J) Locknut must be in contact with the fitting body (K) Cap where applicable

1. Complete a one second inspection of the seal, fitting, and tool for damage.

   Note: Ensure that the locknut on adjustable STOR fittings is positioned above the O-ring groove as shown in Illustration 140.

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   Illustration 141	g06230236
   Installation of O-ring on tool

2. Place the O-ring over tool.
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   Illustration 142	g06230238
   STOR installation tool on fitting

3. Place the tool over the fitting threads.
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   Illustration 143	g06230239
   Installation of the O-ring in fitting

4. Place the fingers above seal and applying even, steady pressure around the seal. Glide seal onto fitting taking care to prevent twisting. If the O-ring is twisted when seated, it can fail prematurely due to high strain. If a twist is observed, remove the seal and re-install.

   Note: In most cases the O-ring that is to be installed onto a fitting should have PTFE (Teflon) coating. If your facility does not use PTFE (Teflon) coated seals, notify Sealing Center of Excellence (Design Control A623) immediately.

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   Illustration 144	g06230240
   Removal of tool

5. Remove the tooling from fitting.
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   Illustration 145	g06230241
   Inspection of seal seating

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   Illustration 146	g06230243
   Seal placement

6. Inspect the placement (seating) of the seal. Refer to Illustration 145.

   Note: Seal shall be placed over the O-ring groove and resting on washer as shown in Illustration 146.

7. Cap the STOR end for contamination prevention where applicable.

   Note: If the O-ring is twisted when seated it can fail prematurely due to high strain. If a twist is observed, remove the seal and re-install.

ORFS (O-Ring Face Seal)

Illustration 147	g06230254
Anatomy of ORFS O-ring insertion tool (L) Plunger platform

Illustration 148	g06230256
(M) O-ring slot (N) Plunger/Trigger

Illustration 149	g06230258
Typical installer

Table 61

ORFS Installation Tool Part Numbers
Fitting Size	CAT Part Numbers
(-4)	179-6884
(-6)	179-6885
(-8)	179-6886
(-10)	179-6887
(-12)	179-6888
(-16)	179-6889
(-20)	179-6890
(-24)	179-6891

1. Complete a one second inspection of the seal, fitting, and tool for damage.

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Illustration 150	g06230261
Insert O-ring

1. Insert the O-ring through O-ring slot near top of ORFS insertion tool.
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   Illustration 151	g06230263
   O-ring on plunger platform

2. Check to see that the O-ring is properly placed on the plunger platform.
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   Illustration 152	g06230319
   Plunger pressed

3. Place the ORFS end of the fitting into the tool and depress the plunger/trigger.

4. Remove the tool from fitting.
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   Illustration 153	g06230320
   O-ring installed

5. Verify that the O-ring has been properly placed into the groove.
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   Illustration 154	g06230321
   Finger sweep check

6. Conduct a "finger sweep" by placing a finger on top of the installed seal, while gently pushing down on top of the seal and running the finger around the circumference of the seal.

   Note: The finger sweep helps ensure that the seal is properly placed and fully depressed into the groove of the ORFS fitting as shown in Illustration 154.

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   Illustration 155	g06230322
   Visual inspection

7. Complete a final visual inspection of seal seating after finger sweep.

8. Cap ORFS end for contamination prevention where applicable.
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   Illustration 156	g06230332
   Fully seated seal

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   Illustration 157	g06230333
   Incorrectly seated seal

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   Illustration 158	g06230334
   Incorrectly seated seal

9. Before and after completing the finger sweep, verify that the seal has been properly seated in the groove as shown in Illustration 156. For demonstrate improperly seated seals, refer to Illustration 157 and Illustration 158.

Illustration 159	g06230335
Cutting damage

Illustration 160	g06230336
Pinching damage

Note: Improper seal installation increases the risk of leaks due to damage by cutting, pinching, or tearing of the seal after assembly as shown in Illustration 159 and Illustration 160. Installation damage can increase in size when the connection is pressurized, resulting in a leak.

Error Code

Error codes may be displayed on the operator monitor because some harnesses are disconnected due to disassembling the boom, stick, and bucket. Be sure these error codes clear after assembling the front structures. Refer to Table 62 for a list of the error codes. Refer to Troubleshooting , UENR2724 , "374F and 390FExcavators and 390F MHPU Mobile Hydraulic Power Unit" for detailed troubleshooting procedures.

Table 62

Machine ECM
DTC	Description	Procedure
1952-9	Chassis Angle Sensor: Abnormal Update Rate	CAN Data Link - Test
1956-3	Bucket Cylinder Position Sensor : Voltage Above Normal	Sensor Signal (PWM) - Test
1956-13	Bucket Cylinder Position Sensor : Out of Calibration	Sensor Signal (PWM) - Test
2425-3	Boom Angle Sensor: Voltage Above Normal	Sensor Signal (PWM) - Test
2425-13	Boom Angle Sensor: Out of Calibration	Sensor Signal (PWM) - Test
2426-3	Stick Angle Sensor: Voltage Above Normal	Sensor Signal (PWM) - Test
2426-13	Stick Angle Sensor: Out of Calibration	Sensor Signal (PWM) - Test