Modification Procedure for Moving the Color Marking System from the Stick to the Harvester Head{6393} Caterpillar

Wheel Harvesters:

550 (S/N: 7ZN1-UP)

570 (S/N: 4XR1-UP)

580 (S/N: 7CN1-UP)

Harvester Heads:

HH45 (S/N: 2JZ1-UP)

HH55 (S/N: 3MZ1-UP)

HH65 (S/N: 4RZ1-UP)

Introduction

Use the information in this document to remove the color marking system from the stick. Also, use this information to install the color marking system on the harvester head.

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document. Do not order parts until you understand the information that is contained in this document.

Removal Procedure for the Color Marking System

Reference: Refer to Disassembly and Assembly, "Preparation for Disassembly" for detailed instructions on preparing the 550, 570, and 580 Wheel Harvesters for disassembly.

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At operating temperature the implement hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible injury, release the pressure in the implement hydraulic system before hydraulic lines or components are disconnected or removed.

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Illustration 1	g00798690

1. Remove two paint tanks (2) from the color marking system.

   Note: Save the two paint tanks. The paint tanks will be used on the new bracket on the harvester head.

2. Remove line (1) from each of the paint tanks on the color marking system.

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Illustration 2	g00798461

3. Disconnect hydraulic lines (3) and (4) from the bracket assembly.

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Illustration 3	g00798699

4. Plug pressure line (3) and install a 4C-9521 Cap on the fitting. Use a tie strap in order to secure pressure line (3) .

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Illustration 4	g00798667

5. Remove hydraulic line (4) that goes to the tank.

6. Remove tee fitting (6) .

7. Connect hydraulic line (7) to fitting (5) .

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Illustration 5	g00798674
Bundle (8) contains four wires, wire number 29, the Green/Yellow wire, wire number 26, and wire number 27.

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Illustration 6	g00797876

8. Remove the wiring harness FARG 1 and FARG 2 from electrical connector (9) that is located in the junction box on the stick. FARG 1 and FARG 2 supply power to the color marking box.

9. Insert wires 29, Green/Yellow, 26, and 27 from bundle (8) into electrical connector (9) in the position that was held by FARG 1 and FARG 2. Bundle (8) is connected to the harvester head.

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Illustration 7	g00797675

10. Seal the hole in junction box (10) that is located on the stick.

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Illustration 8	g00815373

11. Remove the two paint pumps from the color marking box that is located on the stick.

    Note: Save the two 175-6677 Paint Pumps . The paint pumps will be used on the new bracket assembly on the harvester head.

12. Remove the two bolts that hold the color marking box to the stick. Use two people to remove the color marking box. The weight of the color marking box is approximately 10.75 kg (25 lb).

Installation Procedure for the Color Marking System

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

1. Prepare the harvester head for disassembly. Refer to Disassembly and Assembly, "Preparation for Disassembly" for detailed instructions on preparing the harvester head for disassembly.

2. Place the harvester head in the horizontal position.

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Illustration 9	g00815387

3. The color marking system will be mounted to the harvester head on the side opposite the saw motor. Remove any dirt and any paint from the surface of the harvester head in order to install the new bracket assembly.

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Illustration 10	g00844504

4. Use mild steel in order to fabricate two spacers. Dimension (KK) is 40 mm (1.6 inch). Dimension (MM) is 20 mm (0.8 inch).

5. Drill a center hole in the spacers so that dimension (LL) is 14.25 mm (0.6 inch).

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Illustration 11	g00797353

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Illustration 12	g00797887

6. Weld two spacers (11) on the harvester head.

   Note: Before you weld on the harvester head, make sure that the cover for the valve bank is in place in order to protect the valves and the hoses from weld spatter. Also, cover all hoses, wires, or tubes that could be damaged during the welding process.

   Note: The following dimensions are for the HH55 and HH65. Dimension (A) is 68.7 mm (2.70 inch). Dimension (B) is 137.4 mm (5.40 inch).

   Note: The following dimensions are for the HH45. Dimension (A) is 98.7 mm (3.88 inch). Dimension (B) is 197.4 mm (7.77 inch).

7. Use a 14.00 mm tap in order to cut M16X2 threads into each spacer.

8. Use dimension (A) and dimension (B) in order to determine the size and the location of pin hole (12). Drill and deburr a hole in the 189-5793 Bracket Assembly that matches the size and the location of pin hole (12). This will allow electrical wires to be routed from the bracket assembly through the pin hole for added protection.

9. Paint any surfaces of the harvester head that need paint.

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Illustration 13	g00797355

10. Install a 189-5793 Bracket Assembly (13) to the harvester head. Use four 156-5824 Washers and two 7X-2552 Bolts (14) to attach the bracket assembly to the harvester head.

11. Install two 157-2772 Fittings (15) and (16) to the end of the bracket assembly.

12. Install one 156-0986 Adapter to fitting (16) on the pressure port in order to allow both hoses to fit along the bracket assembly.

13. Install one 157-2691 Elbow to fitting (15) .

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Illustration 14	g00798753

14. Remove hydraulic line (17) from the pressure reducing valve that goes to the measuring arm cylinder.

15. Install a 156-1237 Tee Fitting (18) in the position that was held by hydraulic line (17). Install a 157-2691 Elbow to fitting (18). Connect hydraulic line (17) to tee fitting (18) .

16. Connect a 156-4137 Hose Assembly (19) to the elbow that is located on tee fitting (18). Connect the other end of hose assembly (19) to the adapter that is located on fitting (16) .

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Illustration 15	g00798739

17. Remove hydraulic return line (20) .

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Illustration 16	g00797668

18. Install a 157-2764 Tee Fitting (21) in the position that was held by hydraulic return line (20) .

19. Connect hydraulic return line (20) to tee fitting (21) .

20. Connect a 197-6621 Hose Assembly (22) to tee fitting (21). Connect the other end of hose assembly (22) to the elbow that is located on fitting (15) on the bracket assembly.

    Reference: Refer to Special Instruction, REHS0957, "Installation Procedure for Improved Hose Routing on Harvester Heads" for information about routing the hydraulic lines on the HH55 and the HH65.

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Illustration 17	g00797737

21. Install the two original 175-6677 Pumps (23) and (24) into the new bracket assembly. Use four 8T-9534 Bolts and four 8T-4223 Hard Washers to install the pumps.

22. Connect twelve 6V-0404 Bonded Seals and twelve 156-1684 Fittings to four ports (25) on the inside of the bracket assembly and to the four ports on top of both pumps.

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Illustration 18	g00798766

23. Assemble four hoses. Each hose should include one 162-6113 Nipple (26), two 162-6107 Adapters (27), one 162-6112 Nipple (29) and 162-5782 Hose (28). The length of hose (28) is 410 mm (16.25 inch).

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Illustration 19	g00797760

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Illustration 20	g00798850

24. Attach one hose assembly to the bottom left port (E) on the inside of the bracket assembly. This is the pressure line. Attach the other end of the hose to pressure port (32) on pump (24) .

25. Attach one hose assembly to the bottom right port (F) on the inside of the bracket assembly. This is the return line to the tank. Attach the other end of the hose to tank port (33) on pump (24).

26. Attach one hose assembly to the top left port (C) on the inside of the bracket assembly. This is the pressure line. Attach the other end of the hose to pressure port (30) on pump (23) .

27. Attach one hose assembly to the top right port (D) on the inside of the bracket assembly. This is the return line to the tank. Attach the other end of the hose to tank port (31) on pump (23) .

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Illustration 21	g00798317

28. Use two 8T-4224 Washers (35) and two 099-3649 Bolts (36) to fasten a 189-5106 Plate Assembly (34) to the end of the bracket assembly.

29. Use two 8T-7547 Bolts and two 8T-4224 Washers to fasten plate assembly (34) to the side of the bracket assembly.

30. Attach a 192-3002 Harness Assembly to each pump.

31. Four wires are needed in order to construct a wiring harness. Each wire should be 1.00 square millimeters (18 gauge). Each wire should be 100 cm (39.4 inch) long.

32. Attach four 9X-3402 Sockets to one end of each of the four wires.

33. Install the four sockets into a 102-8809 Plug Kit .

34. Route the wire assembly out of the bracket assembly, through pin hole (12) and to the junction box.

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Illustration 22	g00800416

35. Attach four 156-4617 Sockets to the other end of each of the four wire assemblies. Place these sockets into the electrical connector that is located in junction box (37). Junction box (37) is located at the bottom of the harvester head frame.

    Note: Cut the wires to the appropriate length for the harvester head that is being reworked.

    Note: Find the two wires that are inserted into pin 1 and into pin 2 of the 102-8809 Plug Kit . Connect the ends of the two wires into the same screw terminal as wire 29. Find the wire that is inserted into pin 3 of the 102-8809 Plug Kit . Connect the end of the wire into the same screw terminal as wire 26. Find the wire that is inserted into pin 4 of the 102-8809 Plug Kit . Connect the end of the wire into the same screw terminal as wire 27.

    Note: Leave the green/yellow wire in junction box (37). The green/yellow wire can be used in the future, if necessary.

36. Attach the 102-8809 Plug Kit to the receptacle on the end of the 192-3002 Harness Assembly in the bracket assembly.

    Note: Keep both the plug and the receptacle inside the bracket assembly for extra protection.

    Note: Do not permit the wire assembly to interfere with other components when the wire assembly is routed through the pin hole to the electrical connector.

37. Place the harvester head in the vertical position.

    Reference: Refer to Disassembly and Assembly, "Preparation for Disassembly" for detailed information on placing the harvester head in the vertical position.

38. Open the holding arm.

39. Use a grinder to remove the block from the holding arm.

    Note: Do not use a torch to remove the block. Damage to the holding arm can result from the use of a torch.

40. Modify the HH45 holding arm.

    Note: Continue to the step 41 in order to modify an HH55 Harvester Head. Continue to step 41 in order to modify an HH65 Harvester Head.

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    Illustration 23	g00802668
    Typical example

    1. Weld a 199-7758 Block (38) onto holding arm (39). Install the block so that the nozzles face toward the saw. Position the 199-7758 Block on the holding arm as illustration 23 shows.

       Note: It is not necessary to remove the holding arm in order to perform step 40.a.

       Note: Remove the paint from the surface of the holding arm before you weld on the holding arm.

    2. Install three 156-3862 Plugs and three 6V-8397 O-rings into the block.

    3. Install two 197-9215 Nozzles and two 6V-8397 O-rings into the block.
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    Illustration 24	g00833125

    4. Install four 9X-6608 Setscrews (40) into the block. Weld each setscrew in place. The weld that is on each set screw must be free of leaks.
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    Illustration 25	g00832822

    5. Fabricate a bar in order to support the nozzles that are located on the block. The thickness of the bar is 5 mm (.2 inch). The width of the bar is 20 ± 1 mm (.8 ± .04 inch). The length of the bar is 105 mm (4.1 inch). Dimension (G) is 95.5 ± 1 mm (3.76 ± .04 inch). Dimension (H) is 80.5 ± 1 mm (3.17 ± .04 inch). Dimension (I) is 46.9 ± 1 mm (1.85 ± .04 inch). Dimension (J) is 31.2 ± 1 mm (1.23 ± .04 inch). Dimension (K) is 10 ± 1 mm (.4 ± .04 inch).
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    Illustration 26	g00832634

    6. Place bar (41) on the block. The top edge of bar (41) should be flush with the top edge of the 199-7758 block . Dimension (L) is 205 ± 1.5 mm (8 ± .06 inch). Bend bar (41) with a soft hammer in order to match the shape of the block.

       Note: The two notches in bar (41) should allow the 197-9215 Nozzles and the 156-3862 Plugs to be removed after bar (41) is welded to the block.

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    Illustration 27	g00832785

    7. Weld bar (41) to the block. Weld (e) is a 3 mm (0.1 inch) square groove weld. Weld (f) is a 5 mm (.2 inch) fillet weld. Do not weld from point (a) to point (b). Do not weld from point (c) to point (d) .

       Note:

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    Illustration 28	g00832635

    8. Fabricate a plate for the holding arm. The thickness of the plate is 10 mm (.4 inch). The width of the plate is 40 ± 1.5 mm (1.58 ± .06 inch). The length of the plate is 158 ± 1.5 mm (6.22 ± .06 inch).

    9. Two corners of the bar are cut diagonally at a 45° angle. The length of angle (42) is 20 mm (.79 inch).
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    Illustration 29	g00832791

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    Illustration 30	g00832703

    10. Weld plate (43) to holding arm (39) with a 10 mm (.40 inch) fillet weld. Dimension (M) is 132.9 ± 1.5 mm (5.23 ± .06 inch). Dimension (N) is 250.3 ± 1.5 mm (9.86 ± .06 inch). Weld plate (43) at an angle. Dimension (P) is between 95° and 105°. Welds (g) and (h) are 10 mm (.4 inch) fillet welds.

    11. Paint any unpainted areas of the holding arm.

    12. Go to step 42.

41. Modify the holding arms on the HH55 and HH65.

    Note: In order to modify an HH45 Harvester Head, go to step 40.

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    Illustration 31	g00802668
    Typical example

    1. Weld a 197-9477 Block (38) onto holding arm (39). Install the block so that the nozzles face toward the saw. Position the 197-9477 Block as illustration 31 shows.

       Note: It is not necessary to remove the holding arm in order to perform step 41.a.

       Note: Remove the paint from the surface of the holding arm before you weld on the holding arm.

    2. Install three 156-3862 Plugs and three 6V-8397 O-rings into the block.

    3. Install two 197-9215 Nozzles and two 6V-8397 O-rings into the block.
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    Illustration 32	g00833173

    4. Install four 9X-6608 Setscrews (44) into the block. Weld each setscrew in place. The weld on each setscrew must be free of leaks.
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    Illustration 33	g00833193

    5. Fabricate a bar in order to support the nozzles that are located on the block. The thickness of the bar is 5 mm (.20 inch). The width of the bar is 20 ± 1 mm (0.79 ± .04 inch). The length of the bar is 115 ± 1.5 mm (4.53 ± 0.06 inch). Dimension (Q) is 102.8 ± 1 mm (4.05 ± .04 inch). Dimension (R) is 88.8 ± 1 mm (3.5 ± .04 inch). Dimension (S) is 53.3 ± 1 mm (2.1 ± .04 inch). Dimension (T) is 38.6 ± 1 mm (1.52 ± .04 inch). Dimension (U) is 11.4 ± 1 mm (.45 ± .04 inch).
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    Illustration 34	g00833217

    6. Place bar (45) on the block. The top edge of bar (45) should be flush with the top edge of the 199-7758 block . Dimension (V) is 281.5 ± 1.5 mm (11.08 ± .06 inch). Bend bar (45) with a soft hammer in order to match the shape of the block.

       Note: The two notches in bar (45) should allow the 197-9215 Nozzles and the 156-3862 Plugs to be removed after bar (45) is welded to the block.

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    Illustration 35	g00834423

    7. Weld bar (45) to the block. Weld (n) is a 3 mm (.12 inch) square groove weld. Weld (p) is a 5 mm (.20 inch) fillet weld. Do not weld from point (i) to point (j) and from point (k) to point (m) .
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    Illustration 36	g00832635

    8. Fabricate a plate that will attach to the holding arm. The thickness of the plate is 10 mm (.4 inch). The width of the plate is 40 ± 1.5 mm (1.58 ± .06 inch). The length of the plate is 158 ± 1.5 mm (6.22 ± .06 inch).

       Note: The same plate is used for the HH45, HH55, and HH65 Harvester Heads.

    9. Two corners of the plate are cut diagonally at a 45° angle. The length of angle (42) is 20 mm (.79 inch).
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    Illustration 37	g00834450

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    Illustration 38	g00834503

    10. Weld plate (46) to the holding arm. Dimension (W) is 228.3 ± 1.5 mm (9.0 ± .06 inch). Dimension (X) is 329.8 ± 1.5 mm (13.0 ± .06 inch). Weld plate (46) at an angle. Dimension (Y) is between 95° and 105°. Welds (q) and (r) are 10 mm (.40 inch) fillet welds.

    11. Paint any unpainted area of the holding arm.

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Illustration 39	g00800442

42. Construct four hose assemblies. Each hose assembly should have two 162-6113 Nipples (47), two 162-6107 Adapters (48), one 156-1684 Fitting (49), one 6V-0404 Bonded Seal (50), and 162-5782 Hose (s), (t), (u), and (v).

43. The length of the hose that makes up hose assembly (s) is 670 mm (26.5 inch).

44. The length of the hose in hose assembly (t) is 1020 mm (40.25 inch).

45. The length of the hose in hose assembly (u) is 300 mm (11.8 inch).

46. The length of the hose in hose assembly (v) is 300 mm (11.8 inch).

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Illustration 40	g00802421

47. Attach hose (s) to fitting (51) on pump (23). Attach hose (t) to fitting (52) on pump (24) .

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Illustration 41	g00811063

48. Attach a 199-3329 Guard (53) to the bottom of the color marking box on the HH45 Harvester Head.

    Note: This guard is used only on the HH45 Harvester Head.

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Illustration 42	g00813978

49. Attach a 176-1095 Support (54) to the HH45 Harvester Head, as shown.

50. Route hose assemblies (s) and (t) out of the bracket assembly.

    Note: On the HH45 Harvester Head, route hose assemblies (s) and (t) through the 176-1095 Support .

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Illustration 43	g00802668

51. Route hose assemblies (s) and (t) to block (38) that was welded onto holding arm (39). Attach hose assemblies (s) and (t) to the two ports on the block.

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Illustration 44	g00832578

52. Use two 156-0298 Washers and two 8T-4200 Bolts (55) to install a 201-4043 Guard Assembly (56) onto the block.

53. Wrap hose assemblies (s) and (t) in 145-8494 Guard . The length of the guard should be approximately half the length of the hose assemblies.

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Illustration 45	g00797311

54. Attach hose assembly (u) to port (57) on pump (23) .

55. Attach hose assembly (v) to port (58) on pump (24) .

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Illustration 46	g00815030

56. Remove 55 mm (2.17 inch) of material from the edge of tab (60) that is located on the end of paint tank (59) without a cap assembly.

    Note: You only need to trim the tab from one paint tank. Trim the tab from the paint tank in order to avoid contact with fitting (15) on the bracket assembly.

57. Attach the remaining end of hose (u) to one paint tank. Attach the remaining end of hose (v) to another paint tank.

58. Use two 8T-4224 Washers and two 8T-1158 Socket Head Bolts to attach each paint tank to the bracket assembly.