545 Wheel Skidder Machine Systems Caterpillar


Hydraulic Rotator - Assemble - Continuous Rotator Grapple

Usage:

545 2FZ

Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Description  Qty 
1P-2420  Transmission Repair Stand 
FT-0957 Positioning Gp 
194-7586  Pneumatic Wrench Gp 
140-1770 Spanner Wrench As 
6V-5696 Bolt 
5P-0600  Hose Clamp 
138-7575  Link Bracket 
Nut 5/8 x 11 
- Bolt 5/8 x 11 
4C-4774  Water and Temperature Resistant Grease 

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.



    Illustration 1g01057987

  1. Install seal (40) and O-ring seal (41) to shaft (33).


    Illustration 2g01057984

  2. Apply Tooling (H) to bearing cone (38). Install spacer (39) onto shaft (33). Raise the temperature of bearing cone (38) to a temperature of 49° ± 11 °C (120° ± 20°F). Install bearing cone (38) onto shaft (33).


    Illustration 3g01057956

  3. Install seal (36). Lower the temperature of bearing cup (37). Install bearing cup (37) into motor housing (32).


    Illustration 4g01057918

  4. Invert motor housing (32). The weight of the motor housing is approximately 59 kg (130 lb). Lower the temperature of bearing cup (35). Install bearing cup (35) into motor housing (32).


    Illustration 5g01058175

  5. Attach Tooling (E) to motor housing (32) and position motor housing (32) to shaft (33). The weight of the motor housing is approximately 60 kg (130 lb).


    Illustration 6g01058181

  6. Apply Tooling (F) to bearing cone (34). Raise the temperature of bearing cone (34) to 49° ± 11 °C (120° ± 20°F) and install bearing cone (34) onto shaft (33).


    Illustration 7g01058184


    Illustration 8g01058187

  7. Install nut (31). Attach Tooling (E) and a suitable lifting device to motor housing (32). The weight of motor housing (32) and shaft (33) is approximately 150 kg (330 lb). Place motor housing (32) and shaft (33) into Tooling (B).


    Illustration 9g01057853

  8. Use Tooling (C) in order to tighten locknut (31). Tighten locknut (31) to a torque of 1290 N·m (950 lb ft).


    Illustration 10g01057842

  9. Install set screws (30) into locknut (31). Tighten setscrews (30) to a torque of 34 N·m (25 lb ft).


    Illustration 11g01057758

  10. Install tube (29).


    Illustration 12g01057744


    Illustration 13g00866196

  11. Install dowels (26) into cover (21). Install O-ring seal (27). Install seal (28). Bend seal (28) for installation. Use a finger in order to shape seal (28) into the original shape.


    Illustration 14g01058215

  12. Install springs (25) and vanes (24) to motor shaft (23). Use blocking in order to position springs (25) and vanes (24) to motor shaft (23).


    Illustration 15g01058256

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  13. Use Tooling (D) in order to install vanes (24) to motor shaft (23). Use Tooling (G) in order to ensure that Tooling (D) is in the center of vanes (24).


    Illustration 16g01057708

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  14. Slowly tighten Tooling (D) onto motor shaft (23).


    Illustration 17g01057694

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  15. Install stator frame (18) into motor shaft (23). Lower stator frame (18) onto motor shaft (23). Remove Tooling (D) from vanes (22).


    Illustration 18g01057679

  16. Install O-ring seal (19) into stator frame (18). Install valves (20) into stator frame (18).


    Illustration 19g01057666


    Illustration 20g00866196

  17. Install dowels (16) into cover (13). Bend seal (17) for installation. Use a finger in order to shape seal (17) into the original shape. Install seal (17).


    Illustration 21g01057609

  18. Position the grapple motor with cover (13) in the upright position, as shown. Install bolts (15). Tighten bolts (15) to a torque of 61 N·m (45 lb ft).


    Illustration 22g01057599

  19. Attach Tooling (A) and a suitable lifting device to cover (13). The weight of grapple motor is approximately 47 kg (105 lb). Install the grapple motor and tighten bolts (14).


    Illustration 23g01057595

  20. Install seals (11) and O-ring seal (12) to tube (10).


    Illustration 24g01057593

  21. Install tube (10).


    Illustration 25g01057587

  22. Install seal (4) and O-ring seal (5) from block (3). Install O-ring seal (9), seal (8), O-ring seal (7) and seal (6) into block (3).


    Illustration 26g01057579

  23. Install block (3).


    Illustration 27g01057578

  24. Install block (2). Install bolts (1). Tighten bolts (1) to a torque of 60 N·m (44 lb ft).

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