NEHS0566 4C-9832 Large Engine Roll-Over Stand {0599, 0701} Caterpillar

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Introduction

Important Safety Information

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Think Safety

European Union Compliant, CE marked

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DUST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Crushing hazard (foot)

Crushing hazard (hand)

Pinch point

Fire hazard

Electrical Shock - Hazard

Fire hazard

General Information

Introduction

This manual provides the necessary information to assemble and operate the Large Engine Roll-Over Stand. A single operator can assemble and use the stand to lift and rotate engines in the 3516-3412 size class without the use of any overhead lifting devices.

Do not perform any procedure outlined in this publication until you read and understand the information contained within.

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4C-9832 Large Engine Roll-Over Stand

Contact Information

For product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

Preparing the Roll-Over Stand for Use

When received, the roll-over stand may be in a partially disassembled condition for packaging purposes. The following steps are for assembly of the roll-over stand.

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1. Set outboard end frame (1) and cylinder end frame assembly (2) on a flat shop floor.
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2. Fasten counterbalance valve (3) to cylinder end frame assembly (2) with two 7X-0265 Bolts (1/4"-20 THD x 69.9 mm (2.75 inch) (4).

3. Insert assembly pin (5) into the button of the four holes in cylinder end frame assembly (1). Install cotterless hitch pin (6).
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4. Place cylinder (10) on assembly pin (5) and index arm (7). Insert two pins (8) and four hitch pin cotters (9). The weight of the cylinder is 22 kg (48.5 lb).
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5. Connect hose (12) between the lower connector on cylinder (10) and the coupler assembly labeled "cylinder extend" on counterbalance valve (3).

6. Connect hose (13) between the upper connector on cylinder (10) to the coupler assembly labeled "cylinder retract" on counterbalance valve (3)

7. Connect two hoses (14) as shown, one hose from the coupler assembly labeled "port B" on counterbalance valve (3) to "port B" coupler assembly on air/hydraulic pump (15). Connect the other hose to coupler assembly labeled "port A" on counterbalance valve (3) to the "port A" coupler assembly on air/hydraulic pump (15).
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8. Support jack tube assembly (16) and remove pin assembly (11). Tilt hydraulic jack (17) and install the jack in place in cylinder end frame assembly (2).

9. Install hydraulic jack (17) in the outboard end frame assembly (2).

10. Insure air/hydraulic pump (15) is in the off position. Connect the air supply hose to the pump. The roll-over stand is ready for use.

Preparing the Engine for Mounting

Note: This stand isnot intendedto be used on fully assembled engines. Use of untested or modified mounting brackets may result in damage to the stand or cause uncontrolled movement.

1. Transport the engine to the work area and place upright on a flat shop floor. If the engine is a marine or industrial version with a full length oil pan installed, the engine may be rested directly on floor on the pan. If the engine is equipped with a vehicular oil pan of if the pan has been removed, use blocking on cribbing to support the engine so that the oil pan flange (oil pan gasket) is 290 to 635 mm (11.4 to 25.0 inch) from the floor.

2. Once the engine is securely positioned on the floor, remove engine components from each end. Expose the ends of the cylinder block. From the rear of the engine, remove flywheel, flywheel housing, and all gears except the crankshaft gear. Remove the small covers located behind the idler gears. From the front, remove exterior components and the front cover. Remove all gears except the crankshaft gear. Remove the small covers located behind the idler gears.

3. If oil galleries are to be flushed, remove the plugs from each end of the two main oil galleries. (Holes in the mounting brackets allow use of a steam cleaner or pressure washer nozzle to flush the galleries with the brackets installed).

4. The engine is now ready for installation of the roll-over stand.

Raising the Engine To Proper Working Height

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Note: Make sure index assembly screw (1) is in one of the 12 locking positions to prevent the engine from rotating while raising the engine.

1. Support cylinder (6). Remove two hitch pin cotters (2). Remove two pins (3) and cylinder (6). The weight of the cylinder is 22 kg (48.5 lb).
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2. Extend two hydraulic jacks (7) to support the weight of the engine. Remove two bolts (4) from each end frame.
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3. Extend two hydraulic jacks (7).

   Note: To prevent binding and unbalance, never extend or lower the hydraulic jacks with more than 2 inches difference between the height of the two jacks.

4. Visibly align the bolt holes and insert two bolts (4) in each end frame assembly.

   To raise engine higher:

5. Lower both jacks (7).

6. Remove pin assembly (5) and insert in a lower hole.

7. Repeat steps 2 through 4 to raise the engine.

   If the engine is at the desired height:

8. Remove the cotterless hitch pin and remove cylinder mount pin (8).

9. Insert cylinder mount pin (8) in the appropriate hole in the end frame assembly.
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10. Support the cylinder and insert two pins (3) and two hitch pin cotters (2). The weight of the cylinder is 21.8 kg (48.0 lb).

Rotate the Engine

Note: Index assembly screw (1) and (2) can be removed or installed by hand. If the weight of the engine prevents index assembly screw (1) or (2) from being loosened or tightened by hand, rotate the engine slightly in one direction or the other by slightly extending or retracting cylinder (3).

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1. Remove index assembly screw (1).
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2. Switch the air/hydraulic pump to port A and extend cylinder (3) to rotate the engine.
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   Note: The engine may be blocked every 30° in any of the 12 rotational positions.

3. When the appropriate hole in index plate (4) is aligned with the threaded hole in pivot assembly (5), turn off the air/hydraulic pump. Install index assembly screw (1).

   Note: The engine can be rotated 90° with one full stroke of the cylinder.

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4. With index assembly screw (1) removed, switch the air/hydraulic pump to port A and extend cylinder (3) and rotate the engine 90°.
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5. Switch off the air/hydraulic pump. Install index assembly screw (1).

6. Remove index assembly screw (2).
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7. Switch the air/hydraulic pump to port B to retract cylinder (3).

8. When the hole in index plate (4) is aligned with the threaded hole in index arm (6), switch off the air/hydraulic pump. Install assembly screw (2) in the threaded hole in index arm (6).

9. To rotate the engine another 90°, repeat Steps 1 through 8.

Disassembly of Roll-Over Stand

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1. Disconnect air supply hose (6).

2. Disconnect two hoses (3) from counterbalance valve (2).

3. Disconnect hoses (1) and (5) from counterbalance valve (2).
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4. Remove two jacks (4).

5. Remove hitch pin cotters (7).

6. Support cylinder (10) and remove two pins (9) and cylinder (10). The weight of the cylinder is 21.8 kg (48.0 lb).

7. Remove the two mounting bolts and counterbalance valve (2).
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8. Remove two bolts (8).

9. Fasten a hoist to engine mounting bracket (9) and pivot end pivot assembly (10).

10. Support jack tube assembly (12) and remove assembly pin (11). Remove jack tube assembly (12).

11. Remove engine mounting bracket (9) and pivot end pivot assembly (10). The weight of the engine mounting bracket and the pivot end pivot assembly is 102.1 kg (225.0 lb). The weight of the engine mounting bracket and the cylinder end pivot assembly is 127.0 kg (280.0 lb).

Maintenance

Inspect prior to each use for nicks, burrs, dents, cracks, bends, or worn parts. If damage is found, discontinue use until inspected and released for use by an approved inspector at a dealership.

1. Have tools inspected annually by an approved dealership inspector. Maintain a written record of all inspections.

2. Do not use unless all load identification markings are legible.

3. It is recommended that the user implement an inspection and maintenance program every 6 months, or if excessive play is observed in the rotation axis.

   Excessive wear between the 9U-5758 Cylinder End Shaft Weldment, and the 9U-7828 Index Plate can cause uncontrolled rotation that could lead to economic loss or personal injury.

Inspection Process

In the photograph below, reference the arrow pointing to 9U-7828 Index Plate. Remove bolt and spring washer to inspect visually, the 9U-5758 Cylinder End Shaft Weldment and the 9U-7828 Index Plate joint. Ensure that there is no load or engine mounted in the rollover stand at the time of disassembly for inspection.

Wear indicators are shown in the attached photographs. Replace the 9U-7828 and 9U-5758 when the corners show signs of rounding.

Recommendations

The 4C9832 stand is designed for a working load limit (WLL) of 20,000 lbs (9071.85 kg). The stand is intended to support and rotate only an engine "short block" configuration (block, crankshaft, cylinder packs, camshaft, and cylinder heads), with the remaining assembly/disassembly to be completed on an appropriate stationary fixture. Non-Cat adapter plates have been used to rotate complete engine assemblies which can overload the stand, and change the center of rotation. This results in accelerated wear to these components. Modified adapter plates are not recommended for use.

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