Instructions for Converting Hot Saw to Harvester Head Saw{5051, 5051, 5057, 6543} Caterpillar

Track Feller Buncher:

TK711 (S/N: 101210-UP)

TK721 (S/N: 102211-UP)

TK722 (S/N: 103206-UP)

TK732 (S/N: 104194-UP)

Introduction

This Special Instruction provides the necessary procedures for converting the Hot Saw to a Harvester Head Saw.

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

Preparation of the Machine

1. Clean the machine. Cleaning the machine will help to prevent dirt from entering the hydraulic system when hydraulic components are being installed.

2. Start the engine. Fully extend the stick. Lower the attachment to the ground.

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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, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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Personal injury can result from contact with hot hydraulic oil and from contact with hydraulic oil that is under high pressure. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. The hydraulic oil pressure must be released before any service on the hydraulic system is performed or serious personal injury could occur. Verify that all of the work tools have been completely lowered to the ground. Release the hydraulic oil pressure at the hydraulic tank through the breaker relief valve when the breaker relief valve is cool enough to touch with your bare hand. Verify that the hydraulic oil is cool before you begin to remove any hydraulic components or hydraulic lines.

3. Release the oil pressure in all of the implement circuits (the boom, the stick and the attachment) before any of the hydraulic lines or any of the components are disconnected or removed. Procedure to release the pressure

   1. Shut off the engine and turn the switch to the ON position. Put the hydraulic lockout control in the UNLOCK position.

   2. Cycle all control levers through the full range of motion. This will release any pressure that might be present in the hydraulic system.

      Note: If the hydraulic circuit requires the activation of a switch for operation, activate the necessary switches for the hydraulic circuit.

   3. Open the hood for the engine compartment.

      Note: The switch for the hood is located underneath the right armrest on earlier models. The switch for the hood is located on the right hand console for the later models.

   4. Turn the start switch to the OFF position.

   5. Move the hydraulic lockout control to the LOCKED position.

      Note: When the hydraulic lockout control is in the LOCKED position no implements will function.

   6. Push down on the hydraulic tank breaker relief valve until all pressure is released.

   7. When the pressure in the hydraulic system has been released then the hydraulic oil lines and the components can be removed.

4. Drain the oil from the hydraulic oil tank in a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 262 L (69.2 US gal).

Removal Procedure

Remove the Felling Head

Reference: For the correct procedures to remove the felling head, refer to Disassembly and Assembly, RENR6297, "TK711, TK721, TK722 and TK732 Track Feller Bunchers Machine Systems", "Felling Head - Remove".

Remove the Stick

Reference: For the correct procedures to remove the stick, refer to Disassembly and Assembly, RENR6297, "TK711, TK721, TK722 and TK732 Track Feller Bunchers Machine Systems", "Stick - Remove".

Remove the Boom

Reference: For the correct procedures to remove the boom, refer to Disassembly and Assembly, RENR6297, "TK711, TK721, TK722 and TK732 Track Feller Bunchers Machine Systems", "Boom - Remove".

Remove the Joystick Control Gp

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Illustration 1	g01185410

1. Remove cover (1) and mounting bolts (2) from both joystick controls. Disconnect the wiring harnesses from both joystick controls and remove the joystick controls.

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Illustration 2	g01158958

2. Remove the 265-0830 Film that is located on the inside of the right hand cab window.

Installation Procedure

Install the Boom and the Cylinder Group

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Illustration 3	g01180722

1. Attach a suitable lifting device to boom (1), as shown. Place a protective cover over the exposed cylinder head valves. Install the boom. Install the pin for the boom. The weight of the boom is approximately 1360 kg (3000 lb). The weight of the pin is approximately 56 kg (125 lb).

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Illustration 4	g01180720

2. Install oil filler cap (2). Slide clip (3) into position. Tighten bolt (4) that holds clip (3) .

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Illustration 5	g01180719

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Illustration 6	g01026345

3. Install engine valve cover (6) and install bolts (5). Install bolts (5) in the following sequence. A, B, C, D, E, F, G, H, I, J and K

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Illustration 7	g01180714

4. Install coolant reservoir (7). Install bolt (8) .

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Illustration 8	g01180713

5. Attach a suitable lifting device by using Tooling (A) to boom cylinder (9), as shown. Use Tooling (A) in order to raise the rod end of boom cylinder (9). Raise boom cylinder (9) into position. Install any shims that may have been present during removal. Check the lateral clearance. The maximum lateral clearance should be 1.6 mm (0.0630 inch). Install pin assembly (10) and install bolt (11) .

Install the Stick and the Cylinder Group

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Illustration 9	g01180754

1. Attach a suitable lifting device to the stick. Install the stick. The weight of the stick is approximately 1225 kg (2700 lb). Install pin assembly (1). Install bolt (2) and install any shims that were present during removal. Check the lateral clearance of the stick. The maximum lateral clearance should be 1.6 mm (0.0630 inch).

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Illustration 10	g01188072

2. Attach a suitable lifting device to the stick cylinder, as shown. Install stick cylinder (3). The weight of stick cylinder is approximately 255 kg (560 lb). Install pin assembly (4) and bolt (5).

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Illustration 11	g01188069

3. Attach a suitable lifting device by using Tooling (A) to stick cylinder (3), as shown. Raise the head end of stick cylinder (3) into position. Install pin assembly (7) and install bolt (6) .

Install the Hydraulic Lines

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Illustration 12	g01180833

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Illustration 13	g01181044
(1) Two 6V-4245 Elbows (2) 240-0336 Hose As (3) 240-0335 Hose As (4) One 4K-8864 Clip , one 8T-4191 Bolt and one 8T-4121 Hard Washer (5) One 2R-1939 Clip , one 8T-4133 Nut and one 8T-4121 Hard Washer (6) One 4K-8864 Clip , one 8T-4133 Nut and one 8T-4121 Hard Washer (7) Four 3B-8489 Grease Fittings (8) One 4D-6466 Clip , one 8T-4133 Nut and one 8T-4121 Hard Washer (9) 253-2615 Hose As (10) 253-2616 Hose As (11) 3B-6552 Elbow

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Illustration 14	g01187934
(12) Two 4M-8973 Elbows (13) Two 253-2618 Hose As (14) 8L-5008 Pipe Elbow (15) 253-2617 Hose As (16) Two 2R-1939 Clips , two 8T-4133 Nuts and two 8T-4121 Hard Washers (17) Three 3B-8489 Grease Fittings

1. Install the components that are listed in Illustrations 12, 13 and Illustration 14.

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Illustration 15	g01181205
(A) Reinstall hose assembly, bolts and the bracket. (18) One 246-7437 Valve As , three 8T-4223 Hard Washers and three 8T-4648 Bolts (19) 6V-8637 Connector , three 3D-2824 O-Ring Seals and three 6V-9746 O-Ring Seals (20) 6V-8946 Reducer , 6V-9746 O-Ring Seal , 6V-8785 Tee , 5K-9090 O-Ring Seal and one 7M-8485 O-Ring Seal (21) One 253-2619 Manifold , one 4J-0522 O-Ring Seal , four 7X-2549 Bolts and four 8T-4223 Hard Washers (22) 253-2620 Check Valve Gp (23) 258-1085 Hose As and two 205-0828 Identification Tags (24) Three 258-1082 Hose As and three 1P-3702 Rectangular Seal (25) 258-1084 Hose As and two 205-0827 Identification Tags (26) 258-1083 Hose As (27) 6V-8990 Elbow and one 6V-9746 O-Ring Seal (28) 6V-8997 Union , one 8P-8701 Thrust Washer , two 2P-1293 Locknuts and two 6V-9746 O-Ring Seals (29) Three 5P-0046 Covers and three 1P-3702 Rectangular Seals (30) 193-9230 Check Valve Gp (31) 253-2610 Cover As , two 8T-4910 Bolts , two 129-3180 Locknuts , eight 8T-4223 Hard Washers , two 8T-4195 Bolts , two 7X-7729 Washers and two 133-3260 Spacers

2. Install the components that are listed in Illustration 15.

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Illustration 16	g01181905
Rear end of the boom (A) Install hoses from valve bank. (25) 258-1084 Hose As and two 205-0827 Identification Tags (32) 258-1071 Hose As (33) 258-1074 Hose As and two 205-0827 Identification Tag (34) 258-1073 Hose As (35) 226-2926 Hose As (36) Two 6V-8997 Union , four 6V-9746 O-Ring Seal and two 2P-1293 Locknut (37) Two 6V-8998 Union , four 5K-9090 O-Ring Seal and two 6V-9172 Nut

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Illustration 17	g01181350
Rear end of the boom (A) Install hoses from valve bank. (38) 258-1072 Hose As (39) 226-3623 Hose As (40) 258-1073 Hose As (41) One 160-4094 Hose As and two 205-0829 Identification Tags (42) Three 6V-8997 Unions , three 2P-1293 Locknuts and six 6V-9746 O-Ring Seals (43) One 110-9160 Union , one 6V-9173 Bulkhead Nut and two 6V-8400 O-Ring Seal

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Illustration 18	g01181947
Front end of the boom (44) 258-1079 Hose As (45) 258-1078 Hose As (46) 6C-6299 Hose As (47) One 2P-1293 Locknut , one 6V-8997 Union and two 6V-9746 O-Ring Seals (48) One 6V-9172 Nut , one 6V-8998 Union and two 5K-9090 O-Ring Seals (49) One 6V-9172 Nut , one 6V-8998 Union and two 5K-9090 O-Ring Seals

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Illustration 19	g01181952
Front end of the boom (50) 258-1079 Hose As (51) 258-1080 Hose As and two 205-0828 Identification Tag (52) 258-1081 Hose As and two 205-0829 Bands (53) One 2P-1293 Locknut , one 6V-8997 Union and two 6V-9746 O-Ring Seals (54) One 6V-9173 Bulkhead Nut , one 110-9160 Union and two 6V-8400 O-Ring Seals (55) One 2P-1293 Locknut , one 6V-8997 Union and two 6V-9746 O-Ring Seals

3. Install the components that are listed in Illustration 16, Illustration 17, Illustration 18 and Illustration 19 to the boom.

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Illustration 20	g01183214
Right side of the Stick, rear end (45) 258-1078 Hose As (51) 258-1080 Hose As and two 205-0828 Identification Tag (52) 258-1081 Hose As and two 205-0829 Bands (56) 9W-6261 Hose As and two 205-0829 Bands (57) 258-1075 Hose As and two 205-0828 Identification Tags (58) 258-1076 Hose As and two 205-0827 Identification Tags (59) 6V-8997 Union , two 6V-9746 O-Ring Seals and one 2P-1293 Locknut (60) One 6V-9173 Bulkhead Nut , one 110-9160 Union and two 6V-8400 O-Ring Seals (61) One 6V-9172 Nut , one 6V-8998 Union and two 5K-9090 O-Ring Seals

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Illustration 21	g01183906
Right side of the Stick, rear end (44) 258-1079 Hose As (50) 258-1079 Hose As (64) 6V-8997 Union , two 6V-9746 O-Ring Seals and one 2P-1293 Locknut (65) 6V-8997 Union , two 6V-9746 O-Ring Seals and one 2P-1293 Locknut (66) 258-1077 Hose As (67) 258-1077 Hose As

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Illustration 22	g01183911
Front end of the Right side of the Stick (56) 9W-6261 Hose As and two 205-0829 Bands (57) 258-1075 Hose As and two 205-0828 Identification Tags (58) 258-1076 Hose As and two 205-0827 Identification Tags (68) One 6V-9832 Cap As , one 2P-1293 Locknut , one 6V-8997 Union and two 6V-9746 O-Ring Seals (69) One 6V-9834 Cap As , one 110-9160 Union , two 6V-8400 O-Ring Seals and one 6V-9173 Bulkhead Nut (70) One 6V-9833 Cap As , one 6V-9172 Nut , one 6V-8998 Union and two 5K-9090 O-Ring Seals

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Illustration 23	g01183915
Front end of the right side of the Stick (66) 258-1077 Hose As (67) 258-1077 Hose As (71) One 6V-9832 Cap As , one 2P-1293 Locknut , one 6V-8997 Union and two 6V-9746 O-Ring Seals (72) One 6V-9832 Cap As , one 2P-1293 Locknut , one 6V-8997 Union and two 6V-9746 O-Ring Seals

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Illustration 24	g01183213
Left side of Stick (46) 6C-6299 Hose As (73) One 226-4966 Plate , two 8T-4137 Bolts and two 8T-4121 Hard Washers (74) Install two 212-8121 Guards , eight 8T-4137 Bolts and eight 8T-4121 Hard Washers . Attach one on the left side of the stick and one on the right side of the stick. (75) Install two 219-6485 Flood Lamp Gp . Attach one on the left side of the stick and one on the right side of the stick. (76) One 253-2609 Lighting Harness As (77) One 6V-8998 Union , one 5K-9090 O-Ring Seal and one 6V-9172 Nut (78) 246-1775 Plate , two 8T-4223 Hard Washers and two 160-8749 Bolts

4. Install the components that are listed in Illustration 20, Illustration 21, Illustration 22, Illustration 23 and Illustration 24 to the stick.

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Illustration 25	g01183211
Debris guard at Boom and Stick (79) One 212-8079 Debris Guard , six 8T-4956 Bolts , six 8T-4223 Hard Washer , one 212-8092 Plate , and one 212-8076 Plate

5. Install the components that are listed in Illustration 25.

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Illustration 26	g01184888
Debris guard at base of Boom (80) 212-8080 Debris Guard , three 8T-4244 Nuts , three 8T-4223 Hard Washers and one 212-8092 Plate

6. Install the components that are listed in Illustration 26.

Install the Joystick Control Gp

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Illustration 27	g01185410

1. Install both joystick controls and connect the wiring harnesses from both joystick controls to the wiring harness that is in the cab. Install mounting bolts (2) and cover (1) from the old joystick control gp.

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Illustration 28	g01178615
265-7988 Film

2. Attach the 265-7988 Film to the inside of the right hand cab window.

3. Load the application software for a processing head arrangement onto your MDM Display.
   • 260-0879 TK English/Spanish

   • 260-0880 TK English/French

   Reference: For information on loading software, refer to Systems Operation, RENR6345, "IQAN Monitoring & Control System" Flash Software or Upgrading the IQAN Machine System.