Instructions for Converting Hot Saw to Intermittent 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 guidelines for converting the Hot Saw to a Intermittent Saw.

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

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.

Show/hide table

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 Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Show/hide table

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.

   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).

Show/hide table



Illustration 1	g01159003
(1) 256-0492 Hose (2) 256-0493 Hose (3) One 148-8455 Union , two 221-1446 Reducers and one 2P-1293 Locknut (4) 256-0485 Hose (5) 256-0485 Hose (6) 256-0489 Hose (7) 256-0489 Hose (8) One 148-8455 Union , two 222-6388 Reducers and one 2P-1293 Locknut (9) 256-0485 Hose (10) 256-0485 Hose (A) One 213-0100 Plate , four 8T-4139 Bolt and four 8T-4223 Washer

5. Remove 213-0100 Plate with bolts and washers at location (A) .

   Note: The 213-0100 Plate at location (A) are not shown.

6. Remove the hoses from the boom and stick. See Illustration 1 for hose locations.

7. Remove unions, reducers and locknuts from the bulkhead plates of the boom and stick. See Illustration 1 for the location of components.

Show/hide table



Illustration 2	g01167395
(11) 256-0493 Hose (12) 256-0492 Hose (13) 8W-6687 Hose (14) 164-6862 Tee (15) 225-5476 Hose (16) 216-6122 Hose (17) 203-3840 Hose (18) 259-2637 Plate

8. Remove hoses (11), (12), (16) and (17) .

9. Disconnect hoses (13) and (15) from tee (14). Then remove tee (14) .

10. Remove plate (18) .

Show/hide table



Illustration 3	g01158958
265-0830 Film

11. Remove 265-0830 Film from the inside of the right hand cab window.

Installation Procedure

Show/hide table



Illustration 4	g01166149
(1) 242-4240 Valve (2) 242-3273 Manifold (3) One 8T-8987 Elbow , one 2S-4078 Seal and one 5K-9090 O-Ring Seal (4) One 9S-8008 Plug and one 3D-2824 O-Ring Seal (5) Location for six 8T-4198 Bolts , six 8T-4121 Washers and two 1P-3703 Rectangular Seals (6) One 8T-6451 Elbow and one 3D-2824 O-Ring Seal (7) One 6V-8733 Union and two 6V-9746 O-Ring Seals (8) Location for two 1P-4578 Half Flange , four 8T-4121 Washers , four 8T-4196 Bolts and one 4J-0522 O-Ring Seal (9) Locations for two 6V-8724 Elbows , two 6V-8397 O-Ring Seals and two 3J-1907 O-Ring Seals (10) Location for two 9S-4191 Plugs and two 3J-1907 O-Ring Seals (11) 161-6858 Hose (12) 258-6705 Hose (13) 258-6713 Hose (14) Location for two 6V-0400 Half Flange , four 8T-4223 Washers , four 8T-4184 Bolts and one 1P-3703 Rectangular Seal (15) 271-6430 Hose (16) 258-6700 Hose (17) 258-6707 Hose (18) Location for four 8T-9403 Half Flange , eight 8T-4121 Washers , eight 8T-4182 Bolts , two 1P-3702 Rectangular Seals and two 5P-0046 Cover

1. Attach 242-3273 Manifold (2) to 242-4240 Valve (1) with six 8T-4198 Bolts , six 8T-4121 Washers and two 1P-3703 Rectangular Seals .

2. Install 242-4240 Valve (1) to the boom with six 8T-4137 Bolts and six 8T-4121 Washers .

3. Install the components to the valve that are listed in Illustration 4.

Show/hide table



Illustration 5	g01166174
(19) One 9S-6130 Plug and one 2S-4078 O-Ring Seal (20) 148-0903 Hose (21) 140-1701 Hose (22) 271-7358 Hose (23) Location for two 127-4837 Clips and one 144-6734 Bolt and one 8T-4121 Washer (24) 9S-4191 Plug and one 3J-1907 O-Ring Seal (25) One 6V-9182 Elbow , one 7M-8485 O-Ring Seal and one 6V-9746 O-Ring Seal (26) 6V-8724 Elbow , one 6V-8397 O-Ring Seal and one 3J-1907 O-Ring Seal (27) One 6V-9850 Elbow and one 6V-8397 O-Ring Seal (28) 2P-8421 Adapter and one 3D-2824 O-Ring Seal (29) 148-8309 Adapter and one 3D-2824 O-Ring Seal

4. Attach the components that are listed in Illustration 5.

5. Install the hoses to the valve in Illustration 5.

6. Attach clips (23) in Illustration 5.

Show/hide table



Illustration 6	g01173800

7. Install the 235-4146 Harness to the solenoids and to the harness from the cab.

Show/hide table



Illustration 7	g01166175
Right side view of boom (17) 258-6707 Hose (29) 258-1085 Hose (30) 256-0486 Hose (31) 258-6709 Hose (32) 256-0485 Hose (33) 271-6429 Hose (34) 258-6711 Hose (35) 256-0489 Hose (36) 6V-9833 Cap (A) One 6V-8998 Union , two 5K-9090 O-Ring Seals , two 225-5473 Reducers and one 6V-9172 Bulkhead Nut (B) One 110-9160 Union , two 6V-8400 O-Ring Seals and one 6V-9173 Bulkhead Nut (C) One 6V-8997 Union , two 6V-9746 O-Ring Seals , two 221-1446 Reducers and one 2P-1293 Bulkhead Nut

Show/hide table



Illustration 8	g01166971
Right side view of stick (33) 271-6429 Hose (34) 258-6711 Hose (35) 256-0489 Hose (37) 256-0485 Hose (38) 256-0486 Hose (39) 258-6709 Hose (40) 6V-9833 Cap (41) Two 6V-9834 Caps (42) Two 213-0100 Plates , eight 8T-4139 Bolts and eight 8T-4223 Washers (B) One 110-9160 Union , two 6V-8400 O-Ring Seals and one 6V-9173 Bulkhead Nut (C) One 6V-8997 Union , two 6V-9746 O-Ring Seals , two 221-1446 Reducers and one 2P-1293 Bulkhead Nut (D) One 6V-8998 Union , two 5K-9090 O-Ring Seals and one 6V-9172 Bulkhead Nut

8. Install the components to the boom and stick that are listed in Illustration 7 and Illustration 8.

Show/hide table



Illustration 9	g01166228
(15) 271-6430 Hose (29) 258-1085 Hose (43) 8T-3611 Connector , one 2S-4078 O-Ring Seal and one 6V-8400 O-Ring Seal (44) Location for eight 7X-2549 Bolts and eight 8T-4223 Washers (45) Location for two 253-2619 Manifolds and two 4J-0522 O-Ring Seal (46) 143-4281 Elbow , one 2S-4078 O-Ring Seal and one 5K-9090 O-Ring Seal (47) Reconnect 222-0529 Hose .

9. Install the components that are listed in Illustration 9.

Show/hide table



Illustration 10	g01163934
(11) 161-6858 Hose (12) 258-6705 Hose (16) 258-6700 Hose (48) Location for one 6V-8635 Connector , one 7M-8485 O-Ring Seal and one 5K-9090 O-Ring Seal (49) 7D-1553 Clip (50) Location for one 193-9230 Check Valve , one 6V-9746 O-Ring Seal and one 3D-2824 O-Ring Seal (51) 161-1818 Hose (52) 222-5781 Manifold (53) Location for one 127-9323 Bracket , one 8D-9671 Clip , one 8T-4137 Bolt and one 8T-4121 Washer

10. Install the components that are listed in Illustration 10.

    Note: Route hoses (11) and (12) through existing 7D-1553 Clip (49) .

    Note: Detach hose (51) from manifold (52) in order to install check valve and O-ring seals (50) .

Show/hide table



Illustration 11	g01166375
(11) 161-6858 Hose (54) 6V-9843 Tee and two 6V-8397 O-Ring Seal

11. Install the components that are listed in Illustration 11.

Show/hide table



Illustration 12	g01166479
(20) 148-0903 Hose (21) 140-1701 Hose (55) 6V-8781 Tee , one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal (56) 2P-8421 Adapter and one 3D-2842 O-Ring Seal (57) 6V-8636 Connector , one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal (58) 6V-9843 Tee and two 6V-8397 O-Ring Seals (59) 6V-9850 Elbow and one 6V-8397 O-Ring Seal (60) 9X-6279 Socket Setscrew (61) 117-6105 Hose

12. Install the components that are listed in Illustration 12.

13. At port TP, install connector (57). Then install tee (58). Then install elbow (59) .

14. Remove the plug in order to install socket setscrew (60) .

    Note: Install 9X-6279 Socket Setscrew before applying suction to the hydraulic tank. Suction on the hydraulic tank may pull the screw into the system.

Show/hide table



Illustration 13	g01166492
(12) One 258-6705 Hose (22) One 271-7358 Hose (61) One 6V-9853 Elbow and one 6V-9746 O-Ring Seal (62) One 6V-9839 Swivel Tee and two 6V-9746 O-Ring Seal (63) One 6V-9850 Elbow and one 6V-8397 O-Ring Seal (64) One 6V-8636 Connector , one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal (65) One 271-7357 Hose and one 6V-9746 O-Ring Seal

15. Install the components that are listed in Illustration 13.

Show/hide table



Illustration 14	g01166497
(13) 258-6713 Hose (14) 8W-6687 Hose (15) 225-5476 Hose (66) One 6V-8997 Union , two 6V-9746 O-Ring Seals , one 8P-8701 Washer and one 2P-1293 Locknut

16. Install union (66) to the bracket with the washer and locknut .

17. Connect 8W-6687 Hose (14) to union (66) .

18. Connect 225-5476 Hose (15) to union (66) .

19. Install 258-6713 Hose (13) .

Show/hide table



Illustration 15	g01166500
(67) 259-2641 Cover (68) Two 8T-4136 Bolts and two 8T-4121 Washers (69) Two 8T-0389 Locknuts , two 8T-4136 Bolts and four 8T-4121 Washers

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

Show/hide table



Illustration 16	g01159094
259-1068 Film

21. Attach the 259-1068 Film to the inside of the right hand cab window.

22. Load the application software for a intermittent saw configuration onto your MDM Display.
    • 260-0873 TK English/Spanish

    • 260-0874 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.