Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 4C-6486 | Stand | 2 |
8S-7611 | Tube | 2 | |
8S-8048 | Saddle | 2 | |
8S-7615 | Pin | 2 | |
B | - | M16 by 2 by 40 mm Forcing Screws | 2 |
C | 1U-5197 | Hydraulic Cylinder | 1 |
3S-6224 | Electric Hydraulic Pump | 1 | |
9U-6753 | Retaining Plate | 1 | |
9T-2240 | Rod | 4 | |
8T-4133 | Nut | 4 | |
8T-4121 | Washer | 4 | |
155-8191 | Sleeve | 1 | |
138-2353 | Adapter Plate | 1 | |
8T-0271 | Bolt | 3 | |
220-1776 | Puller Stud | 1 | |
9U-6809 | Nut (M36 by 4.0) | 1 | |
8T-5463 | Washer | 1 | |
D | 6V-0014 | Double Acting Cylinder | 1 |
3S-6224 | Electric Hydraulic Pump | 1 | |
9U-6753 | Retaining Plate | 1 | |
9T-2240 | Rod | 4 | |
8T-4133 | Nut | 4 | |
8T-4121 | Washer | 4 | |
155-8191 | Sleeve | 1 | |
136-5747 | Puller Stud(1) | 1 | |
9U-6810 | Nut (M48 by 5.0) | 1 | |
7X-0542 | Washer | 1 | |
E | 3S-6224 | Electric Hydraulic Pump | 1 |
9T-2240 | Rod | 4 | |
8T-4133 | Nut | 4 | |
8T-4121 | Washer | 4 | |
5P-5201 | Double Acting Cylinder | 1 | |
4C-8152 | Retaining Plate | 1 | |
137-8792 | Sleeve | 1 | |
4C-6504 | Puller Stud | 1 | |
9U-6800 | Nut (M64 by 6.0) | 2 | |
138-1135 | Bearing Puller Plate | 1 |
(1) | The rod must be shortened to a length of |
Start By:
- Remove the bucket. Refer to Disassembly and Assembly, "Bucket - Remove".
- Remove the tilt cylinder. Refer to Disassembly and Assembly, "Tilt Cylinder - Remove".
- Remove the boom links. Refer to Disassembly and Assembly, "Boom Links - Remove".
- Remove the bucket link. Refer to Disassembly and Assembly, "Bucket Link - Remove".
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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
Illustration 1 | g00863575 |
Note: Alignment of the pin joints is an important factor. The pins that are used in the pin joints are a slip fit. It is important to relieve the pin joint pressure from the pin joints that are being serviced. It is important to park the machine on a surface that is flat and level. Use the implement hydraulics, hoists, or suitable lifting devices in order to relieve the pin joint pressure. Use Illustration 1 as a guide for the pins and the pin joints that are referenced in this procedure.
- Place boom (1) on Tooling (A) at a height of
457 mm (18 inch) , as shown.Show/hide tableIllustration 3 g00421559 - Use a suitable lifting device and a lifting sling to support lift cylinder (4). The weight of the lift cylinder is approximately
1035 kg (2280 lb) . - Remove bolt (2), the washer, and the spacer from plate (3).
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Illustration 4 g00863582 - Install Tooling (B) in the threaded holes of plate (3). Tighten Tooling (B) evenly in order to remove plate (3). Remove the two dowel pins.
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Illustration 5 g00863750 - Remove O-ring seal (5) from the face of the L-pin (6).
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Illustration 6 g00863752 Right Side - Remove bolt (8), the washer, and spacer (7) from plate (9).
- Remove plate (9).
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Illustration 7 g00692942 Right Side - Remove maintenance free linkage seal (10) from plate (9).
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Illustration 8 g00692944 Right Side - Remove plate (11) from L-pin (7).
- Remove O-ring seal (12) from L-pin (7).
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Illustration 9 g00863753 - Attach a hoist and a suitable lifting sling to Tooling (C). The weight of Tooling (C) is
215 kg (475 lb) . Install Tooling (C) on the head end of the L-pin. Use Tooling (C) to pull out the L-pin enough in order to free the bore of lift cylinder (4).Show/hide tableIllustration 10 g00421858 - Lower lift cylinder (4) onto cribbing, as shown.
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Illustration 11 g00863756 - Attach chains and a suitable lifting device to lift cylinder (13) before you pull out the remainder of L-pin (7). The weight of the lift cylinder is
1035 kg (2280 lb) . - Tooling (C) will retain L-pin (7) when the pin is removed. The weight of the L-pin is
295 kg (650 lb) . The combined weight of Tooling (C) and of L-pin (7) is510 kg (1125 lb) .Show/hide tableIllustration 12 g00693195 - Lower lift cylinder (13) onto cribbing, as shown.
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Illustration 13 g00693196 - Remove clamps (15) that secure wiring harness (14) to boom (1). Place wiring harness (14) aside.
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Illustration 14 g00422003 Note: The weight of the boom that is used in this lift arrangement is
5993 kg (13180 lb) . - Use a hoist and a suitable lifting sling to support boom (1). The weight of the boom is
5650 kg (12450 lb) . Raise boom (1) enough in order to remove Tooling (A).Show/hide tableIllustration 15 g00422011 - Lower boom (1) to a height of approximately
25 mm (1 inch) above the ground.Show/hide tableIllustration 16 g00693206 Note: The following steps are for the removal of the H-pin. The H-pin is located in the upper frame.
- Remove bolt (16) and the washer from plate (17).
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Illustration 17 g00863755 - Install Tooling (B) in the threaded holes of plate (17). Tighten Tooling (B) evenly in order to remove plate (17). Remove the two dowel pins.
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Illustration 18 g00863799 - Remove O-ring seal (18) from the face of H-pin (19).
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Illustration 19 g00863805 - Disconnect the harness for the right headlamps. The electrical connector is located under the fender.
- Remove four bolts (21) and headlamp (20) from the right fender.
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Illustration 20 g00863806 - Remove four bolts (22), the washers and plate (23) from the head end of H-pin (19).
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Illustration 21 g00863808 - Attach a hoist and a suitable lifting sling to Tooling (D). The weight of Tooling (D) is
213 kg (470 lb) . Install Tooling (D) in order to remove the H-pin. - Tooling (D) will retain the H-pin when the H-pin is removed. The weight of the H-pin is
209 kg (460 lb) . The combined weight of Tooling (D) and of the H-pin is420 kg (925 lb) .Show/hide tableIllustration 22 g00422399 Show/hide tableIllustration 23 g00422401 Note: The weight of the boom in this lift arrangement is
5993 kg (13212 lb) . - Carefully remove boom (1). The weight of the boom is
5650 kg (12456 lb) .Show/hide tableIllustration 24 g00863832 - Remove collar (24) from the frame. The collar is a slip fit in the H-pin bore. Remove the remaining collar assembly on the opposite side of the machine.
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Illustration 25 g00863833 - Remove seal assembly (25) from each side of collar (24). Remove the seal assemblies from the remaining collar.
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Illustration 26 g00863838 Note: The following steps are for the removal of bearings (26) at the four pin joints of boom (1).
Show/hide tableIllustration 27 g00863856 - Assemble Tooling (E). The bearing plate will rotate enough in order to allow insertion through the inside diameter of the bearing that is being removed.
- The bearing plate will then rotate into position after the bearing plate has passed through the inside diameter of the bearing.
- The following steps are for preparing the bearing for removal.
- Cut approximately 3/4 of the way through the bearing in four locations. See Illustration 28. This will relax the bearing. Minimum force will then be required in order to pull the bearing .
- Allow the bearing to reach ambient temperature before removal.
Show/hide tableIllustration 28 g00565676 Note: Before the bearing is removed, use air arc gouging or a torch gouging tip in order to remove material. Do not allow the air arc gouging to damage the bore. This can create high spots under the bearing or a leak path.
Show/hide tableIllustration 29 g00863877 Show/hide tableIllustration 30 g00863878 - Use a hoist and a suitable lifting sling to support Tooling (E). The weight of Tooling (E) is
159 kg (350 lb) . Mount Tooling (E) in place on the rear side of bearing (27). - Remove bearing (27) from the boom bore.
- Repeat Steps 32 through 34 in order to remove the bearings from the opposite side of the boom.
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Illustration 31 g00422820 H-pin Bore - Remove spacer (28) from the H-pin bore of the boom. The spacer is a slip fit inside the H-pin bore. The weight of spacer (28) is
18 kg (40 lb) .Note: Use the same procedure for the remaining pin joints. The weight of the bearing spacer in the L-pin joint is
34 kg (75 lb) . Use a hoist and a suitable lifting sling to remove the spacer. - If the bores in the boom are damaged, perform the following procedures:
- Perform a repair weld on any gouges.
- Use the die grinder to repair the welds.
- Use a die grinder to grind any high spots.
Show/hide tableIllustration 32 g00863879 - Remove seal assemblies (29) from lift cylinder (4). Repeat this step for the remaining lift cylinder.
Illustration 2 | g00421518 |