Relocation Of The Expansion Tanks For The Implement Hydraulic System{1354, 5057, 5505} Caterpillar

Introduction

This special instruction explains the installation procedure in order to relocate the expansion tanks for the implement hydraulic system. Do not begin the rework procedure until you have read the information that is contained in this procedure.

Note: Refer to Special Instruction, REHS1841, "General Welding Procedures" for information on welding specifications, qualifications, and procedures.

Required Parts

Removal of Old Parts

Show/hide table



Illustration 1	g01918599
Left side of rear frame

1. Remove the expansion tank, mounting brackets, clips, tubes, and hoses that are pictured in Illustration 1 from the left side of the rear frame.

Show/hide table



Illustration 2	g01920714
Right side of rear frame

2. Remove the expansion tank, clips, tubes, and hoses that are pictured in Illustration 2 from the right side of the rear frame.

Show/hide table



Illustration 3	g01920715
Top of rear frame

3. Remove tubes, clips, fittings, brackets, and hoses that are pictured in Illustration 3 from the top of the rear frame.

Show/hide table



Illustration 4	g01920716
Drain hose across hitch

Show/hide table



Illustration 5	g01920717
Drain hose across hitch

4. Remove the drain hose that is across the hitch that connects to the bottom of the oil level gauge for the implement hydraulic tank. Refer to Illustration 4 and Illustration 5.

Show/hide table



Illustration 6	g01920718
(A) Hose assembly (B) Breather (C) Hose assembly

5. Refer to Illustration 6. Remove hose (A) that is connected to breather (B) and to the rear frame.

   Remove hose (C) that is connected to the implement hydraulic tank and to breather (B) .

Show/hide table



Illustration 7	g01920719
(B) Breather (D) Tee fitting (E) Elbow fitting

Show/hide table



Illustration 8	g01920720

6. Refer to Illustration 7 and Illustration 8.

   Remove elbow fitting (E) and tee fitting (D) .

   Discard tee fitting (D) and reconnect elbow fitting (E). Elbow fitting (E) will be used later in order to connect the breather to the hydraulic tank.

7. Remove the implement hydraulic tank from the front frame. Refer to Disassembly and Assembly, RENR6321, "Hydraulic Tank (Implement) - Remove" for additional information on removing the hydraulic tank.

Show/hide table



Illustration 9	g01920721
(F) 107 mm (4.2 inch) (G) 705 mm (27.8 inch) (H) 60 mm (2.4 inch) hole

8. Refer to Illustration 9. Cut a 60 mm (2.4 inch) hole into the frame on the right hand side of the machine.

Show/hide table



Illustration 10	g01925055
(F) 107 mm (4.2 inch) (G) 705 mm (27.8 inch) (H) 60 mm (2.4 inch)

9. Refer to Illustration 10. Cut a 60 mm (2.4 inch) hole into the frame on the left hand side of the machine.

Installation of the New Components

Illustration 11	g01925151
(1) 314-9694 Block (2) 8T-4192 Bolt (3) 8T-4223 Hard Washer (4) 6V-8625 Elbow (5) 3K-0360 O-Ring Seal (6) 6V-8398 O-Ring Seal (7) 9S-4185 O-Ring Plug (8) 314-9684 Hose Assembly (9) 314-9674 Hose Assembly (10) 6V-8400 O-Ring Seal (11) 314-9677 Tube Assembly (12) 314-9680 Hose Assembly (13) 8T-4182 Bolt (14) 091-0081 Spacer (15) 8C-3206 Half Flange (16) 4J-0520 O-Ring Seal (17) 314-9678 Tube Assembly (18) 321-7836 Bracket (19) 7X-2429 Swivel Tee (20) 8T-4983 Hose Clamp (21) 5P-6412 Hose (22) 321-7837 Tube Assembly (23) 6V-9173 Bulkhead Nut (24) 9X-6653 Swivel Tee (25) 314-9676 Tube Assembly (26) 229-1444 Elbow (27) 8T-4910 Bolt (28) 5P-7468 Clip (29) 5P-7469 Clip (30) 6V-1874 Grommet (31) 9R-2216 Boss (32) 314-9693 Reservoir (33) 6V-8995 Union (34) 6V-9169 Bulkhead Nut (35) 8T-4137 Bolt (36) 8T-4121 Hard Washer (37) 8D-9671 Clip (38) 314-9686 Bracket Assembly (39) 6V-9009 Elbow (40) 2S-4078 O-Ring Seal (41) 314-9681 Hose Assembly (42) 314-9683 Hose Assembly (43) 314-9682 Hose Assembly (44) 8S-0948 Clip (45) 8T-4133 Nut (46) 8T-4136 Bolt (47) 6V-9854 Elbow (48) 5K-9090 O-Ring Seal (49) 9X-6579 Orifice Nut (50) 6V-8944 O-Ring Reducer (51) 6V-9837 Swivel Tee

Illustration 12	g01935453
(6) 6V-8398 O-Ring Seal (42) 314-9683 Hose Assembly (43) 314-9682 Hose Assembly (47) 6V-9854 Elbow (48) 5K-9090 O-Ring Seal (49) 9X-6579 Orifice Nut (50) 6V-8944 O-Ring Reducer (51) 6V-9837 Swivel Tee

Show/hide table



Illustration 13	g01925090
(2) 8T-4192 Bolt (3) 8T-4223 Hard Washer (10) 6V-8400 O-Ring Seal (11) 314-9677 Tube Assembly (12) 314-9680 Hose Assembly (13) 8T-4182 Bolt (14) 091-0081 Spacer (15) 8C-3206 Half Flange (16) 4J-0520 O-Ring Seal (17) 314-9678 Tube Assembly (18) 321-7836 Bracket (19) 7X-2429 Swivel Tee (20) 8T-4983 Hose Clamp (21) 5P-6412 Hose (22) 321-7837 Tube Assembly (23) 6V-9173 Bulkhead Nut (24) 9X-6653 Swivel Tee (25) 314-9676 Tube Assembly (26) 229-1444 Elbow (52) 6C-8258 Block

Show/hide table



Illustration 14	g01925089
(11) 314-9677 Tube Assembly (25) 314-9676 Tube Assembly

1. Insert 314-9676 Tube Assembly (25) and 314-9677 Tube Assembly (11) into the front frame. Refer to Illustration 13 and Illustration 14.

Show/hide table



Illustration 15	g01925093
(2) 8T-4192 Bolt (3) 8T-4223 Hard Washer (10) 6V-8400 O-Ring Seal (11) 314-9677 Tube As (13) 8T-4182 Bolt (14) 091-0081 Spacer (15) 8C-3206 Half Flange (16) 4J-0520 O-Ring Seal (17) 314-9678 Tube As (18) 321-7836 Bracket (19) 7X-2429 Swivel Tee (20) 8T-4983 Hose Clamp (21) 5P-6412 Hose (22) 321-7837 Tube As (23) 6V-9173 Bulkhead Nut (24) 9X-6653 Swivel Tee (25) 314-9676 Tube As (26) 229-1444 Elbow (52) 6C-8258 Block

2. Assemble the listed hardware onto 314-9676 Tube Assembly (25) and 314-9677 Tube Assembly (11) .

   Refer to Illustration 13 and Illustration 15.

Show/hide table



Illustration 16	g01925095
(A) 102 mm (4.0 inch) Reference dimension (B) 572 mm (22.5 inch) Reference dimension (20) 8T-4983 Hose Clamp (21) 5P-6412 Hose (22) 321-7837 Tube Assembly (23) 6V-9173 Bulkhead Nut (52) 6C-8258 Block

3. Refer to Illustration 15 and Illustration 16. Use reference dimensions (A) and (B) in order to locate 6C-8258 Block (52) onto the machine. Apply a 3 mm (0.12 inch) fillet weld in order to fasten 6C-8258 Block (52) onto the machine.

Show/hide table



Illustration 17	g01925097
Right hand side example (C) Existing boss (53) 9R-2640 Boss

Show/hide table



Illustration 18	g01938194
Right hand side example (C) Existing boss (D) 167 mm (6.6 inch) (E) 46 mm (1.8 inch) (53) 9R-2640 Boss

Show/hide table



Illustration 19	g01925098
Right hand side example (3) 8T-4223 Hard Washer (27) 8T-4910 Bolt (28) 5P-7468 Clip (29) 5P-7469 Clip (30) 6V-1874 Grommet (31) 9R-2216 Boss

4. Refer to Illustration 17, Illustration 18 and Illustration 19. Remove boss (C) on the right hand side of the frame and the left hand side of the frame.

   Use reference dimensions (D) and (E) in order to locate 9R-2640 Bosses (53). Apply a 3 mm (0.12 inch) fillet weld in order to secure bosses (53) onto the right hand side and the left hand side.

   Note: Dimension (D) and dimension (E) are reference dimensions. Install the listed hardware in Illustration 19 onto tube assemblies (11) and (25) in order to assist locating 9R-2640 Boss (53) .

Show/hide table



Illustration 20	g01938735

Show/hide table



Illustration 21	g01925100
Right hand side of frame (F) 36 mm (1.4 inch) Reference dimension (G) 44 mm (1.7 inch) Reference dimension (1) 314-9694 Block

Show/hide table



Illustration 22	g01925102
(1) 314-9694 Block (2) 8T-4192 Bolt (3) 8T-4223 Hard Washer (9) 314-9674 Hose Assembly (10) 6V-8400 O-Ring Seal (32) 314-9693 Reservoir (39) 6V-9009 Elbow (40) 2S-4078 O-Ring Seal

5. Refer to Illustration 20, Illustration 21 and Illustration 22.

   1. Use the listed hardware in order to assemble the 314-9694 Blocks (1) onto 314-9693 Reservoir (32) .

   2. Assemble O-ring (10), elbow (39), O-ring (40), and hose assembly (9) onto the reservoir (32) .

   3. Dimension (F) and dimension (G) are only reference dimensions. Locate reservoirs (32) onto the frame and tack weld blocks (1) onto the plates on the right side and the left side of the frame.

   4. Remove the reservoirs and finish weld the blocks with a 3 mm (0.12 inch) fillet weld on both sides.

   5. Reinstall the reservoirs on both sides.

   6. Ensure that the fittings contain O-rings and tighten the connections on both reservoirs.

Show/hide table



Illustration 23	g01925105
(H) 16 mm (0.625 inch) drilled hole (J) Elbow (K) Hose

Show/hide table



Illustration 24	g01925103
(6) 6V-8398 O-Ring Seal (8) 314-9684 Hose Assembly (33) 6V-8995 Union (34) 6V-9169 Bulkhead Nut (54) 2P-1279 Locknut (55) 7X-7945 Adapter (56) 4J-5477 O-Ring Seal (57) 6V-8627 Elbow (58) 214-7568 O-Ring Seal (59) 228-7088 O-Ring Seal (60) 8C-8408 Elbow

Show/hide table



Illustration 25	g01926782
(4) 6V-8625 Elbow (5) 3K-0360 O-Ring Seal (6) 6V-8398 O-Ring Seal (8) 314-9684 Hose Assembly (32) 314-9693 Reservoir

6. Refer to Illustration 23, Illustration 24, and Illustration 25 in order to modify the mounting plate for the grease lines on both sides of the frame.

   1. Drill a 16 mm (0.625 inch) hole (H) above elbow (J) .

   2. Remove hose (K) and elbow fitting (J). Discard fitting (J) .

   3. Drill the existing hole from Step 6.b in order to obtain a 22 mm (0.875 inch) hole.

   4. Install 6V-8995 Union (33), 6V-9169 Bulkhead Nut (34), and 6V-8398 O-Ring Seal (6) into the 22 mm (0.875 inch) hole.

      Connect one end of 314-9684 Hose Assembly (8) onto 6V-8995 Union (33). Do not tighten hose assembly (8) at this time.

   5. Install 6V-8625 Elbow (4), 3K-0360 O-Ring Seal (5), and 6V-8398 O-Ring Seal (6) into reservoir (32) .

      Connect the other end of 314-9684 Hose Assemblies (8) onto 6V-8625 Elbows (4). Tighten the hose fittings at both end of hoses (8) .

   6. Use the listed hardware in order to install 7X-7945 Adapter (55), 6V-8627 Elbow (57), and 8C-8408 Elbow (60) into 16 mm (0.625 inch) drilled hole (H) .

   7. Reconnect hose (K) onto 8C-8408 Elbow (60) .

Show/hide table



Illustration 26	g01926784
(6) 6V-8398 O-Ring Seal (33) 6V-8995 Union (34) 6V-9169 Bulkhead Nut (35) 8T-4137 Bolt (36) 8T-4121 Hard Washer (37) 8D-9671 Clip (38) 314-9686 Bracket Assembly (41) 314-9681 Hose Assembly (42) 314-9683 Hose Assembly (43) 314-9682 Hose Assembly (44) 8S-0948 Clip (45) 8T-4133 Nut (46) 8T-4136 Bolt (42) 314-9683 Hose Assembly (43) 314-9682 Hose Assembly (47) 6V-9854 Elbow (48) 5K-9090 O-Ring Seal (49) 9X-6579 Orifice Nut (50) 6V-8944 O-Ring Reducer (51) 6V-9837 Swivel Tee (61) 314-9696 Bracket As

Show/hide table



Illustration 27	g01944457
(6) 6V-8398 O-Ring Seal (42) 314-9683 Hose Assembly (43) 314-9682 Hose Assembly (47) 6V-9854 Elbow (48) 5K-9090 O-Ring Seal (49) 9X-6579 Orifice Nut (50) 6V-8944 O-Ring Reducer (51) 6V-9837 Swivel Tee

7. Use the listed hardware from Illustration 26 and Illustration 27 in order to connect the hydraulic lines from the expansion tanks onto the oil level gauge.

   Note: Remove the old bracket in order to install 314-9696 Bracket As (61) .

Show/hide table



Illustration 28	g01926785
(L) Breather (12) 314-9680 Hose Assembly

8. Connect 314-9680 Hose Assembly (12) onto breather (L). 314-9680 Hose Assembly (12) will connect onto the elbow fitting that was removed and reconnected in Step 6 under ""Removal of Old Parts" ".

Show/hide table



Illustration 29	g01926786
(2) 8T-4192 Bolt (3) 8T-4223 Hard Washer (10) 6V-8400 O-Ring Seal (11) 314-9677 Tube Assembly (12) 314-9680 Hose Assembly (13) 8T-4182 Bolt (14) 091-0081 Spacer (15) 8C-3206 Half Flange (16) 4J-0520 O-Ring Seal (17) 314-9678 Tube Assembly (18) 321-7836 Bracket (19) 7X-2429 Swivel Tee (20) 8T-4983 Hose Clamp (21) 5P-6412 Hose (22) 321-7837 Tube Assembly (23) 6V-9173 Bulkhead Nut (24) 9X-6653 Swivel Tee (25) 314-9676 Tube Assembly (26) 229-1444 Elbow

9. Install the hydraulic tank and make all of the necessary connections. Refer to Disassembly and Assembly, RENR6321, "Hydraulic Tank (Implement) - Install" for additional information on installing the hydraulic tank.

   Ensure that the fittings contain O rings and connect 5P-6412 Hose (21) onto the implement hydraulic tank.