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


`
Relocation Of The Expansion Tanks For The Implement Hydraulic System{1354, 5057, 5505} [REHS4951]
HYDRAULIC SYSTEM
TANK GP
Relocation Of The Expansion Tanks For The Implement Hydraulic System{1354, 5057, 5505}
1.1. Introduction
2.1. Required Parts
3.1. Removal of Old Parts
4.1. Installation of the New Components
Wheel Loader:
994F (S/N: 4421-282)

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

Table 1
Required Parts    
Part Number     Part Name     Quantity    
6V-9854     Elbow     1    
6V-9009     Elbow     2    
6V-8625     Elbow     2    
9S-4185     O-Ring Plug     2    
6V-8944     O-Ring Reducer     1    
6V-9837     Swivel Tee     1    
6V-8995     Union     3    
9X-6653     Swivel Tee     1    
7X-2429     Swivel Tee     1    
229-1444     Elbow     1    
5K-9090     O-Ring Seal     1    
6V-8400     O-Ring Seal     10    
6V-8398     O-Ring Seal     11    
3K-0360     O-Ring Seal     4    
2S-4078     O-Ring Seal     2    
314-9686     Bracket Assembly     1    
321-7836     Bracket     1    
091-0081     Spacer     4    
314-9674     Hose Assembly     2    
314-9676     Tube Assembly     1    
314-9677     Tube Assembly     1    
314-9678     Tube Assembly     1    
314-9680     Hose Assembly     1    
314-9681     Hose Assembly     1    
314-9682     Hose Assembly     1    
314-9683     Hose Assembly     1    
314-9684     Hose Assembly     2    
321-7837     Tube Assembly     1    
4J-0520     O-Ring Seal     1    
5P-6412     Hose     1    
5P-7468     Clip     2    
5P-7469     Clip     2    
6V-1874     Grommet     2    
6V-8400     O-Ring Seal     3    
6V-9169     Bulkhead Nut     3    
6V-9173     Bulkhead Nut     1    
8C-3206     Half Flange     2    
8D-9671     Clip     1    
8S-0948     Clip     2    
8T-4121     Hard Washer     3    
8T-4133     Nut     1    
8T-4136     Bolt     1    
8T-4137     Bolt     1    
8T-4182     Bolt     4    
8T-4192     Bolt     10    
8T-4223     Hard Washer     12    
8T-4910     Bolt     2    
8T-4983     Hose Clamp     4    
9R-2216     Boss     2    
9X-6579     Orifice Nut     1    
314-9694     Block     4    
6C-8258     Block     1    
9R-2640     Boss     2    
7X-7945     Adapter     2    
6V-8627     Elbow     2    
8C-8408     Elbow     2    
2P-1279     Locknut     2    
4J-5477     O-Ring Seal     4    
214-7568     O-Ring Seal     2    
228-7088     O-Ring Seal     2    
314-9693     Reservoir     2    
314-9696     Bracket As     1    

Removal of Old Parts




    Illustration 1g01918599

    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.



    Illustration 2g01920714

    Right side of rear frame

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



    Illustration 3g01920715

    Top of rear frame

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



    Illustration 4g01920716

    Drain hose across hitch




    Illustration 5g01920717

    Drain hose across hitch

  1. 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.



    Illustration 6g01920718

    (A) Hose assembly

    (B) Breather

    (C) Hose assembly

  1. 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) .




    Illustration 7g01920719

    (B) Breather

    (D) Tee fitting

    (E) Elbow fitting




    Illustration 8g01920720

  1. 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.

  1. 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.



    Illustration 9g01920721

    (F) 107 mm (4.2 inch)

    (G) 705 mm (27.8 inch)

    (H) 60 mm (2.4 inch) hole

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



    Illustration 10g01925055

    (F) 107 mm (4.2 inch)

    (G) 705 mm (27.8 inch)

    (H) 60 mm (2.4 inch)

  1. 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 11g01925151

(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 12g01935453

(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




    Illustration 13g01925090

    (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




    Illustration 14g01925089

    (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.



    Illustration 15g01925093

    (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

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

    Refer to Illustration 13 and Illustration 15.




    Illustration 16g01925095

    (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

  1. 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.



    Illustration 17g01925097

    Right hand side example

    (C) Existing boss

    (53) 9R-2640 Boss




    Illustration 18g01938194

    Right hand side example

    (C) Existing boss

    (D) 167 mm (6.6 inch)

    (E) 46 mm (1.8 inch)

    (53) 9R-2640 Boss




    Illustration 19g01925098

    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

  1. 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) .




    Illustration 20g01938735



    Illustration 21g01925100

    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




    Illustration 22g01925102

    (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

  1. 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) .

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

    1. 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.

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

    1. Reinstall the reservoirs on both sides.

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



    Illustration 23g01925105

    (H) 16 mm (0.625 inch) drilled hole

    (J) Elbow

    (K) Hose




    Illustration 24g01925103

    (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




    Illustration 25g01926782

    (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

  1. 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) .

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

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

    1. 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.

    1. 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) .

    1. 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) .

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



    Illustration 26g01926784

    (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




    Illustration 27g01944457

    (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

  1. 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) .




    Illustration 28g01926785

    (L) Breather

    (12) 314-9680 Hose Assembly

  1. 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" ".



    Illustration 29g01926786

    (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

  1. 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.

Information System:

Field Installation of the Payload Monitor Gp Kits{7494}
C9.3 Engines for Caterpillar Built Machines Injector Trim File - Install
C13 Tier 4 Final Engines General Information - C13 Engines
C9.3 Engines for Caterpillar Built Machines ECM Software - Install
C27 and C32 Engines for Caterpillar Built Machines Valve Mechanism Cover - Remove and Install - C32
C9.3 Engines for Caterpillar Built Machines Electrical Connectors - Inspect
D5R Track-Type Tractor Hydraulic System Steering - Calibrate
2009/05/04 A Repair Kit for the Magnet is Now Available for the AccuGrade CD700 Display {7490}
C13 Tier 4 Final Engines Lubrication System
A New Flange Assembly For the Torque Converter On the D10T Is Now Used{3101}
C15 and C18 Industrial Engines Flame Detection Temperature Sensor - Remove and Install - Clean Emissions Module
Installation of VIMS Guardian on Underground Mining Machines{7601}
2009/06/01 A New Bracket Updates the Access Door Group {7251, 7273}
C15 and C18 Industrial Engines Air Inlet Elbow - Remove and Install
2009/05/11 Improved Wiring Harnesses Are Now Available {1408}
C15 and C18 Engines for Caterpillar Built Machines Exhaust Gas Valve (NRS) - Assemble
C13 Tier 4 Final Engines Electronic Control System Components
C13 Engines for Caterpillar Built Machines Combustion Head - Remove and Install - Clean Emissions Module
AccuGrade</SUP> GPS / Single UTS / Site and Laser Reference v11 for Excavators Universal Total Station - MT900
D7E Track-Type Tractor Power Train Track Roller Frame - Remove and Install
Procedure to Align the Dial on the Fuel Sender{1273, 7481, 7857}
C13 Engines for Caterpillar Built Machines Air Control Valve - Remove and Install - ARD Combustion, Clean Emissions Module
C13 Engines for Caterpillar Built Machines Fuel Manifold (ARD) - Remove and Install - Clean Emissions Module
C15 and C18 Industrial Engines Nozzle Heater Harness - Remove and Install