D8T Powered Bottom Guard Retrofit Instructions {7153} Caterpillar

Track-Type Tractor

D8T (S/N: FMC1-UP; MLN1-UP; FCT1-UP)

Introduction

A new powered bottom guard assembly is available for D8T machines. The new powered bottom guards include a quick-opening feature to facilitate regular bottom guard clean-out. The bottom guards also incorporate the traditional bottom opening to facilitate regular maintenance. This update will take approximately 50 hours to complete.

Safety

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Note: Prior to tightening, do not coat any fasteners with oil or grease unless a coating is specified in the procedure.

Welding Processes and Air Arc Gouging

The following welding processes are acceptable for this repair procedure:

• Gas metal arc welding (GMAW)Use 35 ± 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The AWS Class ER70S-3 is a welding process that can be used with the following welders: Lincoln L-50 and Hobart HB-25.

• Flux cored arc welding (FCAW)Use 35 ± 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The FCAW process is called the AWS Class E71T-1 process.

• Shielded metal arc welding (SMAW)Use E7018 electrodes in this DCEP process.

• Air arc gouging (DCEP)Use 5/16 inch diameter rods for carbon arc.

Required Parts

Table 1

446-5115 Bottom Guard Ar
Qty	Part Number	Description
1	4P-7581	Clip
1	7K-1181	Cable Strap
1	8T-4186	Bolt
1	125-8534	Plate As
1	200-6345	Mount
2	204-2281	Cable Strap
484-8980 Wiring Gp
1	3E-5239	Relay As
5	3S-2093	Cable Strap
3	4P-7581	Clip
2	4P-8134	Clip
2	6V-7978	Screw
7	7K-1181	Cable Strap
1	7X-2619	Bolt
8	8T-4121	Hard Washer
1	8t-4133	Nut
1	8T-4136	Bolt
2	8T-4137	Bolt
1	8T-4186	Bolt
2	8T-4196	Bolt
1	9X-8256	Washer
2	130-5300	Clip
2	132-5789	Clip
13	177-2215	Strap
4	200-6345	Mount
19	204-2281	Cable Strap
10	204-8000	Cable Tie Mounting
1	216-4970	Circuit Breaker As
1	283-1524	Plate As
1	352-3968	Clip
1	349-7801	Bracket
1	480-0124	Harness As
1	484-8981	Cable As
1	484-8982	Cable As
1	484-8983	Wiring Gp
1	484-8985	Cable As
1	484-8986	Bracket As
488-9393 Hyd Lines Gp
2	1S-0996	Clip
1	4K-6177	Clip
6	6K-5967	Clip
1	6V-8397	O-Ring Seal
2	8C-3451	Dust Cap
10	8T-4121	Hard Washer
2	8T-4137	Bolt
3	8T-4178	Bolt
2	8T-4195	Bolt
4	8T-4196	Bolt
2	8T-7934	Hard Washer
1	090-8635	Spacer
1	123-2169	O-Ring Face Seal Fitting
2	148-8305	Adapter As
6	148-8336	Connector As
1	148-8378	Elbow As
1	148-8433	Tee As
1	148-8435	Tee As
1	148-8449	Swivel Tee
1	150-4043	Connector As
1	153-6259	Tee As
2	164-5590	Fluid Sampling Valve Gp
1	168-1968	Tee As
2	195-0882	Bracket As
2	200-6345	Mount
4	204-2281	Cable Strap
1	236-8929	Handle
2	344-5675	Nut
1	448-5440	Plate As
1	488-3068	Control Valve Gp
1	488-9394	Hose As
1	488-9395	Hose As
1	488-9396	Hose As
1	488-9397	Hose As
1	488-9398	Hose As
1	488-9400	MTG GP- Pump
1	488-9402	Hose As
1	488-9403	Hose As
1	488-9405	Bracket As
446-5119 Basic Cyl Gp
4	3B-4631	Cotter Pin
8	299-3426	Hard Washer
4	436-0891	Pin
2	509-0252	Basic Cyl Gp
480-7603 Front Bottom Guard Gp
Qty	Part Number	Description
5	3B-4631	Cotter Pin
4	5H-9899	Retaining Ring
4	7X-0584	Hard Washer
1	7X-0594	Hard Washer
4	7X-2562	Bolt
4	8T-4123	Washer
8	8T-4821	Washer
8	194-5041	Hard Washer
4	436-0891	Pin
1	446-5124	Door As
1	446-5124	Door As
1	446-5126	Plate
1	446-5128	Pin
1	446-5129	Bar
1	446-5130	Bar
4	446-5156	Pin Clevis
1	480-7604	Guard As
480-7605 Rear Bottom Guard Gp
5	3B-4631	Cotter Pin
4	5H-9899	Retaining Ring
4	7X-0584	Hard Washer
1	7X-0594	Hard Washer
8	7X-2562	Bolt
8	8T-4123	Washer
8	8T-4821	Washer
8	194-5041	Hard Washer
4	436-0891	Pin
1	446-5147	Door As
1	446-5148	Door As
1	446-5126	Plate
1	446-5128	Pin
1	446-5129	Bar
1	446-5130	Bar
4	446-5156	Pin Clevis
1	480-7604	Guard As
459-8157 Support Gp
2	1M-8534	Drawbar Pin
2	3B-4631	Cotter Pin
1	3B-4640	Cotter Pin
1	4D-7388	Clip
9	5P-1088	Seal
1	5P-7464	Clip
1	5P-7465	Clip
34	5P-7512	Seal
1	6V-7359	Grommet
8	7X-0594	Hard Washer
10	7X-2532	Bolt
2	7X-2548	Bolt
2	7X-2565	Bolt
1	7X-7729	Washer
6	8T-4121	Hard Washer
12	8T-4131	Nut
1	8T-4136	Bolt
3	8T-4191	Bolt
3	8T-4195	Bolt
2	8T-4223	Hard Washer
12	8T-5439	Hard Washer
5	9R-2613	Weld Boss
2	9R-2640	Boss
1	9R-2821	Boss
2	9R-3761	Boss
1	148-8327	Connector As
1	175-1540	Ground Boss
1	203-6689	Adapter As
12	217-3655	Retainer
2	448-5441	Plate As
1	448-5443	Hose As
1	448-5444	Hose As
1	472-0862	Bracket As
1	472-0863	Plate
2	472-0864	Plate
2	472-0865	Clevis Pin
1	480-7599	Bracket
1	488-9399	Hose As
1	488-9404	Tube As
1	492-1925	Hose As
1	496-8109	Plate

Table 2

488-9400 Pump MTG Gp
2	8T-4121	Hard Washer
2	8T-4136	Bolt
2	8T-4223	Hard Washer
2	8T-5414	Stud
2	329-3356	Nut
1	446-5137	Hydraulic Pump Gp
1	488-9401	Bracket

Table 3

If Not Equipped With Low Fan Speed Valve
1	420-6436	Bracket As
3	8T-4195	Bolt
3	8T-4121	Hard Washer
1	278-0518	Spacer

Removal

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Illustration 1	g03716446

1. Remove all bottom guards.

   Note: Front guard will be reused. The other guards will be replaced.

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   Illustration 2	g03716458

2. Remove enclosure doors and lower enclosure guards from both side of the machine.
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   Illustration 3	g03716465

3. Remove batteries and battery box front panel.

4. Remove floor plate, seat, and seat mounting plate from inside the cab.
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   Illustration 4	g03716503

5. Disconnect fan return line.
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   Illustration 5	g03716514

6. Remove hydraulic oil cooler (A), bypass line and lower fitting (B), and baffle (C). Remove and retain two clips, bolt, and washer (D) for later use.

   Note: The bypass line and lower fitting will not be reused.

   Note: Remove the low fan speed valve if equipped.

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   Illustration 6	g03716520

7. Unbolt A/C accumulator mount bracket and quick oil change bracket from the frame. Lay outside the frame, as shown. Remove the lower ATAAC inlet tube.

   Note: Unbolt the quick change oil hose bracket (If Equipped).

8. Remove P-Clips (1) for fan lines on left-hand frame, just below top of frame rail, for access to locate and weld cylinder mount.
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   Illustration 7	g06124841
   Location of quick change oil hoses.

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   Illustration 8	g03716580

9. If Equipped, remove the quick change oil hose
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   Illustration 9	g06124845
   Location of the power train cooler hose.

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   Illustration 10	g03716624

10. Remove power train cooler hose. These parts will be replaced.

Welding Procedure

Necessary Parts

Table 4

459-8157 Support Gp
Item	Qty	Part Number	Description
1	1	472-0862	Plate
2	1	175-1540	Ground Boss
3	2	448-5441	Plate As
4	2	9R-2640	Boss
5	5	9R-2613	Weld Boss
6	1	496-8109	Plate
7	1	9R-2821	Boss
8	2	9R-3761	Boss
9	1	480-7599	Plate
10	2	472-0864	Plate
11	1	472-0863	Plate
12	3	8T-4191	Bolt
13	5	8T-4121	Hard Washer
14	2	8T-4223	Hard Washer
15	2	7X-2548	Bolt

Procedure

1. Remove paint from all welding locations and brackets before positioning and welding parts.
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   Illustration 11	g03716645
   (A) 242 mm (9.53 inch) (B) 58 mm (2.30 inch) (C) 13 mm (0.50 inch) (D) 277.6 mm (10.90 inch) (E) 28 mm (1.10 inch) (W1) 8 mm (0.30 inch) fillet weld (W2) 6 mm (0.20 inch) fillet weld

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   Illustration 12	g03717409

2. Position two plates (10) on the left-hand frame rail using dimensions above. Tack weld in place and weld (W2) on both sides.

   Note: Do not weld within 1 inch of the corner of the frame rail. See dimension (F).

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   Illustration 13	g03726895

3. Position plate assembly (3) nose facing down on the left-hand frame rail using dimensions above. Tack weld in place and weld (W1) around the parts.

   Note: Follow vertical weld procedure where applicable.

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   Illustration 14	g03717473

4. If equipped with current powered bottom guards, remove part (G) from the left-hand frame, under rear engine mount.
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   Illustration 15	g03717651
   (H) 40 mm (1.60 inch) (J) 277.6 mm (10.90 inch) (L) 36 mm (1.42 inch) (N) 123 mm (4.84251 inch) (W1) 8 mm (0.30 inch) fillet weld (W2) 6 mm (0.20 inch) fillet weld

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   Illustration 16	g03717687

5. Position plate (1) on the left-hand frame rail using dimensions above. Tack weld in place.

   Note: After the cylinder mount is tacked in place, cut the "T" shaped end of the hinge loop at the notch (arrow) and discard.

6. Weld plate (1) using dimensions (W2).

   Note: Do not weld within 1 inch of the corner of the frame rail.

7. Position rear plate assembly (3) nose facing down on the left-hand frame rail using dimensions above. Tack weld in place and weld (W1) around the parts.

   Note: Follow vertical weld procedure where applicable.

8. Position plate (9) on the left-hand frame rail using dimensions above. Tack weld in place and weld (W2) on both sides.
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   Illustration 17	g03717714
   (P) 216 mm (8.50 inch) (R) 13 mm (0.51 inch) (W3) 3 mm (0.10 inch) filet weld

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   Illustration 18	g03717725

9. Position boss (8) on the left-hand frame rail using dimensions above. Tack weld in place and weld (W3) around part.
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   Illustration 19	g03717753
   (W) 37.7 mm (1.48 inch) (Y) 90.4 mm (3.56 inch) (W3) 3 mm (0.12 inch) filet weld

10. Position boss (8) on left-hand frame rail using dimensions above. Tack weld in place and weld (W3) around part.
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    Illustration 20	g06125160

11. Install bosses (2), (4), and (5) to plate (6) using three bolts (12), two bolts (15), three washers (13), and two washers (14). Install two washers (13) to act as a spacer for locating boss (2).
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    Illustration 21	g03718239
    (K) 8T-4223 Hard Washer (M) 7X-2548 Bolt (W4) 5 mm (0.20 inch)

12. Position bosses (2), (4), and (5) using plate assembly (6) from Step 11. Locate plate assembly (6) using two bolts (M) and two washers (K). Tack weld in place and weld (W4) around parts.

13. Remove bolts, washers, and plate (6).
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    Illustration 22	g03718264
    (AN) 260 mm (10.24 inch) (AP) 54.5 mm (2.15 inch) (W4) 5 mm (0.20 inch)

14. Position boss (5) on right-hand frame rail using dimensions above. Tack weld in place and weld (W4) around boss (5).
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    Illustration 23	g03824261
    (W4) 5 mm (0.20 inch)

15. Position plate (11) using existing two bosses (S). Position two bosses (5) in top two holes in plate (11). Tack weld in place and weld (W4) around part.

16. Remove plate (11).
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    Illustration 24	g03718346
    (AL) 48.05 ± 2 mm (1.89 ± 0.08 inch) (AM) 1.6 ± 2 mm (0.06 ± 0.08 inch) (W3) 3 mm (0.10 inch) filet weld

17. Position boss (7) on inside battery box front panel using dimensions above. Tack weld in place and weld (W3) around part.

Installation Procedure

After all bosses, brackets, and plates have been welded to the frame and painted, begin the component installation.

Hydraulic Pump And Motor Installation

Table 5

484-8980 Wiring Gp
Item	Qty	Part Number	Description
1	1	3E-5239	Relay As
2	1	480-0124	Harness As
3	1	484-8981	Cable As
4	1	484-8982	Cable As
5	5	204-8000	Cable Tie Mounting
6	9	204-2281	Cable Strap
7	13	177-2215	Strap
8	4	7K-1181	Cable Strap
9	2	132-5789	Clip
10	4	200-6345	Mount
488-9393 Hyd Lines Gp
11	1	148-8336	Connector As
11A	1	6V-8626	Elbow
11B	1	3J-1907	O-Ring Seal
11C	1	6V-8397	O-Ring Seal
12	1	148-8378	Elbow As
12A	1	6V-8724	Elbow
12B	1	3J-1907	O-Ring Seal
12C	1	6V-8397	O-Ring Seal
488-9400 Pump MTG Gp
13	1	446-5137	Elec Dr pump Gp
14	1	488-9401	Bracket
15	2	8T-4121	Hard Washer
16	2	8T-4136	Bolt
17	2	329-3356	Nut
18	2	8T-5414	Stud
19	2	8T-4223	Hard Washer

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Illustration 25	g03718534

1. Mount pump and motor (13) to bracket (14) using two washers (15) and two bolts (16).
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   Illustration 26	g03718580

2. Assemble the elbow and adapter assemblies using elbow (12A), o-ring (12B), o-ring seal (12C), elbow (11A), o-ring seal (11B), and o-ring seal (11C) before installation. Install elbow and adapter assemblies (12) and (11) into pump (13).
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   Illustration 27	g03718589

3. Connect relay (1), located in the battery box, to wire harness (2) at connector "R-C6". Secure using strap (7). Located inside the compartment.
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   Illustration 28	g06126363

4. Route wire harness (2) and cable (3) using twelve straps (7) secure to left-hand side of the frame.
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   Illustration 29	g06126393

5. Route wire harness (2) and cable (3) across the front of frame. Secure using three cable tie mountings (5), seven cable straps (6), two cable straps (8), two clips (9), and two mounts (10).
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   Illustration 30	g03718526

6. Route wiring harness (2), cable (3), and cable (4) to the location of motor (13) on the right-hand frame rail.

   Note: Wires and cables should be routed between frame and hoses as shown.

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   Illustration 31	g03718857

7. Install two studs (18) into block on the frame. Install motor bracket (14) onto two studs (18) in the block on the frame using two washers (19), and two nuts (17).
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   Illustration 32	g03718599

8. Connect wire harness (2), cable (3), and cable (4) to pump motor (13).

9. Clip wire harness and cable together with cable strap (6) and mount-tie wrap (5).

10. Pull wiring harness and cables until slack is removed.

Valve Block Installation

Table 6

Valve Block Installation Necessary Parts
Item	Qty	Part Number	Description
488-9393 Hyd Lines Gp
1	1	488-9405	Bracket As
2	1	488-3068	Control Valve Gp
3	2	8T-4178	Bolt
4	4	8T-4121	Hard Washer
5	4	8T-4196	Bolt
6	2	8T-7934	Hard Washer
7	2	1S-0996	Clip
8	2	344-5675	Nut
9	1	236-8929	Handle
10	1	150-4043	Connector As
10A	1	3J-1907	O-Ring Seal
10B	1	6V-8398	O-Ring Seal
10C	1	6V-9873	Connector
11	3	148-8336	Connector As
11A	3	3J-1907	O-Ring Seal
11B	3	6V-8397	O-Ring Seal
11C	3	6V-8636	Connector

Table 7

Item	Qty	Part Number	Description
459-8157 Support Gp
12	1	492-1925	Hose As
13	1	148-8327	Connector As
13A	1	6V-8637	Connector
13B	1	3D-2824	O-Ring Seal
13C	1	6V-9746	O-Ring Seal

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Illustration 33	g03718938

1. Assemble connector assembly (10) using o-ring seal (10A), o-ring seal (10B), and connector (10C). Assemble three adapter assemblies (11) using o-ring seal (11A), o-ring seal (11B), and connector (11C). Install adapter assembly (10), three adapter assemblies (11), in control valve group (2).
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   Illustration 34	g06068020

2. Install right-hand baffle (A), hydraulic oil cooler (B). If equipped, install low fan speed valve (C).

3. Assemble connector assembly (13) using o-ring seal (13B), o-ring seal (13C), and connector (13A).

4. Install hose (12) and connector (13). Secure hose (12) using two clips, bolt, and washer (D).
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   Illustration 35	g03718933

5. Mount powered bottom guard bracket assembly (1) to radiator guard with two washers (6) and two bolts (5).

6. Mount handle (9) with two clips (7), two bolts (5), two washers (4) and two nuts (8).
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   Illustration 36	g03718944

7. Mount pump group (2) to bracket assembly (1) using two washers (4) and two bolts (3).

Power Train Oil Hoses Installation

Table 8

Power Train Oil Hoses Installation Necessary Parts
Item	Qty	Part Number	Description
459-8157 Support Gp
1	1	448-5443	Hose As
2	1	448-5444	Hose As
3	1	4D-7388	Clip
4	1	8T-4136	Bolt
5	1	7X-7729	Washer
6	1	5P-7464	Clip
7	1	5P-7465	Clip
8	1	6V-7359	Grommet
9	1	488-9404	Tube As
10	1	203-6689	Adapter As
10A	1	5K-9090	O-Ring Seal
10B	1	203-6688	Connector

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Illustration 37	g03719282

1. Replace current hose with hose (1) on the left-hand rail from the case to the quick evac (If Equipped) connection at the front left-hand side of the rail. Replace current hose with hose (2) on the left-hand side of the case to the lower right-hand bulk head under the cab. Reuse clips and hardware.
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   Illustration 38	g03719310

2. Reuse clips and hardware and add clip (3), washer (5), and bolt (4).
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   Illustration 39	g06048688

3. Assemble connector assembly (10) using o-ring seal (10A), and connector (10B).

4. Install connector assembly (10) to tube (9).

5. Replace current hose, clips, and grommet with tube (9), clips (6) and (7), and grommet (8) on the left-hand rail of case.

Electrical Component Installation

Table 9

Electrical Component Installation Necessary Parts
Item	Qty	Part Number	Description
484-8980 Wiring Gp
1	1	484-8986	Bracket As
2	2	6V-7978	Screw
3	1	216-4970	Circuit Breaker As
4	1	8T-4136	Bolt
5	1	8T-4121	Hard Washer
6	1	349-7801	Bracket
7	1	480-0124	Harness As
8	2	204-2281	Cable Strap
9	1	7K-1181	Cable Strap

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Illustration 40	g06126940
Installation location.

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Illustration 41	g06126834

1. Install circuit breaker assembly (3) into mounting bracket (1) with two screws (2).

2. Mount breaker bracket (6) to battery box support with bolt (4) and washer (5).

3. Secure harness assembly (7) to bracket (6) using cable strap (8).

4. Secure harness assembly (7) to bracket assembly (1) using cable strap (8), and cable strap (9).

Tank Hose from Valve Routing and Pump Inlet and Outlet Hose Routing

Table 10

488-9393 Hyd Lines Gp
Item	Qty	Part Number	Description
1	1	488-9403	Hose As
2	1	488-9402	Hose As
3	1	488-9395	Hose As
4	1	148-8449	Swivel Tee
4A	1	6V-9839	Swivel Tee
4B	2	6V-9746	O-Ring Seal
5	1	153-6259	Tee As
5A	1	6V-8777	Face Seal Tee
5B	2	6V-9746	O-Ring Seal
6	2	204-2281	Cable Strap
7	1	200-6345	Mount
459-8157 Support Gp
8	1	488-9399	Hose As

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Illustration 42	g06126956

1. Replace elbow assembly with tee assembly (5), and swivel tee (4).

2. Connect hose (2) to pump and tee assembly (4).

3. Connect hose (3) to valve block manifold and tee assembly (4).

4. Connect hose (1) to valve block manifold and tee assembly (4). Clip hose (1) with mount-swivel (7), and two clips (6) to tilt hose assembly.
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   Illustration 43	g03719416

5. Replace current hose with hose (8) on the right-hand frame of the case. Reuse adapter (A), clips, bolts, and washers (B).

Front Cylinder Hose Routing and Clipping

Table 11

Front Cylinder Hose Routing and Clipping Necessary Parts
Item	Qty	Part Number	Description
488-9393 Hyd Lines Gp
1	2	195-0882	Bracket As
2	1	488-9396	Hose As
3	1	488-9397	Hose As
4	1	448-5440	Plate As
5	1	090-8635	Spacer
6	3	148-8336	Connector As
6A	3	6V-8636	Connector
6B	3	6V-8397	O-Ring Seal
6C	3	3J-1907	O-Ring Seal
7	1	148-8433	Tee As
7A	1	6V-9836	Swivel Tee
7B	2	6V-8397	O-Ring Seal
8	4	6K-5967	Clip
9	4	8T-4121	Hard Washer
10	2	8T-4137	Bolt
11	1	8T-4178	Bolt
13	1	148-8435	Tee As
13A	1	6V-8781	Tee
13B	2	6V-8397	O-Ring Seal
13C	1	3J-1907	O-Ring Seal
14	1	200-6345	Mount
15	2	8T-4195	Bolt
446-5119 Cylinder Gp
16	2	436-0891	Pin
17	1	509-0252	Cylinder Gp
18	4	299-3426	Hard Washer
19	2	3B-4631	Cotter Pin
If Not Equipped With Low Fan Speed Valve
20	1	420-6436	Bracket As
21	3	8T-4195	Bolt
22	3	8T-4121	Hard Washer
23	1	278-0518	Spacer

1. Assemble connector assembly (6) using connector (6A), and o-ring seal (6B), and o-ring seal (6C). Assemble tee assembly (7) using swivel tee (7A), and two o-ring seals (7B). Assemble tee assembly (13) using tee (13A), o-ring seal (13C), and two o-ring seals (13B).
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   Illustration 44	g03720470

2. Connect tee assembly (7) to adapter (6), orienting T parallel with cylinder valve block facing down, on the rod end of the front cylinder.

3. Install tee assembly (13) to the head end of the front cylinder.
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   Illustration 45	g06050972

4. Connect 90° connector on hose (2) to rod end of cylinder tee assembly (7).

5. Connect 90° connector on hose (3) to head end of cylinder tee assembly (13).
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   Illustration 46	g06050978

6. Connect straight end on hose (2) to adapter (6) on port C1 on guard control valve (towards inside the machine).

7. Connect straight end on hose (3) to adapter (6) on port C2 on guard control valve (towards outside of machine).
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   Illustration 47	g06050985

8. Both hoses will route behind the cylinder toward the valve mounted on the radiator guard with hose (2) towards the top of the machine during routing.
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   Illustration 48	g06050991

9. Clip both front cylinder hoses (2) and (3) together from cylinder to control valve using double p-clips (8) with hose (2) towards the top of the machine during routing.

10. Mount p-clips (8) to bosses welded to left-hand rail of case using bolts (10) and washers (9).
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    Illustration 49	g03720496

11. Secure hose (2) and (3) with clip (8) to plate assembly (4) and plate (1) using bolt (15) and washer (9).

12. Clip hose (3) using bracket (1) and secure using bolt (15), washer (9), and clip (8).
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    Illustration 50	g06135028

    Note: If equipped with low fan speed bracket disregard Step 13. If not equipped, install low fan speed bracket.

13. Install bracket (20) using washer (22), and bolt (21). Use spacer (23) (not shown) to secure clip (8), washer (9), and bolt (10).
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    Illustration 51	g03720812

14. Install spacer (5) plate assembly (1) with bolt (11) and washer (9) into lower hole of low fan speed valve.

15. Mount clip (8) to plate assembly (1) using bolt (10) and washer (9).
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    Illustration 52	g03719349

16. Mount front cylinder (17) to frame with two pins (16), four washers (18), and two cotter pins (19).

    Note: Lubricate pin (17) before installation.

    Note: The valve blocks on the cylinders should face the middle of the machine.

Rear Cylinder Hose Routing and Clipping

Table 12

Rear Cylinder Hose Routing and Clipping Necessary Parts
Item	Qty	Part Number	Description
488-9393 Hyd Lines Gp
1	1	200-6345	Mount
2	2	204-2281	Cable Strap
3	1	488-9394	Hose As
4	1	488-9398	Hose As
5	1	123-2169	Adapter - Tee
6	1	168-1968	Tee As
6A	1	126-6872	Tee
6B	1	6V-8397	O-Ring Seal
6C	1	3J-1907	O-Ring Seal
7	1	148-8433	Tee As
8	1	148-8435	Tee As
9	2	6K-5967	Clip
10	2	148-8305	Adapter As
10A	1	5P-9617	Adapter
10B	1	3J-1907	O-Ring Seal
11	2	164-5590	Fluid Sampling Valve Gp
11A	1	3J-7354	O-Ring Seal
11B	1	8C-3446	Sampling Valve
12	2	8C-3451	Dust Cap
13	3	148-8336	Connector As
13A	1	6V-8636	Connector
13B	1	6V-8397	O-Ring Seal
13C	1	3J-1907	O-Ring Seal
14	1	6V-8397	O-Ring Seal
15	1	4K-6177	Clip
446-5119 Cylinder Gp
16	2	436-0891	Pin
17	1	509-0252	Cylinder Gp
18	4	299-3426	Hard Washer
19	2	3B-4631	Cotter Pin

1. Assemble adapter assembly (13) using adapter (13A), o-ring seal (13B), and o-ring seal (13C).

2. Assemble valve assembly (11) using valve (11B), o-ring seal (11A).

3. Assemble two adapter assembly (10) using o-ring seal (10B), and adapter (10A).

4. Assemble adapter assembly (6) using adapter (6A), o-ring seal (6B), and o-ring seal (6C).
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   Illustration 53	g03731665

5. Mount rear cylinder (17) to frame with two pins (16), four washers (18), and two cotter pins (19).

   Note: Lubricate pin (16) before installation.

   Note: The valve blocks on the cylinders should face the middle of the machine.

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   Illustration 54	g03720934

6. Install adapter assembly (6) and (10) to head end of rear cylinder. Install valve assembly (11) on with adapter assembly (10). Assemble dust cap (12) on valve (11).

7. Install adapter assembly (13), adapter-tee (5), and o-ring seal (14) to the rod end of rear cylinder. Install valve assembly (11) on adapter (10). Assemble dust cap (12) on valve (11).
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   Illustration 55	g03720958

8. Connect 90° connector on hose (4) to tee assembly (8), from section "Front Cylinder Hose Routing and Clipping", on head end of front cylinder.

9. Connect hose (3) to tee assembly (7), from section "Front Cylinder Hose Routing and Clipping", on rod end of front cylinder.
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   Illustration 56	g03720949

10. Connect hose (4) straight connector to elbow assembly (6) on head end of rear cylinder.

11. Connect hose (3) to connector assembly (5) and o-ring seal (14) on rod end of rear cylinder .
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    Illustration 57	g03720976

12. Clip both hoses with double P-Clip (9) behind and in front of rear engine mount using existing hardware.

13. Clip both hoses with mount-swivel (1) and two tie-wrap (2) to fan hose assembly.

14. Clip both hoses with double P-Clip (9) on left-hand rail of case, use existing hardware from hydraulic-fan group.

15. Clip both hoses with double P-Clip (15) on left-hand rail of case, use existing hardware from hydraulic-fan group.
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    Illustration 58	g06049395
    Hydraulic Inlet and Outlet Details

16. Refer to Illustration 58 and Table 13 for hydraulic inlet and outlet details.
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    Table 13

    Routing Index
    Identification	Description	Start	End
    A	Supply-Head End	Cylinder-Front	Cylinder-Rear
    B	Supply-Rod End	Cylinder-Front	Cylinder-Rear
    C	Supply-Rod End	Valve	Cylinder-Front
    D	Supply-Head End	Valve	Cylinder-Front
    E	Oil-Outlet (Pressure)	Pump	Valve
    F	Oil-Inlet	Adapt	Pump
    G	Oil-Return	Valve	Adapter-Cooler

Power Cable Routing

Table 14

Power Cable Routing Necessary Parts
Item	Qty	Part Number	Description
484-8980 Wiring Gp
1	1	216-4970	Circuit Breaker As
2	1	283-1524	Plate As
3	10	177-2215	Cable Strap
4	10	204-2281	Cable Strap
5	6	204-8000	Cable Tie Mounting
6	1	484-8985	Cable As
7	1	484-8981	Cable As
8	6	8T-4121	Hard Washer
9	2	200-6345	Mount
10	1	195-0882	Bracket As
11	1	8T-4137	Bolt
12	2	8T-4196	Bolt
13	1	8T-4186	Bolt
14	4	8T-4195	Bolt
15	1	132-5789	Clip

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Illustration 59	g03721222

1. Connect power cable (6) to breaker (1) located in battery box.

2. Route power cable (6) from battery box under cab.

3. Connect power cable (6) to 24 V power junction block located under the cab on the left-hand side fender.

4. Route motor cable (7) from motor along left-hand rail of case, and follow with bracket assembly of radiator and route along right-hand rail of case to the breaker (1) in the battery box.

5. Mount plate assembly (2) to boss inside the battery box as shown using existing hardware.

6. Fasten tie strap mounts (5) to plate assembly (2) with bolt (12) and washer (8), inside mount to face down and outside mount to face up.

7. Secure power cable (6) and motor cable (7) to mounts with tie straps (4).

8. Fasten tie strap mount (5) to boss with bolt (11) and washer (8) in battery box, secure motor cable (7) to mount with tie strap (4).
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   Illustration 60	g03721257

9. Using two double tie straps (3) secure power and motor cables to chassis wiring harness and power cable on left-hand fender.

10. Fasten tie strap mounts (5) to boss with bolt (13) and washer (8) in battery box, secure power cable (6) to mount with tie strap (4).

11. Fasten tie strap mount (5) to boss with bolt (12) and washer (8) in battery boss, secure power cable (6) to mount with tie strap (4).
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    Illustration 61	g03721273

12. Using two double tie straps (3), secure motor cables to chassis wiring harness on left-hand side fender.
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    Illustration 62	g03721761

13. Using six double tie straps (3) secure motor cables to chassis wiring harness on left-hand rail of case.
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    Illustration 63	g03721766

14. Fasten ladder clip (15) to hydraulic fan bracket, use existing hardware. Secure motor cable with tie strap (4).

15. Use mount swivel (9) and tie straps (4) to secure motor cable (7) with control group fan.
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    Illustration 64	g03721774

16. Use mount swivel (9) and tie straps (4) to secure motor cable (7) with lift lines.

17. Fasten three tie strap mount (5) to boss with existing bolt and washer (8) on right-hand rail of case. Secure motor cable (7) to mount with tie straps (4).

Ground Cable Routing

Table 15

Ground Cable Routing Necessary Parts
Item	Qty	Part Number	Description
484-8980 Wiring Gp
1	1	484-8982	Cable As
2	1	8T-4137	Bolt
3	1	8T-4121	Washer

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Illustration 65	g03721796

1. Connect ground cable (1) to ground boss welded to right-hand side of the frame rail above the motor with bolt (2) and washer (3).

   Note: Remove all paint from connection points before connecting ground cable (1) to boss.

Solenoid Wire Routing and Clipping

Table 16

Solenoid Wire Routing and Clipping Necessary Parts
Item	Qty	Part Number	Description
484-8980 Wiring Gp
1	1	448-0124	Harness As
2	2	4P-8134	Clip
3	6	204-2281	Cable Strap
4	2	200-6345	Mount
5	4	4P-7581	Clip
6	10	7K-1181	Cable Strap
7	1	132-5789	Clip
8	1	177-2215	Strap
9	5	3S-2093	Cable Strap
10	2	130-5300	Clip

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Illustration 66	g03721855

1. Route wire harness (1) along the left-hand rail of case following motor cable up to the bracket assembly radiator. Route the harness (1) bottom of radiator bracket assembly and again follow motor cable on right-hand rail of case up to pump.

2. Mount ladder clip (2) with valve to secure harness (1) with tie strap (6).

3. Use mount swivel to clip harness (1) with front cylinder hose assemblies. Use two tie straps (3).
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   Illustration 67	g03721875

4. Use mount swivel to clip harness (1) with hydraulic fan hose assemblies. Use tie strap (3).

5. Fasten ladder clip (5) to boss. Use the existing hardware on right-hand rail of case. Secure harness (1) with tie strap (6).`
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   Illustration 68	g03721885

6. Mount ladder clip (2) on lift line clip, right bottom of radiator bracket assembly. Use existing hardware to fasten with boss. Secure harness (1) with strap (6).

7. Mount ladder clip (5) on tilt line clip, middle bottom of radiator bracket assembly. Use existing hardware to fasten with block. Secure harness (1) with tie strap (6).

8. Mount ladder clip (7) on hydraulic fan lines, left bottom of radiator bracket assembly. Use existing hardware to fasten with boss. Secure harness (1) with tie strap (6).
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   Illustration 69	g06049953

9. Route wire harness (1) on left-hand rail of case following motor cable up to relay assembly. Use double tie strap (8) to secure harness (1) with motor cable assembly.

10. Use strap (3) to secure wire harness with motor cable assembly.

11. Mount clip (10) using existing bolt, clip, and washer in existing chassis wiring group. Slide the terminals of harness assembly (1) onto clip (10).
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    Illustration 70	g06050365

12. Route wire harness (1) on left-hand rail of case following motor cable. Use double tie strap (8) to secure harness (1) with motor cable assembly.
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    Illustration 71	g06050381

13. Route wire harness (1) on left-hand side of fender following motor cable up to relay assembly. Use double tie strap (8) to secure harness (1) with motor cable assembly.

14. Use tie strap (6) to secure harness (1) with chassis harness.
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    Illustration 72	g06050385

15. Route wire harness (1) underneath of fender beam assembly. Use tie strap (9) to secure wire harness (1).
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    Illustration 73	g06050388

16. Secure wire harness with power breaker bracket assembly. Use tie straps (8), (6), and (3).

Main Harness Routing and Clipping

Table 17

Main Harness Routing and Clipping Necessary Parts
Item	Qty	Part Number	Description
484-8980 Wiring Gp
1	1	480-0124	Harness As
2	1	3E-5239	Relay As
3	1	7X-2619	Bolt
4	1	9X-8256	Washer
5	1	7K-1181	Cable Strap

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Illustration 74	g06050498

1. Route wire harness (1) from motor solenoid to the rear side of radiator bracket assembly and continue toward left-hand rail of case and connect with the relay assembly for remote connector.

2. Fasten relay (2) to boss on the left-hand side of the fender with bolt (3) and washer (4).
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   Illustration 75	g03722188

3. Connect "R-C1" and "R-C8" to Custom Switched Power (Yellow and Black wires) and "R-C2" and "R-C7" to the unswitched Power (Red and Black wires).

Bleeding Air from Circuit

1. Connect all remaining hydraulic lines, ATAAC, A/C accumulator, and any other components removed earlier.

2. Fill the hydraulic tank with oil.

3. Start machine and cycle the implements to allow oil to fill hydraulic circuit (2-5 minutes).

4. Turn off machine and leave disconnect on.

5. Plug the remote controller into the machine.

6. Connect a purge hose to the quick disconnects installed and place other end in bucket to catch oil.

7. On the remote press and hold the Motor switch to On and the Guard switch to Down at the same time.

8. Run cylinders down until stroked completely, then retract cylinders fully.

   Note: Repeat cycling until all air has been removed for bled hose. Repeat for guard up.

9. Once air has been removed, leave cylinders fully extended.

10. Turn off the power, switch off the master switch, and proceed with bottom guard installation.

Powered Bottom Guard Door Assembly

Front Guard Assembly

Table 18

480-7603 Bottom Guard Gp
Item	Qty	Part Number	Description
1	5	3B-4631	Cotter Pin
2	4	5H-9899	Retaining Ring
3	4	7X-0584	Hard Washer
4	1	7X-0594	Hard Washer
5	4	7X-2562	Bolt
6	4	8T-4123	Washer
7	8	8T-4821	Washer
8	8	194-5041	Hard Washer
9	4	436-0891	Pin
10	1	446-5124	Door As
11	1	446-5124	Door As
12	1	446-5126	Plate
13	1	446-5128	Pin
14	1	446-5129	Bar
15	1	446-5130	Bar
16	4	446-5156	Pin Clevis
17	1	480-7604	Guard As

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Illustration 76	g06129316

1. Install door (10) into guard assembly (17).
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   Illustration 77	g06129318

2. Install two pins (9), four washers (8), and two cotter pins (1) into door hinges.
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   Illustration 78	g06178696

3. Repeat Steps 1 and 2 for door (11).
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   Illustration 79	g06129322

4. Install plate assembly (12) into guard assembly (17).
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   Illustration 80	g06129324

5. Install pin (13), washer (4), and cotter pin (1) into plate assembly and guard assembly.
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   Illustration 81	g06129327

6. Insert linkage bar (14) into clevis on door (11) and plate assembly (12).
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   Illustration 82	g06129351

7. Install two pins (16), two washers (3), four washers (7), and two snap rings (2).
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   Illustration 83	g06129355

8. Repeat Steps 6 and 7 for linkage bar (15) into door (10).
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   Illustration 84	g06129360

9. Bolt doors to guard assembly using four bolts (5) and four washers (6).
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   Illustration 85	g06129370
   (A) 1132 mm (44.57 inch) (B) 516 mm (20.31 inch)

10. Install seals into tracks on guard assembly.

Rear Guard Assembly

Table 19

480-7605 Bottom Guard Gp
Item	Qty	Part Number	Description
1	5	3B-4631	Cotter Pin
2	4	5H-9899	Retaining Ring
3	4	7X-0584	Hard Washer
4	1	7X-0594	Hard Washer
5	8	7X-2562	Bolt
6	8	8T-4123	Washer
7	8	8T-4821	Washer
8	8	194-5041	Hard Washer
9	4	436-0891	Pin
10	1	446-5147	Door As
11	1	446-5148	Door As
12	1	446-5126	Plate
13	1	446-5128	Pin
14	1	446-5129	Bar
15	1	446-5130	Bar
16	4	446-5156	Pin Clevis
17	1	480-7604	Guard As

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Illustration 86	g06129418

1. Install door (10) into guard assembly (17).
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   Illustration 87	g06129421

2. Install two pins (9), four washers (8), and two cotter pins (1) into door hinges.
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   Illustration 88	g06178699

3. Repeat Steps 1 and 2 for door (11).
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   Illustration 89	g06129433

4. Install plate assembly (12) into guard assembly (17).
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   Illustration 90	g06129471

5. Install pin (13), washer (4), and cotter pin (1) into plate assembly and guard assembly.
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   Illustration 91	g06129474

6. Insert linkage bar (14) into clevis on door (10) and plate assembly (12).
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   Illustration 92	g06129477

7. Install two pins (16), two washer (3), four washers (7), and two snap rings (2).
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   Illustration 93	g06129489

8. Repeat Steps 6 and 7 for linkage bar (15) into door (11).
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   Illustration 94	g06129493

9. Bolt doors to guard assembly using eight bolts (5) and eight washers (6).
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   Illustration 95	g06129496
   (A) 408 mm (16.06 inch) (B) 280 mm (11.02 inch) (C) 5P-1088 Seal

10. Install seals into tracks on guard assembly.

Guard Installation

Table 20

Guard Installation Necessary Parts
Item	Qty	Part Number	Description
480-7602 Bottom Guard Gp
1	1	480-7605	Bottom Guard Gp
2	1	480-7603	Bottom Guard Gp
459-8157 Support Gp
3	12	217-3655	Retainer
4	2	1M-8534	Pin
5	2	472-0865	Pin
6	2	3B-4631	Cotter Pin
7	2	3B-4640	Cotter Pin
8	8	7X-0594	Hard Washer
9	10	7X-2532	Bolt
10	2	7X-2565	Bolt
11	12	8T-4131	Nut
12	12	8T-5439	Hard Washer
446-5119 Basic Cylinder Gp
13	2	436-0891	Pin
14	4	299-3426	Hard Washer
15	2	3B-4631	Cotter Pin

1. Replace all bolts (9) and (10), retainers (1), nuts (11), and washers (12).

2. With the cylinders extended, place one of the new powered bottom guards on a bottom guard lift device and roll the guard under the machine.

   Note: Ensure that the machine is in zero energy state before working under machine.

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   Illustration 96	g03722231

3. Raise the guard until the front pins (5) and rear pins (4), washers (8), and front cotter pins (6) and rear cotter pins (7) can be installed into the left-hand frame rail.

4. Slowly lower the bottom guard lifting device until the cylinder can be connected to the guard.
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   Illustration 97	g03722250

5. Pin the guards to the cylinder with pins (13), washers (14), and cotter pins (15). Apply lubricant to pin before installation.

6. Repeat step 1 through step 5 for the other guard.

Close Doors and Store Remote and Handle

1. Turn on battery disconnect, ensure that the key is in the off position.

2. Plug the remote into the machine.

3. Press and hold the Motor switch to On and the Guard switch to Up at the same time.

4. Once the guards have closed, tighten nuts on guards.

5. Unplug the remote and store in the tool box in the battery compartment.

6. Store the hand pump handle in the cab.

7. Close the right-hand oil filter cabinet door, causing the switch to become compressed.

Operation Instructions

Note: Leave the operation instructions with the machine.

DC Motor Control

Lower Guards

1. Turn off machine (key in off position). Lockout machine.
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   Illustration 98	g03723279

2. Remove four nuts and washers for the front guard (A) to open and eight nuts and washer for the rear guard (B).

3. Remove remote from tool box in battery compartment.

4. Unlock machine and turn quick disconnect to ON position.
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   Illustration 99	g03723290

5. On the remote (E), press, and hold motor switch to on and guard switch to down.

6. Watch guard lower until cylinders have extended fully. One guard may move before the other guard.

7. Turn disconnect switch to OFF position.

8. Lockout machine.

Raise Guards

1. Unlock machine and turn quick disconnect to ON position.
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   Illustration 100	g03723290

2. On the remote (E), press, and hold motor switch to on and guard switch to up. One guard may move before the other guard.

3. Watch guard raise until guards have finished moving.
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   Illustration 101	g03723279

4. Install nuts and washers on front guard (A) and rear guard (B).

5. Turn disconnect switch to OFF position and lockout machine.

6. Disconnect remote and store.

Illustration 102	g03723294

Note: To open bomb bay doors, do not remove nuts and washer from frame. Remove bolts and washers from center of guard. Follow same procedure as above. Refer to Illustration 102.

Note: Right doors will open slightly. Operator should be positioned away from the right-hand door.

Hand Pump

Lower Guards

1. Turn off machine (key in off position) and lockout machine.
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   Illustration 103	g03723279

2. Remove four nuts and washers for the front guard (A) to open and eight nuts and washer for the rear guard (B).

3. Open right-hand engine enclosure door.
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   Illustration 104	g03723358

4. Insert pump handle into pump (F).

5. Pull up and twist knob (G) on top of solenoid valve.

6. Pump handle until guards have lowered (approximately 115 strokes for both guards).

Raise Guards

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Illustration 105	g03723358

1. Twist knob (G) on top of solenoid valve until stem drops down.

2. Pump handle until guards are raised.
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   Illustration 106	g03723279

3. Install four nuts and washers for the front guard (A) and eight nuts and washer for the rear guard (B).

4. Remove pump handle and store.

5. Close right-hand engine enclosure door.

Illustration 107	g03723294

Note: To open bomb bay doors, do not remove nuts and washer from frame. Remove bolts and washers from center of guard. Follow same procedure as above. Refer to Illustration 13.

Note: Right doors will open slightly. Operator should be positioned away from the right-hand door.