Caterpillar Cat 215B EXCAVATOR (Prefix 4FC) Service Repair Manual (4FC00001 and up).pdf

Service Repair Manual
Models
215B EXCAVATOR

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 215B EXCAVATOR 4FC
Configuration: 215B SA EXCAVATOR 4FC00001-UP (MACHINE) POWERED BY 3304 ENGINE
Disassembly and Assembly
215 EXCAVATOR VEHICLE SYSTEMS
Media Number -SENR2172-00 Publication Date -01/02/1982 Date Updated -11/10/2001
Swing Drive
SMCS - 5459-16; 5459-11; 5459-12; 5459-15
Remove Swing Drive
start by:
a) remove swing motor
b) remove swing brake
1. Lower the level of the hydraulic tank below the sight gauge level.
2. Disconnect hose assembly (1) from the hydraulic tank.
3. Install one 5/8"-11 NC and one 1/2"-13 NC forged eyebolt in the swing drive as shown.
4. Fasten a hoist to the swing drive.
5. Remove the bolt and clip (4) from the swing drive.
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6. Remove the two bolts and clamp (2) that hold the brake cable in position.
7. Remove four bolts (3) that hold the swing drive to the upper frame.
8. Lift the swing drive until the pinion on the output shaft is above the hole in the upper frame.
Remove the swing drive. The weight of the swing drive is 520 lb. (234 kg).
Install Swing Drive
1. Install one 5/8"-11 NC and one 1/2"-13 NC forged eyebolt in the swing drive. Put 4S9416 Anti-
Seize Compound on the finished surfaces of the cartridge. Fasten a hoist and put the swing drive in
position on the upper frame. Install the four bolts (1) that hold the swing drive to the upper frame.
2. Install clamp (2) and the two bolts that hold the clamp.
3. Install the clip and bolt (3) to the swing drive.
4. Connect hose assembly (4) to the hydraulic tank.
5. Fill the hydraulic tank to the correct level after installation of the swing motor.
end by:
a) install swing brake
b) install swing motor
Disassemble Swing Drive
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start by:
a) remove swing drive
1. Drain the oil from the swing drive. Fasten a hoist and put the swing drive in position on tool (A).
2. Remove five bolts (1) that hold bearing cage (2) to the swing drive cover.
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3. Remove O-ring seal (3) and shims (4) from bearing cage (2).
4. Remove the four bolts that hold bearing cage (5) in place. Install two 5/8"-11 NC forcing screws
and remove bearing cage (5) and the shims.
5. Remove bearing cup (6) from the bearing cage with tooling (B). Remove O-ring seal (7) from the
bearing cage.
6. Remove the six bolts that hold bearing cage (8) to the swing drive cover. Install two 1/2"-13 NC
forcing screws and remove bearing cage (8) and shims (9) from the swing drive cover.
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7. Remove bearing cup (10) from the bearing cage with tooling (C). Remove O-ring seal (11) from
the bearing cage.
8. Turn the bearing cage over and remove lip type seal (12) from the bearing cage with tooling (D).
9. Remove the bolts from swing drive cover (13).
10. Install three eyebolts (14), one each 3/8"-16 NC, 7/16"-14 NC and 1/2"-13 NC in the swing drive
cover. Fasten a hoist and remove the cover. The weight of the cover is 78 lb. (35 kg).
11. Turn cover (13) over and remove bearing cup (15) with tooling (C).
12. Remove gear (16) from the housing assembly.
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13. Install tooling (E) and remove bearing cone (17) from gear (16). Remove gear (18).
14. Remove bearing cone (19) with tooling (F) from gear (16).
15. Remove gear (20) from the housing.
16. Remove the bearing cones from each side of gear (20) with tooling (F).
17. Remove gear (21) from gear shaft (20).
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18. Remove pinion gear (22) from the housing.
19. Remove the bearing cones from pinion gear (22) with tooling (E).
20. Remove bolts (23), locks (24), retainer (25) and the shims from the output shaft.
21. Install a 5/8"-11 NC forged eyebolt in the output shaft. Fasten a hoist to hold it in place.
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22. Remove twelve bolts (26) that hold cartridge assembly (27) to the housing. Remove the cartridge
assembly. The weight of the cartridge assembly is 200 lb. (90 kg).
23. Remove gear (28) from the output shaft with tooling (H).
24. Remove three bolts (29), the lock and retainer (30). Remove the O-ring seal.
25. Remove pinion (31), O-ring seal (32), retainer (33) and Duo-Cone seal (34).
26. Install tooling (J) and push the shaft out of the bearing cone. Remove the bearing cone from the
cartridge.
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27. Remove shaft (35) and bearing cone (36) from the cartridge.
28. Remove bearing cone (36) from shaft (35) with tooling (K).
29. Remove bearing cup (37) from the cartridge with tooling (L).
30. Remove the bearing cup from the other end with tooling (C).
31. Remove bearing cups (38), (39) and (40) with tooling (G) from the housing.
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Assemble Swing Drive
1. Make sure all parts are clean. Inspect all O-ring seals for damage and make replacement if
needed.
2. Heat bearing cone (2) to a maximum temperature of 275°F (135°C). Start the bearing cone on
shaft (1).
NOTE: The bearing cone will be pushed into correct position when the pinion is installed.
3. Install Duo-Cone seal (3) with tool (A) in retainer (4).
NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry.
After installation of the seals, put oil on the contact surfaces of the metal seals.
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4. Install O-ring seal (5) in retainer (4). Install the retainer on the shaft.
5. Put 2P2506 Anti-Seize Compound on the shaft and pinion splines. Install pinion (7) on the shaft.
Install retainer (6) on the pinion.
6. Use a press and push the bearing cone and gear into position on the shaft.
NOTE: The pinion and bearing cone are in correct position when the retainer is against the end of
the shaft.
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7. Remove retainer (6). Put lubrication on the O-ring seal and install O-ring seal (8). Install the
retainer. Install the lock and three bolts that hold the retainer. Tighten the bolts a small amount.
8. Lower the temperature of bearing cup (9). Install the bearing cup in cartridge (10).
9. Turn the cartridge over. Lower the temperature of bearing cup (12). Install the bearing cup in the
cartridge.
10. Install Duo-Cone seal (11) with tooling (A) in the cartridge.
NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry.
After installation of the seals, put oil on the contact surfaces of the metal seals.
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11. Lower cartridge (10) into position on the shaft.
12. Heat bearing cone (12) to a maximum temperature of 275°F (135°C). Put the bearing cone in
position on the shaft.
13. Install the gear on the shaft. Put three pieces of solder (13) with a diameter of .059 in. (1.50 mm)
on the end of the shaft between the bolt holes as shown. Install retainer (14) and the three bolts that
hold the retainer. Tighten the bolts to 60 lb.in. (6.8 N·m). Remove the bolts and the retainer.
Measure the thickness of the solder.
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Put the retainer and bolts in position on the shaft to hold the gear in
position while the unit is put on tool (B). The gear can fall off the shaft if
the bolts and retainers are not used to hold it and serious personal
injury be the result.
14. Fasten a hoist to the cartridge and put the cartridge in position on tool (B). Install shims (15) that
are the same thickness as the average thickness of the solder minus .004 to .007 in. (0.10 to 0.18
mm).
15. Install retainer (14) on the end of the shaft. Install the lock and two of the bolts that hold the
retainer in place. Tighten the two bolts a small amount. Put a 5/8"-11 NC forged eyebolt in the other
bolt hole.
16. Tighten the pinion bolts on the other end of the shaft to a torque of 222 ± 20 lb.ft. (298 ± 25
N·m). Bend the locks.
17. Lower the temperature of bearing cups (16) and install the bearing cups in the swing drive
housing.
18. Put 7M7260 Liquid Gasket on the surfaces that make contact with the cartridge assembly and
housing.
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19. Fasten a hoist to the cartridge assembly and put it in position in the housing.
20. Install the twelve bolts (17) that hold the cartridge to the housing. Tighten bolts to a torque of
200 ± 20 lb.ft. (270 ± 25 N·m).
21. Put a brass bar (18) that is 4 1/2 in. (11.4 cm) in length and 1 1/2" (3.81 cm) in diameter between
the housing and gear. Remove the eyebolt and install the last bolt. Tighten bolts (19) to a torque of
222 ± 20 lb.ft. (298 ± 25 N·m). Bend the locks except for one.
NOTE: Make five revolutions of the output shaft with a torque wrench. Check the torque needed to
keep the shaft in rotation. The torque must be 13 ± 3 lb.ft. (18 ± 4 N·m). Make an adjustment to the
shims if needed. Bend the lock.
22. Heat bearing cones (20) and (22) to a maximum temperature of 275°F (135°C). Install the cones
on pinion gear (21).
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23. Install gear (21) in the housing.
24. Heat bearing cone (25) to a maximum temperature of 275°F (135°C). Install the cone on gear
(24).
25. Turn the gear over and install gear (23).
26. Heat bearing cone (22) to a maximum temperature of 275°F (135°C). Install the cone on the
gear.
27. Install gear (24) into swing drive housing.
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(27).
29. Turn the gear over and install gear (26).
(27).
31. Install gear (27) in the swing drive housing.
32. Lower the temperature of bearing cup (29). Install the cup in the cover.
33. Clean the old gasket material from the contact surfaces of the cover and case. Put 7M7260
Liquid Gasket on the surfaces.
34. Install three eyebolts (30) one each, 3/8"-16 NC, 7/16"-14 NC and 1/2"-13 NC in the swing drive
cover. Fasten a hoist and put cover (31) in position on the housing. Install the bolts that hold the
cover to the housing.
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35. Lower the temperature of bearing cup (32). Install the cup in bearing cage (33). Install the lip
type seal with the lip of the seal toward the top of the cage with tooling (C). Put oil on the lip of the
seal.
36. Put cage (33) in position on the cover without the shims and O-ring seal. Install two bolts 180°
apart. Tighten the bolts evenly to a torque of 60 lb.in. (6.8 N·m) while gear (27) is turned. Measure
the gap between the cage and cover at the two bolt locations with a feeler gauge.
37. Install shims (35) that are the same thickness as the average gap measured plus .000 to .0008 in.
(0.00 to 0.02 mm). Install O-ring seal (34) on the cage. Put the cage in position on the cover. Install
the bolts that hold the cage in position and tighten the bolts to a torque of 100 ± 20 lb.ft. (135 ± 14
N·m).
38. Lower the temperature of bearing cup (36). Install the cup in bearing cage (37).
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39. Install cage (37) without shims and O-ring seal. Install two bolts 180° apart. Tighten the bolts
evenly to a torque of 60 lb.in. (6.8 N·m) while pinion gear (21) is turned. Measure the gap between
the cage and the cover at the two bolt locations with a feeler gauge.
(0.05 to 0.08 mm). Install O-ring seal (38) on the cage. Put the cage in position on the cover and
install the bolts that hold it in place.
41. Install cage (40) without shims and O-ring seal. Install two bolts 180° apart. Tighten the bolts
evenly to a torque of 60 lb.in. (6.8 N·m). Measure the gap between the cage and the cover at the two
bolt locations with a feeler gauge.
(0.00 to 0.03 mm). Install O-ring seal (42) on the cage. Put the cage in position on the cover and
install the bolts that hold it in place.
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43. Fill the swing drive with oil to the correct level.
end by:
a) install swing drive
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Dec 28 10:42:36 UTC+0800 2020
20/20
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
Swivel Group
SMCS - 5060-16; 5060-11; 5060-12; 5060-15
Remove Swivel Group
NOTE: Put identification on all the oil lines for installation purpose.
1. Disconnect oil lines (1), (2), (3) and (5) which go to the main control valves.
2. Disconnect oil line (4) which goes to the hydraulic tank.
NOTE: Put plugs in the oil line to keep oil in.
VIEW FROM UNDER MACHINE
3. Disconnect parking brake oil lines (6) and (7). Disconnect track motor return lines (8) and (9)
from the rotor.
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4. Disconnect oil lines (10), (11), (12) and (13) for the track motors from the rotor.
5. Remove the two bolts that hold bracket (14) in place. Remove the bracket.
6. Install two 3/8"-16 NC forged eyebolts in the swivel group. Fasten a hoist to the swivel group.
Remove eight bolts (15) and remove the swivel group. The weight of the swivel group is 170 lb.
(77 kg).
Install Swivel Group
1. Install two 3/8"-16 NC forged eyebolts in the swivel group. Fasten a hoist and put swivel group
(1) in position on the machine. Install the eight bolts that hold the swivel group in place.
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VIEW FROM UNDER MACHINE
2. Install bracket (2) as shown. Install the two bolts that hold it in place.
3. Connect oil lines (3), (4), (5) and (6) for the track motors to the rotor.
4. Connect track motor return lines (7) and (10). Connect parking brake oil lines (8) and (9).
5. Connect oil line (14) which goes to the hydraulic tank.
6. Connect oil lines (11), (12), (13) and (15) to the swivel group which go to the main control
valves.
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Disassemble Swivel Group
start by:
a) remove swivel group
1. Remove bolts (1) and cap (2) from the swivel housing. Remove the O-ring seal from the cap.
2. Remove three screws (3) and remove retainer (4) from the rotor.
3. Turn the swivel housing over and remove the fittings.
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4. Make two 1/2"-13 NC threaded rods 24 in. (610 mm) long. Put the rods in position on the
swivel housing with four 1/2" flat washers and nuts. Install tooling (A) on the rods. Use 1/2" flat
washers and nuts to hold tooling (A) in place.
5. Remove rotor (5) from the housing.
6. Remove seal (6) from the housing. Remove seven inner seals (7) and the seven outer seals from
the housing.
Assemble Swivel Group
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1. Install the seven out seals (rubber) and seven inner seals (plastic) (2) in the swivel housing.
2. Install seal (1) in the swivel housing.
NOTE: Seal (1) does not have a rubber seal behind it. Put lubrication on the seals.
3. Put rotor (3) in position in swivel housing (4). Make two 1/2"-13 NC threaded rods 24 in. (610
mm) long. Put the rods in position on the swivel housing with four flat washers and nuts. Install
tooling (A) on the rods. Use four 1/2" flat washers and nuts to hold tooling (A) in place.
4. Install the rotor as shown.
5. Install fittings (5) and (6) in the rotor.
6. Turn the swivel housing over as shown. Install retainer (7) on the rotor. Install the three screws
that hold the retainer in place.
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7. Install O-ring seal (8) in cap (9). Install cap (9) on the swivel housing. Install the bolts that hold
the cap to the housing.
8. After assembly the rotor must be turned so that the center line of the smallest flat side (10) of
the rotor is in alignment with the center line of fittings (11) in the swivel housing as shown.
end by:
a) install swivel group
Mon Dec 28 10:43:31 UTC+0800 2020
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
Track Motor Guards (If So Equipped)
SMCS - 7162-11; 7162-12
Remove Track Motor Guards (If So Equipped)
1. Remove the bolts that hold covers (1), (2) and (3). Remove the top three covers.
2. Put a floor jack in position under the lower guard assembly. Remove seven bolts that hold lower
guard (4) to the carbody.
3. Remove the lower guard. The weight of the guard is 200 lb. (90 kg).
Install Track Motor Guards (If So Equipped)
1/2
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1. Put lower guard (1) in position with a floor jack and install the seven bolts that hold it in place.
2. Install three top covers (2), (3) and (4) in number sequence as shown.
Mon Dec 28 10:44:27 UTC+0800 2020
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2020/12/28

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Track Motors
SMCS - 5058-11; 5058-12
Remove Track Motors
1. Remove the top covers from over the track motors. Make reference to REMOVE TRACK
MOTOR GUARDS.
2. Disconnect drain hose assembly (1) and the inlet and outlet hose assemblies (2) and (3). Put
plugs in the openings in the hose assemblies and the track motor.
3. Fasten a hoist to track motor (4). Remove two bolts (5) that hold the track motor to the parking
brake.
4. Remove motor (4). The weight of the track motor is 105 lb. (47.3 kg).
Install Track Motors
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1. Install O-ring seals (1) and (2) on track motor (3). Inspect the O-ring seals for damage and make
replacements if needed.
2. Fasten a hoist and install the track motor on the parking brake. Install the two bolts that hold the
track motor in place. Remove the top drain fitting and fill the motor case with SAE 10 W
hydraulic oil.
NOTICE
Do not start the engine until the motor is filled with oil.
4. Remove the plugs from the hose assemblies and the track motor.
5. Connect the drain hose assembly (4).
6. Connect the inlet and outlet hose assemblies (5) and (6) to the track motor.
NOTE: Make sure the O-ring seals are in place on the inlet and outlet hoses.
7. Install the top covers over the track motors. Make reference to INSTALL TRACK MOTOR
GUARDS.
Mon Dec 28 10:45:23 UTC+0800 2020
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Caterpillar Cat 215B EXCAVATOR (Prefix 4FC) Service Repair Manual (4FC00001 and up).pdf

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