Caterpillar Cat 527 TRACK SKIDDER (Prefix 4NS) Service Repair Manual (4NS00001 and up).pdf

Service Repair Manual
Models
527 TRACK SKIDDER

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Product: TRACK SKIDDER
Model: 527 TRACK SKIDDER 4NS
Configuration: 527 TRACK-TYPE SKIDDER Grapple 4NS00001-UP (MACHINE) POWERED BY 3304 Engine
Disassembly and Assembly
527 Track-Type Skidder Machine Supplements
Media Number -SENR9426-04 Publication Date -01/11/2009 Date Updated -03/11/2009
i01188441
Grapple Crosshead - Remove and Install
SMCS - 5569-010
Removal Procedure
Start By:
A. Remove the grapple head.
Illustration 1 g00636309
1. Remove the bolt and retainer (2) .
2. Use two people to separate crossblock (5) from jib boom (1). The approximate weight of the
crossblock is 34 kg (75 lb).
3. Remove the nut and pin (3). Remove the two friction discs, bushings (5), and crossblock (4)
from jib boom (1) .
Installation Procedure
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527 TRACK-TYPE SKIDDER Grapple 4NS00001-UP (MACHINE) POWERED BY ...
2019/9/20
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1. Use two people to install crossblock (4) in jib boom (1). The approximate weight of the
crossblock is 34 kg (75 lb).
2. Install the two friction discs, bushing (5), and pin (3) in the jib boom. Install the nut on pin
(3) .
3. Install retainer (2) and the bolt.
End By: Install the grapple head.
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i01188462
Grapple Arch Cylinder (Fixed Boom) - Remove
SMCS - 5557-011
Removal Procedure
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
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filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
1. Use the following procedure to release the pressure in the hydraulic system:
a. Lower the attachments to the ground.
b. Shut off the engine.
c. Move the control levers through the full travel distance of the levers. This will relieve
any pressure in the pilot system.
d. Slowly loosen the filler cap on the hydraulic oil tank in order to release the pressure.
e. Tighten the filler cap on the hydraulic oil tank.
f. The pressure in the hydraulic system has now been relieved. Lines and components
can now be removed.
Note: Put identification on all lines, hoses, wires, and tubes for installation purposes.
Install a cap or plug on all lines, hoses, and tubes that are disconnected. The caps
and/or plugs prevent the loss of fluid and contaminants cannot enter the system.
2. Lower the arch so that the grapple is sitting on a hard, flat surface. Support the arch in the
area that is indicated by the arrow in Illustration 1.
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3. Disconnect hose assemblies (1) and (2) .
4. Remove retaining bolt (3) and the washer. Remove pin assembly (4) .
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5. Attach a lifting strap to the cylinder and use a suitable lifting device to support the cylinder.
Remove bolt (5), the washer, and pin assembly (6) .
6. Remove cylinder (7) from the arch. The approximate weight of the cylinder is 58 kg (128
lb).
Fri Sep 20 01:56:19 UTC+0800 2019
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i01189605
Grapple Arch Cylinder (Fixed Boom) - Disassemble
SMCS - 5557-015
Disassembly Procedure
Start By:
A. Remove the arch cylinders.
Table 1
Required Tools
Tool Part Number Description Qty
A Footnote (1)
Hydraulic Cylinder Repair Stand 1
B 1P-0510 Driver Group 1
C 9U-6572 Socket 1
( 1 )
Refer to Major Equipment Guide, NEHC2004 for the stand and the tooling that is needed for the disassembly and assembly
of the arch cylinders.
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NOTICE
containing fluids.
Note: Check the condition of bearings (1) and (9) that are located in the end of cylinder body (2) and
rod assembly (10). If the bearings are damaged or worn, install new bearings.
1. Put the arch cylinder in position on Tool (A). The approximate weight of the arch cylinder is 58 kg
(128 lb).
2. Use Tool (A) to extend the cylinder.
3. Remove crown (11) from cylinder body assembly (2) .
4. Use Tool (A) to move cylinder body assembly (2) away from rod assembly (10) .
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5. Use Tool (C) to remove locking bolt (17) and washer (16). The locking bolt holds piston (15) to rod
assembly (10) .
6. Remove piston (15), head (14), and crown (11) from the rod assembly.
7. Remove wear ring (3) and seal assembly (4) from head (14) .
8. Remove seal assembly (5), U-cup seal (6), wear ring (7), and lip seal (8) from head (14) .
9. Remove O-Ring seal (13) and backup ring (12) from head (14) .
Note: Check the condition of all seals and components. Replace any parts that are worn or damaged with
new parts.
Fri Sep 20 01:57:19 UTC+0800 2019
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i01190099
Grapple Arch Cylinder (Fixed Boom) - Assemble
SMCS - 5557-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Description Qty
A Footnote (1)
Hydraulic Cylinder Repair Stand 1
B 1P-0510 Driver Group 1
C 9U-6772 Socket 1
( 1 )
Refer to Major Equipment Guide, NEHC2004 for the stand and the tooling that is needed for the disassembly and
assembly of the arch cylinders.
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Note: Check the condition of all seals and parts. Replace any worn parts or damaged parts with new
parts. Replace any worn seals or damaged seals with new seals.
1. Install O-Ring seal (13) and backup ring (12) on head (14) .
2. Apply 7M-7456 Bearing Mount Compound to the wiper seal groove prior to installing lip seal
(8). Use Tool (B) to install lip seal (8). Install wear ring (7), seal assembly (5), and U-cup seal
(6) on head (14). Lightly lubricate sealing lips with clean hydraulic oil.
3. Install seal assembly (4) and wear ring (3) on piston (15) .
4. Put rod assembly (10) in position on Tooling (A) .
5. Install crown (11), head (14), and piston (15) on rod assembly (10) .
6. Lubricate the threads in the end of cylinder rod assembly (10) with 1P-0808 Multipurpose
Grease. Use Tool (C) to install locking bolt (17) and washer (16) on the end of the cylinder rod.
Tighten the bolt to a torque of 2700 ± 275 N·m (1990 ± 202 lb ft).
7. Use Tooling (A) to install cylinder body assembly (2) on rod assembly (10) .
8. Lubricate the threads on the cylinder body assembly with clean grease. Install crown (11) on
the cylinder body assembly. Tighten the crown to a torque of 600 ± 130 N·m (442 ± 95 lb ft).
End By: Install the arch cylinders.
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Fri Sep 20 01:58:18 UTC+0800 2019
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i01189410
Grapple Arch Cylinder (Fixed Boom) - Install
SMCS - 5557-012
1. Use a lifting strap and a suitable lifting device to put arch cylinder (7) in position for
installation. The approximate weight of the cylinder is 58 kg (128 lb).
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2. Install pin assembly (6), retaining bolt (5), and the washer.
3. Install pin assembly (4), retaining bolt (3), and the washer.
4. Connect hose assemblies (1) and (2) .
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5. Remove the support under the arch.
6. Check the oil level in the hydraulic tank.
Note: Refer to the Operation and Maintenance Manual, SEBU7001, "Hydraulic System Oil Level
- Check" for the correct procedure.
Fri Sep 20 01:59:17 UTC+0800 2019
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i01190175
Grapple Arch (Fixed Boom) - Remove
SMCS - 6308-011
Removal Procedure
Start By:
A. Remove the arch cylinders.
B. Remove the grapple head.
C. Remove the crosshead.
NOTICE
containing fluids.
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can now be removed.
Note: Put identification on all lines, hoses, wires, and tubes for installation purposes. Install
a cap or plug on all lines, hoses, and tubes that are disconnected. The caps and/or plugs
prevent the loss of fluid and contaminants cannot enter the system.
2. Remove the bolts and cover (1) on each side of the machine.
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3. Remove the bolts and rear cover (2) .
4. Disconnect two tube assemblies (3) and (6) .
5. Disconnect three hose assemblies (4) and two hose assemblies (5) .
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6. Attach chains and a suitable lifting device to arch (9). Remove retaining bolt (8) and pin
assembly (7) from both sides of the arch. Remove arch (9). The approximate weight of the
arch is 515 kg (1135 lb).
Fri Sep 20 02:00:17 UTC+0800 2019
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i01190342
Grapple Arch (Fixed Boom) - Install
SMCS - 6308-012
1. Attach chains and a suitable lifting device to grapple arch (9) and put the arch in position for
installation. Install pin assemblies (7) and retaining bolts (8) on each side of the machine.
The approximate weight of the arch is 515 kg (1135 lb).
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2. Connect three hose assemblies (4) and two hose assemblies (5) .
3. Connect two tube assemblies (3) and (6) .
4. Install rear cover (2) .
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5. Install covers (1) on each side of the machine.
Note: Refer to the Operation and Maintenance Manual, SEBU7001, "Hydraulic System Oil Level
- Check" for the correct procedure.
End By:
a. Install the crosshead.
b. Install the grapple head.
c. Install the arch cylinders.
Fri Sep 20 02:01:16 UTC+0800 2019
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i01190369
Grapple Saddle (Fixed Boom) - Remove and Install
SMCS - 6307-010
Removal Procedure
Start By:
A. Remove the grapple arch.
1. Use a lift truck to support saddle assembly (2) .
2. Remove bolts (1) and saddle assembly (2). The approximate weight of the saddle assembly
is 217 kg (478 lb).
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1. Use a lift truck to support saddle assembly (2) in position for installation. The approximate
weight of the saddle assembly is 217 kg (478 lb).
2. Install bolts (1) .
End By: Install the grapple arch.
Fri Sep 20 02:02:16 UTC+0800 2019
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i01190382
Grapple Saddle (Swing Boom) - Remove and Install
SMCS - 6307-010
Removal Procedure
Start By:
A. Remove the grapple boom (swing boom).
NOTICE
containing fluids.
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can now be removed.
Note: Put identification on all lines, hoses, wires, and tubes for installation purposes.
Install a cap or plug on all lines, hoses, and tubes that are disconnected. The caps
and/or plugs prevent the loss of fluid and contaminants cannot enter the system.
1. Disconnect hose assemblies (1) and two hose assemblies (2) .
2. Disconnect wire harness (3) .
2/5
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3. Disconnect hose assembly (4) and two hose assemblies (5) .
4. Disconnect hose assemblies (6) and (7) from the top of the valve.
3/5
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5. Attach a lifting chain and a suitable lifting device to saddle assembly (8). Remove bolts (9)
and saddle assembly (8). The approximate weight of the saddle assembly is 1474 kg (3250
lb).
1. Attach a lifting chain and a suitable lifting device to saddle assembly (8). Put the saddle
assembly in position for installation. Install bolts (9) .
2. Connect hose assemblies (6) and (7) to the top of the valve.
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3. Connect hose assembly (4) and two hose assemblies (5) .
4. Connect wire harness (3) .
5. Connect two hose assemblies (1) and hose assembly (2) .
Note: Refer to the Operation and Maintenance Manual, SEBU7001, "Hydraulic System Oil
Level - Check" for the correct procedure.
Fri Sep 20 02:03:15 UTC+0800 2019
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i04729271
Grapple Jib Boom - Remove and Install
SMCS - 6302-010
Removal Procedure
Start By:
A. Remove the crosshead.
NOTICE
Be sure that the engine is off. Move the control lever in order to be sure
that the weight of the jib boom is being supported by the lifting device.
Move the control lever back and forth from one side to the other side in
order to release the pressure in the hydraulic system. Loosen the filler
cap slowly in order to release any pressure in the hydraulic tank.
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Caterpillar Cat 527 TRACK SKIDDER (Prefix 4NS) Service Repair Manual (4NS00001 and up).pdf

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