|Required Tools    |
|Tool    ||Part Number    ||Part Description    ||Qty    |
|A    ||228-4532    ||Link    ||1    |
|B    ||2P-5550    ||Electric Hydraulic Pump Gp    ||1    |
|8S-7645||Hydraulic Jack Hose Gp    ||3    |
|8S-7650||Cylinder As    ||3    |
|4C-6486||Stand    ||3    |
|8S-7631||Tube    ||3    |
|8S-7615||Pin    ||3    |
|8S-7625||Collar    ||3    |
|8S-8048||Saddle    ||1    |
- Remove the bucket. Refer to Disassembly and Assembly, "Bucket - Remove".
Note: Put identification marks on all hoses for installation purposes. Plug all hoses. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
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, "AVSpare Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on AVSpare products.
Dispose of all fluids according to local regulations and mandates.
- Position the machine on a hard, level surface. Position drain plug (3) for each final drive, as shown. Drain the oil from each final drive into a suitable container for storage or disposal. The capacity of each final drive is 2.5 L (0.7 US gal).
- Remove bolts (1) and cover (2) from each final drive.
- Remove thrust plate (4) .
Without the sun gear in place, the brakes are ineffective. Personal injury or death could result. Provide other means to hold or stop the machine.
- Remove sun gear (5) from each final drive.
- Temporarily reinstall thrust plate (4) and the cover on each final drive.
- Start the machine. Fully extend the stick cylinder. Raise or lower the boom until the center of the pin bore for the bucket is approximately the same height as the bottom of the counterweight.
- Remove right hand boom cylinder (6) from the machine. Refer to Disassembly and Assembly, "Boom Cylinder - Remove".
- Adjust the length of Tooling (A). Install the bolts, the washers and the nuts that hold Tooling (A) together. Install Tooling (A) in place of the right hand boom cylinder.
Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components.
To avoid component damage, follow the recommended procedure using the recommended tools.
- Install Tooling (B) under the stick, as shown.
- Install Tooling (B) under the main frame at the rear of the machine, as shown.
- Remove four hose assemblies (7) from the swivel joint.
- Remove fittings (8) .
- Remove hose assemblies (11) from the swivel joint.
- Remove locking bolt (9) from the swivel joint.
- Loosen hose clamp (10) .
- Disconnect tube assembly (12) from the fitting on the upper frame.
- Remove bolts (13) that hold the upper structure to the undercarriage frame.
- Use Tooling (B) to raise the upper structure off the undercarriage in 13 mm (0.5 inch) increments. Raise the upper structure until the upper structure is above swivel joint (14). Adjust the height of Tooling (B) in order to keep the upper structure level. The weight of the upper structure is approximately 10200 kg (22500 lb).
Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.
Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.
- Fasten a chain to the rear of undercarriage frame (15). Pull the undercarriage frame from the upper structure with a lift truck. Check the clearance between the upper structure and the swivel joint during the removal procedure. The weight of the undercarriage frame is approximately 7200 kg (15875 lb).
Note: The boot on the swivel joint is very flexible. This will allow the swivel joint to slide through the boot as the upper structure is being raised.