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BI644125-00 (EN-US)

May 2016

Disassembly and Assembly

HW300 Highwall Miner


Field Assembly
Serial number HWM00184

SAFETY.CAT.COM
BI644125-00 (EN-US)

Important Safety Information


Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the neces-
sary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product until you have read
and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER,
WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:


Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially pre-
sented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not use
this product in any manner different from that considered by this manual without first satisfying your-
self that you have considered all safety rules and precautions applicable to the operation of the product
in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you start
any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this product


Caterpillar recommends using Caterpillar replacement
parts or parts with equivalent specifications including,
but not limited to, physical dimensions, type, strength
and material.

Failure to heed this warning can lead to premature


failures, product damage, personal injury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and systems
may be performed by any repair establishment or individual of the owners choosing.
BI644125-00 (EN-US) 3

Table of Contents
Disassembly and Assembly Section

Introduction ...........................................................4
General Information (Torque Specifications, Graph-
ic Color Description, and Graphic Symbol De-
scription).........................................................4
Base Frame - Install ........................................... 13
Front Super Beam - Install ................................. 18
Rear Super Beam - Install .................................. 22
Power Head - Install ........................................... 26
Base Power Module - Install ............................... 28
Front PTM Structure - Install .............................. 31
Rear PTM Structure - Install ............................... 34
Bridge - Install ..................................................... 37
Extended Discharge Boom - Install .................... 40
Transformer Frame - Install ................................ 44
Transformer - Install ........................................... 46
Base Power Module Catwalks - Install ............... 51
Cab - Install ........................................................ 62
Cab Ladders - Install .......................................... 64
Push Beam Plow - Install.................................... 69
PTM Transfer Cylinders and Catwalk - Install .... 72
Hose Reel - Install .............................................. 80
Drill and Anchor Masts - Install ........................... 84
Front Canopies - Install ...................................... 88
LH & RH Wing Catwalk Support - Install ............ 93
LH Wing Catwalk - Install ................................... 95
RH Wing Catwalk - Install ................................... 97
LH Hose Reel Catwalk - Install ........................... 99
RH Hose Reel Catwalk - Install .......................... 101
LH & RH Can Covers - Install ............................. 103
Hose Reel Guard - Install ................................... 105
PTM Tables - Install............................................ 107
Cab, Groundman Assembly - Install ................... 110
4 BI644125-00 (EN-US)
Disassembly and Assembly Section

Disassembly and Assembly General Information


Section (Torque Specifications, Graphic Col-
or Description, and Graphic Symbol
Introduction Description)
Introduction Torque Specifications
This Field Assembly Manual contains the assembly
and installation procedures that are required to English (SAE) Fasteners
assemble the Highwall Miner.
The following table has the recommended standard
WARNING! torque values.

Table 1
Do not attempt to assemble this machine until
you read and understand the assembly instruc-
tions. Nuts and Bolts
Thread Size
Improper assembly procedures could result in Standard Torque
Inch
injury or death.
1/4 12 3 Nm (9 2 lb ft)

WARNING! 5/16 25 5 Nm (18 5 lb ft)


3/8 47 10 Nm (35 5 lb ft)
Personal injury or death can result from im-
proper lifting or blocking. 7/16 70 15 Nm (50 10 lb ft)
1/2 105 20 Nm (75 15 lb ft)
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure 9/16 160 30 Nm (120 20 lb ft)
the hoist or jack has the correct capacity to lift
a component. Install blocks or stands before 5/8 215 40 Nm (160 30 lb ft)
performance of any work under a heavy com- 3/4 370 50 Nm (275 37 lb ft)
ponent.
4/5 620 80 Nm (460 60 lb ft)
Approximate weights of the components are 1 900 100 Nm (660 75 lb ft)
shown.
1 1/8 1300 150 Nm (960 110 lb ft)
Clean all surfaces where parts are to be in-
1 1/4 1800 200 Nm (1320 150 lb ft)
stalled.
1 3/8 2400 300 Nm (1780 220 lb ft)
1 1/2 3100 350 Nm (2280 260 lb ft)
NOTICE
Do not allow any dirt or foreign material to get into
the hydraulic system during assembly, connection Metric (ISO) Fasteners
of lines, when component are filled with fluid, or
The following table has the recommended standard
during any maintenance operation.
torque values.

Do not perform any procedure in this publication or


order any parts until you understand the infor-
mation contained in this publication.
BI644125-00 (EN-US) 5
Disassembly and Assembly Section

Table 2 1. Position the flanges parallel over the port.

Nuts and Bolts 2. Evenly install bolts hand-tight, keeping the gap
between flanges at a minimum.
Thread Size
Standard Torque
Inch
3. Put the hose in a position so that the hose
M6 12 3 Nm (9 2 lb ft) does not contact the machine or another hose.
M8 30 5 Nm (20 5 lb ft)
4. Tighten using one of the assembly torque val-
M10 55 10 Nm (40 5 lb ft) ues for bolts, using Illustration 1 for proper
M12 100 20 Nm (75 15 lb ft) torque sequence of various flange fittings.

M14 160 30 Nm (120 20 lb ft) Straight Thread O-Ring Fittings


M16 240 40 Nm (175 30 lb ft)
The following tables have the recommended stand-
M20 460 60 Nm (340 45 lb ft) ard torque values.
M24 800 100 Nm (590 75 lb ft)
Note: Straight Thread O-Ring Fittings for medium
M30 1600 200 Nm (1180 150 lb ft) pressure usage will have shorter threaded ends
M36 2700 300 Nm (2000 220 lb ft) than high-pressure fittings. The torque value for
medium pressure Straight Thread O-Ring Fittings
will be lower than the torque values that are re-
Hydraulic Four Bolt Flange quired for Straight Thread O-Ring Fittings for high-
pressure fittings.

Table 3

Ferrous Straight Thread O-Ring Fitting Tor-


ques for Mating with Ferrous Materials
Medium Pressure use Fittings
Nominal Outer
Thread Size Standard
Diameter of the
Inch Torque
Tube
3.18 mm 10 2 Nm
5/16-24
(.125 inch) (7 1 lb ft)
4.76 mm 17 3 Nm
3/8-24
(.188 inch) (13 2 lb ft)
6.35 mm 35 5 Nm
7/16-20
(.250 inch) (26 4 lb ft)
7.94 mm 45 7 Nm
1/2-20
(.312 inch) (33 5 lb ft)
9.52 mm 45 7 Nm
9/16-18
(.375 inch) (33 5 lb ft)
12.70 mm 80 12 Nm
3/4-16
(.500 inch) (59 9 lb ft)
15.88 mm 110 17 Nm
7/8-14
(.625 inch) (81 13 lb ft)

Illustration 1 (continued)
6 BI644125-00 (EN-US)
Disassembly and Assembly Section

(Table 3, contd) (Table 4, contd)

Ferrous Straight Thread O-Ring Fitting Tor- Ferrous Straight Thread O-Ring Fitting Torques
ques for Mating with Ferrous Materials for Mating with Ferrous Materials
Medium Pressure use Fittings High Pressure use with O-Ring Face Seal Fit-
tings
Nominal Outer
Thread Size Standard
Diameter of the Nominal Outer
Inch Torque Thread Size Standard
Tube Diameter of the
Inch Torque
Tube
19.05 mm 130 20 Nm
1 1/16-12
(.750 inch) (96 15 lb ft)
12.70 mm 110 17 Nm
3/4-16
22.22 mm 200 30 Nm (.500 inch) (81 13 lb ft)
1 3/16-12
(.875 inch) (148 22 lb ft)
15.88 mm 140 21 Nm
25.40 mm 220 33 Nm 7/8-14
1 5/16-12 (.625 inch) (103 15 lb ft)
(1.000 inch) (148 22 lb ft)
19.05 mm 220 33 Nm
31.75 mm 300 45 Nm 1 1/16-12
1 5/8-12 (.750 inch) (148 22 lb ft)
(1.250 inch) (221 33 lb ft)
22.22 mm 260 39 Nm
38.10 mm 350 53 Nm 1 3/16-12
1 7/8-12 (.875 inch) (192 29 lb ft)
(1.500 inch) (258 39 lb ft)
25.40 mm 350 53 Nm
50.80 mm 420 63 Nm 1 5/16-12
2 1/2-12 (1.000 inch) (258 39 lb ft)
(2.000 inch) (310 46 lb ft)
31.75 mm 400 60 Nm
1 5/8-12
(1.250 inch) (295 44 lb ft)
Note: Straight Thread O-Ring Fittings for high
pressure usage will have longer threaded ends 38.10 mm 420 63 Nm
1 7/8-12
than medium pressure fittings. The torque value (1.500 inch) (310 46 lb ft)
for high pressure Straight Thread O-Ring Fittings 50.80 mm 600 90 Nm
will be higher than the torque values required for 2 1/2-12
(2.000 inch) (443 66 lb ft)
Straight Thread O-Ring Fittings.
Table 5
Table 4

Ferrous Straight Thread O-Ring Fitting Tor- Metric Ferrous Straight Thread O-Ring Fitting
ques for Mating with Ferrous Materials Torques for Mating with Ferrous Materials
High Pressure use with O-Ring Face Seal Fit- Medium Pressure use with Fittings
tings
Nominal Outer
Nominal Outer Thread Size Standard
Thread Size Standard Diameter of the
Diameter of the Inch Torque
Inch Torque Tube
Tube
10 2 Nm
4.76 mm 25 4 Nm 4 mm M8 X 1
3/8-24 (7 1 lb ft)
(.188 inch) (18 3 lb ft)
17 3 Nm
6.35 mm 35 5 Nm 5 mm M10 X 1
7/16-20 (13 2 lb ft)
(.250 inch) (26 4 lb ft)
35 5 Nm
7.94 mm 50 8 Nm 6 mm M12 X 1.5
1/2-20 (26 4 lb ft)
(.312 inch) (37 6 lb ft)
45 7 Nm
9.52 mm 70 11 Nm 8 mm M14 X 1.5
9/16-18 (33 5 lb ft)
(.375 inch) (52 8 lb ft)
45 7 Nm
10 mm M16 X 1.5
(33 5 lb ft)
(continued)
BI644125-00 (EN-US) 7
Disassembly and Assembly Section

(Table 5, contd) (Table 6, contd)

Ferrous Straight Thread O-Ring Fitting Torques Ferrous Straight Thread O-Ring Fitting Torques
for Mating with Ferrous Materials for Mating with Ferrous Materials
High Pressure use with O-Ring Face Seal Fit- High Pressure use with O-Ring Face Seal Fit-
tings tings
Nominal Outer Nominal Outer
Thread Size Standard Thread Size Standard
Diameter of the Diameter of the
Inch Torque Inch Torque
Tube Tube
80 12 Nm 110 17 Nm
12 mm M18 X 1.5 12 mm M18 X 1.5
(59 9 lb ft) (81 13 lb ft)
110 17 Nm 140 21 Nm
16 mm M22 X 1.5 16 mm M22 X 1.5
(81 13 lb ft) (103 15 lb ft)
130 20 Nm 220 33 Nm
20 mm M27 X 2 20 mm M27 X 2
(96 15 lb ft) (148 22 lb ft)
200 30 Nm 260 39 Nm
22 mm M30 X 2 22 mm M30 X 2
(148 22 lb ft) (192 29 lb ft)
220 33 Nm 350 53 Nm
25 mm M33 X 2 25 mm M33 X 2
(148 22 lb ft) (258 39 lb ft)
300 45 Nm 400 60 Nm
30 mm M42X3 30 mm M42X3
(221 33 lb ft) (295 44 lb ft)
350 53 Nm 420 63 Nm
38 mm M48 X 2 38 mm M48 X 2
(258 39 lb ft) (310 46 lb ft)
420 63 Nm 600 90 Nm
50 mm M60 X 2 50 mm M60 X 2
(310 46 lb ft) (443 66 lb ft)

Table 6 O-Ring Face Seal Fittings


Ferrous Straight Thread O-Ring Fitting Torques The following tables have the recommended stand-
for Mating with Ferrous Materials ard torque values.
High Pressure use with O-Ring Face Seal Fit-
tings Table 7

Nominal Outer Nuts and Bolts


Thread Size Standard
Diameter of the
Inch Torque Thread Size
Tube Standard Torque
Inch
25 4 Nm
5 mm M10 X 1 9/16-18 30 5 Nm (22 4 lb ft)
(18 3 lb ft)
35 5 Nm 11/16-16 50 8 Nm (37 6 lb ft)
6 mm M12 X 1.5
(26 4 lb ft) 13/16-16 70 11 Nm (42 8 lb ft)
50 8 Nm 1-14 110 17 Nm (81 13 lb ft)
8 mm M14 X 1.5
(37 6 lb ft)
1 3/16-12 160 24 Nm (118 18 lb ft)
70 11 Nm
10 mm M16 X 1.5
(52 8 lb ft) 1 7/16-12 260 39 Nm (192 29 lb ft)
1 11/16-12 300 45 Nm (221 33 lb ft)
2-12 350 53 Nm (258 39 lb ft)
8 BI644125-00 (EN-US)
Disassembly and Assembly Section

Table 9
Tapered Pipe Thread Fittings
The following tables have the recommended stand- Worm Drive Band Type Hose Clamps
ard torque values.
Width of Clamp Torque for New Hose
Table 8
7.5 mm (0.3 inch)
Tapered Pipe Thread Fittings 1.4 +0.3 Nm (12 3 lb in)
or smaller
12 mm (0.5 inch)
Standard Torque 4.5 +0.7 Nm (40 6 lb in)
or smaller
Diameter of the
Pip Thread 14 mm (0.6 inch)
Assembly 7.5 +1 Nm (66 9 lb in)
(inch) or smaller)
Turns after Torque
Hand Tight Width of Clamp Torque for Reused Hose (1)

10 +2 Nm 7.5 mm (0.3 inch)


1/16 3 0.8 +0.3 Nm (7 3 lb in)
(89 18 lb in) or smaller

20 3 Nm 12 mm (0.5 inch)
1/8 3 3.0 +0.5 Nm (27 4 lb in)
(177 27 lb in) or smaller

35 5 Nm 14 mm (0.6 inch)
1/4 3 4.5 +0.7 Nm (40 6 lb in)
(26 4 lb ft) or smaller)

60 9 Nm
3/8 3 (1)
Use this value when the hose is reused. The clamp may be
(44 7 lb ft)
new or reused.
80 12 Nm
1/2 2.5 Table 10
(60 9 lb ft)
100 15 Nm Constant Torque Hose Clamps
3/4 2.5
(74 11 lb ft) Belleveille Washer
120 18 Nm
1 2.5 Diameter of Clamp Standard Torque
(89 13 lb ft)
140 21 Nm Up to 50.8 mm (2 7.5 +1 Nm (65 10 lb
1 1/4 2.5
(103 15 lb ft) inch) in)
160 24 Nm Greater than 50.8
1 1/2 2.5 11 +1 Nm (95 6 10 in)
(118 18 lb ft) mm (2 inch)
180 27 Nm
2 2.5 Table 11
(130 20 lb ft)

Constant Torque Hose Clamps


Hose Clamps Tee Bolt and Spring

The following tables have the recommended stand- Diameter of


Standard Torque
Clamp
ard torque values.
All 7.5 +1 Nm (65 10 lb in)
BI644125-00 (EN-US) 9
Disassembly and Assembly Section

Graphic Color Description


Table 12

The graphic color description table identifies what Assembly Preparation


the colors represent in each graphic.
Required Tools and Supplies
Graphic Symbol Description
Table 13
The graphic symbol description identifies what the
symbols represent in the graphic. Required Tools
Part
Description Qty
No.
208 L (55 US gal) barrels of hoist,
- converter, steering, and brake oil 6
(TDTO, TO-4)

227 L (60 US gal) of transmission/


drive train oil (TDTO). Ambient
temperatures that are extreme
- may require a different oil viscosi- 1
ty. Refer to Service Manual, SE-
BU6250, Caterpillar Machine Lub-
ricant Recommendations

Crane or suitable lifting device with


- lifting capacity of 54430 kg 1
(120000 lb)
Crane or suitable lifting device with
- lifting capacity of 36287 kg (80000 1
lb)
Lift truck with lifting capacity of
- 1
6810 kg (15000 lb)
Cables, lifting straps, and chains
- -
with adequate lifting capacity

(continued)
10 BI644125-00 (EN-US)
Disassembly and Assembly Section

(Table 13, contd) (Table 13, contd)

Required Tools Required Tools


Part No. Description Qty Part No. Description Qty
Shackles with lifting capacity of 386-6033 Lever Puller Hoist Gp 1
- 4
27240 kg (60050 lb)
176-6538 Spanner Wrench As 1
Portable air compressor with
385-7874 Hydraulic Wrench 1
capacity to operate two 25.4
- mm (1 inch) impact wrenches 1 Hydraulic Pump and Motor Gp,
(minimum capacity of 3 CM (100 385-8479 1
115 V
CFM)
Hydraulic Pump and Motor Gp,
Suitable cribbing: 914 mm (8 132-8231 1
220V
inch) Length X 203 mm (8.0
- 1 7X-1062 Ether Cylinder As 2
inch) Width X 102 mm (4 inch)
Height Tool Gp
399-0774 1
- Stepladder, 1.8 m (6 ft) 1 Reaction Arm

- Stepladder, 3.6 m (12 ft) 2 5P-5265 Forcing Bolts 4

Suitable rope: 94 m (308 ft) long 194-7586 Pneumatic Wrench Gp 1


- 1
X 19 mm (0.75 inch) diameter 194-7886 Drive Extension 1
- Paint Spray Gun 1 4C-6723 Socket, 1 7/16 inch 1
Torque Wrench 4C-6724 Socket, 46 mm 1
8T-9293
54 to 342 Nm (40 to 252 lb ft)
208-8785 Plate 1
- T-size Nitrogen Bottles 20
175-5507 Nitrogen Charging Group 1 Required tools and supplies to perform the field
assembly.
9U-5617 Oil Refill Pump
6V-4040 Inflation Gp The required tools and supplies should be present
before assembly. If the required tools and supplies
Loctite Graphite 50 Anti-Seize are not present, assembly will be more difficult and
- -
Lubricant more time will be necessary to complete assembly.
- Loctite C5A Copper Anti-Seize -
Reference: Service Magazine, SEPD05313 July
- Loctite Low Breakloose PST - 2000, Fabric Slings and Protective Sleeves Are
Available for Lifting Truck Bodies
- Loctite 242 -
- Loctite 271 - Reference: Special Instruction, SMHS7867, Use
of 6V-4040 Inflation Group
8T-3087 Hand Tap: M10X1.5 1
Reference: Operation and Maintenance Manual,
8T3091 Tap: M12X1.75 1
SEBU5898, Cold Weather Recommendations for
4C-4968 Tap: M24X3.0 1 Caterpillar Machines

4C-4969 Tap: M30X3.5 1


4C-4970 Tap: M36X4 1
386-6031 Lever Puller Hoist Gp 4

(continued)
BI644125-00 (EN-US) 11
Disassembly and Assembly Section

(Table 14, contd)


Shipping Weights
Component Approximate Weight
WARNING!
BPM/ECM Rear Catwalk 544 kg (1200 lb)
Personal injury or death can result from lifting
BPM/ECM Side Catwalk 544 kg (1200 lb)
a heavy assembly. The heavy assembly can
fall, if incorrect hoists are used to lift the load. BPM/ECM Front Catwalk 544 kg (1200 lb)

Be sure the hoist has the correct lift capacity. BPM/ECM RH Catwalk 181 kg (400 lb)
Approximate assembly weights are given be- BPM/ECM LH Catwalk 181 kg (400 lb)
low.
Cab 7250 kg (16000 lb)
Cab Ladders 227 kg (500 lb)
WARNING!
Super Beam Ladder 113 kg (250 lb)
Personal injury or death can result from im-
Push Beam Plow 1361 kg (3000 lb)
proper lifting or blocking.
Front Canopy 1361 kg (3000 lb)
When a hoist or jack is used to lift any part or
component, stand clear of the area. Be sure Rock Guard 544 kg (1200 lb)
the hoist or jack has the correct capacity to lift PTM Transfer Cylinders
the component. Install blocks or stands before 5443 kg (12000 lb)
and Catwalk
performing any work under a heavy compo-
nent. Hose Reel 21772 kg (48000 lb)
Hose Reel Catwalk 227 kg (500 lb)
Approximate weights of the components are
shown. Hose Reel Guard 680 kg (1500 lb)

Clean all surfaces where parts are to be in- Anchor Drills 1497 kg (3300 lb)
stalled. PTM Tables 1678 kg (3700 lb)
Cab, Groundman As-
Table 14 2268 kg (5000 lb)
sembly
Approximate
Component
Weight
Base Frame 43772 kg (96500 lb)
Front Super Beam 32659 kg (72000 lb)
Rear Super Beam 32659 kg (72000 lb)
Power Head 29030 kg (64000 lb)
BPM/ECM 19051 kg (42000 lb)
Front PTM Structure 5897 kg (13000 lb)
Rear PTM Structure 6350 kg (14000 lb)
Bridge 363 kg (800 lb) each
Extended Discharge Boom 9120 kg (20000 lb)
Transformer Frame 4082 kg (9000 lb)
Transformer 12700 kg (28000 lb)

(continued)
12 BI644125-00 (EN-US)
Disassembly and Assembly Section

Site Layout

Illustration 2
BI644125-00 (EN-US) 13
Disassembly and Assembly Section

Typical Assembly Layout

The work area for the base frame and the compo-
nents should be flat, smooth, and drained. An area
of approximately 46 m (150 ft) by 29 m (95 ft) is
needed for the assembly of the machine.

The base frame should be located in the center of


the assembly area. Keep the assembly area
around the base frame clear. Also, the assembly
area should be left unobstructed in order for the
crane to lift the components.

Base Frame - Install


Parts and Specification Information

Illustration 3

Table 15

Base Frame

Item Qty Part Number Description Approximate Weight

1 1 4592663 Base Frame 43772 kg (96000 lb)


14 BI644125-00 (EN-US)
Disassembly and Assembly Section

Installation Procedure

Illustration 4

1. Use an appropriate lifting device to set the


base frame (1) into position. The approximate
weight of the base frame is 43772 kg (965000
lb).

Illustration 5

Typical view of cribbing use to support the ma-


chine.
BI644125-00 (EN-US) 15
Disassembly and Assembly Section

Illustration 6 View of level being used on the base frame from


side to side.
View of level being used on the base frame from
front to back. 2. Use 153 mm (6 inch) X 153 mm (6 inch) hard-
wood cribbing to position base frame (1). Po-
sition base frame (1) at least 610 mm (24 inch)
above ground level. Make sure the base
frame (1) is level from front to back and side to
side. Check level with 914.5 (36 inch) level.

Illustration 7
16 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 8

3. Remove and discard the shipping brackets.


Retain the hardware.
BI644125-00 (EN-US) 17
Disassembly and Assembly Section

Illustration 9

4. Fold the T-bar ends out and secure in place


using hardware retained from Step 3.
18 BI644125-00 (EN-US)
Disassembly and Assembly Section

Front Super Beam - Install


Parts and Specification Information

Illustration 10

Table 16

Front Super Beam

Item Qty Part Number Description Approximate Weight

1 1 4510739 Front Super Beam 32659 kg (72000 lb)


BI644125-00 (EN-US) 19
Disassembly and Assembly Section

Installation Procedure

Illustration 11

1. Use an appropriate lifting device to set the


front super beam (1) into position. The approx-
imate weight of the front super beam (1) is
32659 kg (72000 lb).
20 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 12

2. Use a suitable tool to align the mounting holes of the front


super beam (1) with the mounting holes of the base frame.
BI644125-00 (EN-US) 21
Disassembly and Assembly Section

Illustration 13

3. Secure the front super beam (1) to the base


frame using bolts, washers, and nuts.
22 BI644125-00 (EN-US)
Disassembly and Assembly Section

Rear Super Beam - Install


Parts and Specification Information

Illustration 14

Table 17

Rear Super Beam

Item Qty Part Number Description Approximate Weight

1 1 4510739 Rear Super Beam 32659 kg (72000 lb)


BI644125-00 (EN-US) 23
Disassembly and Assembly Section

Installation Procedure

Illustration 15

1. Use an appropriate lifting device to set the rear


super beam (1) into position. The approximate
weight of the rear super beam (1) is 32659 kg
(72000 lb).
24 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 16

2. Use suitable tooling to align the mounting holes of the rear


super beam (1) with the mounting holes of the base frame.
BI644125-00 (EN-US) 25
Disassembly and Assembly Section

Illustration 17

3. Secure the rear super beam (1) to the base


frame using bolts, washers, and nuts provided.
26 BI644125-00 (EN-US)
Disassembly and Assembly Section

Power Head - Install


Parts and Specification Information

Illustration 18

Table18

Power Head

Item Qty Part Number Description Approximate Weight

1 1 4592666 Power Head 29030 kg (64000 lb)


BI644125-00 (EN-US) 27
Disassembly and Assembly Section

Installation Procedure

Illustration 19

1. Use an appropriate lifting device to set the


power head (1) into position. The approximate
weight of the power head (1) is 29030 kg
(64000 lb).

2. Move the power head (1) into the base frame.

NOTICE
Make sure the conveyor chain and cables are out
of the way when pushing the power head (1) into
the base frame.
28 BI644125-00 (EN-US)
Disassembly and Assembly Section

Base Power Module - Install


Parts and Specification Information

Illustration 20

Table 19

Base Power Module

Item Qty Part Number Description Approximate Weight

1 1 4835971 Base Power Module 19051 kg (42000 lb)


BI644125-00 (EN-US) 29
Disassembly and Assembly Section

Installation Procedure

Illustration 21

1. Use an appropriate lifting device to set the


base power module (1) into positon. The ap-
proximate weight of the base power module (1)
is 19051 kg (42000 lb).
30 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 22

2. Position the base power module (1) on the four


cone shaped cam locks located on the rear
super beam and the base frame.

Illustration 23

View of cam lock location

3. Turn the lever on the cam locks to secure base


power module 91) on the rear super beam and
on the base frame.
BI644125-00 (EN-US) 31
Disassembly and Assembly Section

Front PTM Structure - Install


Parts and Specification Information

Illustration 24

Table 20

Front PTM Structure

Item Qty Part Number Description Approximate Weight

1 1 4412288 Front PTM Structure 5897 kg (13000 lb)


32 BI644125-00 (EN-US)
Disassembly and Assembly Section

Installation Procedure

Illustration 25

1. Use an appropriate lifting device to set the


front PTM structure (1) into position. The ap-
proximate weight of the front PTM structure (1)
is 5897 kg (13000 lb).
BI644125-00 (EN-US) 33
Disassembly and Assembly Section

Illustration 26

2. Secure the front PTM structure (1) with pins at


the locations shown. Raise and pin the sup-
port legs attached to the base frame to the
front PTM structure (1) at two locations.
34 BI644125-00 (EN-US)
Disassembly and Assembly Section

Rear PTM Structure - Install


Parts and Specification Information

D
FW

Illustration 27

Table 21

Rear PTM Structure

Item Qty Part Number Description Approximate Weight

1 1 4412287 Rear PTM Structure 6350 kg (14000 lb)


BI644125-00 (EN-US) 35
Disassembly and Assembly Section

Installation Procedure

Illustration 28

1. Use an appropriate lifting device to set the rear


PTM structure (1) into position. The approxi-
mate weight of the front PTM structure (1) is
6350 kg (14000 lb).
36 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 29

2. Secure the rear PTM structure (1) with pins at


the locations shown. Raise and pin the sup-
port legs attached to the base frame to the rear
PTM structure (1) at two locations.
BI644125-00 (EN-US) 37
Disassembly and Assembly Section

Bridge - Install
Parts and Specification Information

Illustration 30

Table 22

Bridge

Item Qty Part Number Description Approximate Weight

1 2 4208239 Bridge 363 kg (800 lb)


38 BI644125-00 (EN-US)
Disassembly and Assembly Section

Installation Procedure

Note: Install the following prior to installing the two


bridges:

PTM Tables
PTM Transfer Cylinders and Catwalk
Stagger Skid Catwalk

Illustration 31
BI644125-00 (EN-US) 39
Disassembly and Assembly Section

Illustration 32

1. Use an appropriate lifting device to set each


bridge (1) into position. The approximate
weight of each bridge (1) is 363 kg (800 lb).

2. Secure the bridges (1) using two nuts on the


pins of each bridge (1). Use to 50.8 mm (2
inch) bolts and a washer with a nut on each
end.
40 BI644125-00 (EN-US)
Disassembly and Assembly Section

Extended Discharge Boom - Install


Parts and Specification Information

Illustration 33

Table 23

Extended Discharge Boom

Item Qty Part Number Description Approximate Weight

1 1 4509196 Extended Discharge Boom 9120 kg (20000 lb)


BI644125-00 (EN-US) 41
Disassembly and Assembly Section

Illustration 34

1. Use an appropriate lifting device to set the ex-


tended discharge boom (1) into position. The
approximate weight of the extended discharge
boom (1) is 9120 kg (20100 lb).
42 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 35

2. Secure the extended discharge boom (1) to the


base frame using two pins.
BI644125-00 (EN-US) 43
Disassembly and Assembly Section

Illustration 36

3. Feed the conveyor chain around the sprocket


and assemble the chain with connecting links.
44 BI644125-00 (EN-US)
Disassembly and Assembly Section

Transformer Frame - Install


Parts and Specification Information

Illustration 37

Table 24

Transformer Frame

Item Qty Part Number Description Approximate Weight

1 1 4281682 Transformer Frame 4082 kg (9000 lb)


BI644125-00 (EN-US) 45
Disassembly and Assembly Section

Installation Procedure

Illustration 38

1. Use an appropriate lifting device to set the


transformer frame (1) into position. The ap-
proximate weight of the transformer frame (1)
is 4082 kg (9000 lb).

2. Secure the transformer frame (1) to the back of


the T-bar with eighteen bolts on each side.
46 BI644125-00 (EN-US)
Disassembly and Assembly Section

Transformer - Install
Parts and Specification Information

Illustration 39

Table 25

Transformer

Item Qty Part Number Description Approximate Weight

1 1 4830241 Transformer 12700 kg (28000 lb)


BI644125-00 (EN-US) 47
Disassembly and Assembly Section

Installation Procedure

Illustration 40

1. Use an appropriate lifting device to set the


transformer (1) into position. The approximate
weight of the transformer is 12700 kg (28000
lb).
48 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 41

2. Secure the transformer (1) to the top of the


transformer frame with eight bolts on the front
and the rear of the transformer (1).
BI644125-00 (EN-US) 49
Disassembly and Assembly Section

Illustration 42

Illustration 43

3. Secure the exhaust tubes to the exhaust


bracket with eight bolts, twelve washers, and
eight nuts.

4. Position the two exhaust tubes in the trans-


former (1).
50 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 44

5. Secure the exhaust bracket to the transformer


(1) with six bolts and eighteen washers.
BI644125-00 (EN-US) 51
Disassembly and Assembly Section

Base Power Module Catwalks - Install


Parts and Specification Information

Illustration 45

Table 26

Base Power Module Catwalks

Item Qty Part Number Description Approximate Weight

1 1 4510910 Rear Catwalk 544 kg (1200 lb)

2 1 4412241 LH Catwalk 544 kg (1200 lb)

3 1 4412239 Front Catwalk 544 kg (1200 lb)

4 1 4412240 RH Catwalk 544 kg (1200 lb)

5 1 4207996 RH Catwalk 181 kg (400 lb)

6 1 4207997 LH Catwalk 181 kg (400 lb)


52 BI644125-00 (EN-US)
Disassembly and Assembly Section

Installation Procedure

Illustration 46

View of the location of the front catwalk (1).


BI644125-00 (EN-US) 53
Disassembly and Assembly Section

Illustration 47

View of the mounting location for the front catwalk


(3).

1. Use an appropriate lifting device to set the


front catwalk (3) into position. The approxi-
mate weight of the front catwalk (1) is 544 kg
(1200 lb).

2. Secure the front catwalk (3) to the rear super


beam with twelve bolts, twenty-four washers,
and twelve nuts.
54 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 48

View of the locations of the RH catwalk (4) and the


LH catwalk (2).
BI644125-00 (EN-US) 55
Disassembly and Assembly Section

Illustration 49

View of the mounting locations for the RH catwalk


(4).
56 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 50 6. Secure the LH catwalk (2) and the RH catwalk


(4) to the rear super beam with four bolts, eight
View of the mounting location for the RH catwalk washers, and four nuts.
(4).

3. Use an appropriate lifting device to set the LH


catwalk (2) and RH catwalk (4) into position.
The approximate weight of the LH catwalk (2)
and the RH catwalk (4) is 544 kg (1200 lb).

4. Secure the LH catwalk (2) and the RH catwalk


(4) to the base frame with four bolts and eight
washers.

5. Secure the LH catwalk (2) and RH catwalk (4)


to the front catwalk (3) with four bolts, eight
washers, and four nuts.
BI644125-00 (EN-US) 57
Disassembly and Assembly Section

Illustration 51
58 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 52

View of the mounting bolt locations for the LH cat-


walk (6) and RH catwalk (5).
BI644125-00 (EN-US) 59
Disassembly and Assembly Section

Illustration 53

7. Use an appropriate lifting device to set the LH


catwalk (6) and RH catwalk (5) into position.
The approximate weight of the LH catwalk (6)
and the RH catwalk (5) is 181 kg (400 lb).

8. Secure the LH catwalk (6) and the RH catwalk


(5) to the LH and RH catwalks that were previ-
ously installed to the base frame with four
bolts, eight washers, and four nuts.

9. Secure the LH catwalk (6) and RH catwalk (5)


to the transformer frame with six bolts, twelve
washers, and six nuts.
60 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 54
BI644125-00 (EN-US) 61
Disassembly and Assembly Section

Illustration 55

Bolt locations on the LH side of the rear catwalk (1)

10. Use an appropriate lifting device to set the rear


catwalk 91) into position. The approximate
weight of the rear catwalk 91) is 544 kg (1200
lb).

11. Secure the front catwalk (1) to the previously


installed catwalks with fourteen bolts, twenty-
eight washers, and fourteen nuts.
62 BI644125-00 (EN-US)
Disassembly and Assembly Section

Cab - Install
Parts and Specification Information

Illustration 56

Table 27

Cab

Item Qty Part Number Description Approximate Weight

1 1 4829476 Cab 7257 kg (16000 lb)


BI644125-00 (EN-US) 63
Disassembly and Assembly Section

Installation Procedure

Illustration 57

1. Use an appropriate lifting device to set cab (1)


into position. The approximate weight of the
cab (1) is 7257 kg (16000 lb). Position the cab
(1) on the four cone shaped cam locks located
on the base power module.

2. Turn the lever on the cam locks to secure the


cab (1) to the base power module.
64 BI644125-00 (EN-US)
Disassembly and Assembly Section

Cab Ladders - Install


Parts and Specification Information

Illustration 58

Table 28

Cab Ladders

Item Qty Part Number Description Approximate Weight

1 1 4207928 RH Super Beam Ladder 113 kg (250 lb)

2 1 4207989 LH Rear Super Beam Ladder 113 kg (250 lb)

3 1 4207940 RH Cab Ladder 227 kg (500 lb)

4 1 4207941 LH Cab Ladder 227 kg (500 lb)


BI644125-00 (EN-US) 65
Disassembly and Assembly Section

Installation Procedure

Illustration 59

1. Use an appropriate lifting device to set the RH


rear super beam ladder (1) and LH rear super
beam ladder (2) into position. The approxi-
mate weight of the RH rear super beam ladder
(1) and the LH rear super beam ladder (2) is
113 kg (250).
66 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 60

2. Secure the RH rear super beam ladder (1) and


LH rear super beam ladders (2) using three bolts
and three washers for each ladder.
BI644125-00 (EN-US) 67
Disassembly and Assembly Section

Illustration 61

View of RH cab ladder (3) and LH cab ladder (4).

3. Use appropriate lifting device to set the RH cab


ladder (3) and RH cab ladder (4) into position.
The approximate weight of the RH cab ladder
and the LH cab ladder (4) is 227 kg (500 lb).
68 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 62

View of RH cab ladder (3)

4. Secure the RH cab ladder (3) and the LH cab


ladder (4) using five bolts and five washers for
each ladder.
BI644125-00 (EN-US) 69
Disassembly and Assembly Section

Push Beam Plow - Install


Parts and Specification Information

Illustration 63

Table 29

Push Beam Plow

Item Qty Part Number Description Approximate Weight

1 1 4207991 Push Beam Plow 1361 kg (3000 lb)


70 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 64

1. Use an appropriate lifting device to set the


push beam plow (1) into position. The approxi-
mate weight of the push beam plow (1) is 1361
kg (3000 lb).
BI644125-00 (EN-US) 71
Disassembly and Assembly Section

Illustration 65

2. Secure the push beam plow (1) to the front


super beam using two pins.

3. Connect the cylinder.


BI644125-00 (EN-US) 72
Disassembly and Assembly Section

PTM II Lift Mechanism - Install


Parts and Specification Information

Illustration 66
73 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 67

Table 30

PTM II Lift Mechanism

Item Qty Part Number Description Approximate Weight

1 1 4412284 PTM II Lift Mechanism 5443 kg (12000 lb)


BI644125-00 (EN-US) 74
Disassembly and Assembly Section

Illustration 68

1. Use an appropriate lifting device to position the


PTM II lift mechanism (1) into position. The
approximate weight of the rear PTM structure
(1) is 5443 kg (12000). Support the PTM II lift
mechanism (1) with appropriate cribbing for
assembly.
75 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 69

2. Secure the two beams and two cylinders to the


PTM II lift mechanism (1) with sixteen bolts,
sixteen washers, sixteen lock washers, and
sixteen nuts.
BI644125-00 (EN-US) 76
Disassembly and Assembly Section

Illustration 70
77 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 71

3. Use an appropriate lifting device to set the cat-


walk and handrail into position. The approxi-
mate weight of the catwalk and handrail is 182
kg (400 lb).

4. Secure the catwalk and handrail PTM structure


(1) using four bolts, four flat washers, four lock
washers, and four nuts.
BI644125-00 (EN-US) 78
Disassembly and Assembly Section

Illustration 72

5. Use an appropriate lifting device to set the


PTM II lift mechanism (1) into position. The
approximate weight of the rear PTM structure
(1) is 5443 kg (12000 lb). Lift the PTM II lift
mechanism (1) by the top bracket and slide the
rollers onto the I-beam (catwalk facing the RH
side).
79 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 73

6. Use an appropriate lifting device to set the end


bracket into position. The approximate weight
of the end bracket is 182 kg (400 lb).

7. The end bracket can be bolted to the I-beam in


one of two locations, depending on which side
from which the push beams will be loaded.
After determining the location, secure the end
bracket to the I-beam with four bolts, four lock
washers, and four nuts on each side.
BI644125-00 (EN-US) 80
Disassembly and Assembly Section

Hose Reel - Install


Parts and Specification Information

Illustration 83

Table 33

Base Frame

Item Qty Part Number Description Approximate Weight

1 1 4835743 Hose Reel 21772 kg (48000 lb)


81 BI644125-00 (EN-US)
Disassembly and Assembly Section

Installation Procedure

Illustration 84

View of hose reel (1) as shipped.


BI644125-00 (EN-US) 82
Disassembly and Assembly Section

Illustration 85 4. Assemble the temporary stand for the tempo-


rary hose reel and set next to the machine
1. Remove all beams that are assembled with hose reel. Straighten cables and hoses and,
bolts in the hose reel shipping frame. using the required hose chain, permanently
connect the two spools of hose chain.
2. Using an oxygen/acetylene torch, cut through
the lifting plate and bottom beam on both sides 5. Using the highwall miner hydraulic power, or
of the frame to create a base for the hose reel an alternate hydraulic power source, apply hy-
to stand upright on. draulic power to the hose reel motor.

3. Using four shackles and 9.1 m (30 ft) cables, 6. Reel the hose chain from the temporary hose
lift the hose reel 91) and set in front of the reel to the machine hose reel.
highwall miner in the upright position. The ap-
proximate weight of the hose reel (1) is 21772
kg (48000 lb).
83 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 86

7. Clean the hose reel mounting pads.

8. Once all hose chain has been transferred to


the machine hose reel (1), set it in place on the
front super beam.

9. Secure the hose reel (1) with ten bolts on each


side.
BI644125-00 (EN-US) 84
Disassembly and Assembly Section

Drill and Anchor Masts - Install


Parts and Specification Information

Illustration 74

Table 31

Drill and Anchor Masts

Item Qty Part Number Description Approximate Weight

1 1 4207740 RH Drill and Anchor Mast 1497 kg (3300 lb)

2 1 4281509 LH Drill and Anchor Mast 1497 kg (3300 lb)


85 BI644125-00 (EN-US)
Disassembly and Assembly Section

Installation Procedure

Illustration 75

View of the mounting locations on the RH drill and


anchor mast (1).
BI644125-00 (EN-US) 86
Disassembly and Assembly Section

Illustration 76

View of the mounting locations on the LH drill and


anchor mast (2).
87 BI644125-00 (EN-US)
Disassembly and Assembly Section

1
2

Illustration 77 3. Secure the LH drill and anchor mast (1) using


eight bolts on the top mounting plate and ten
1. Use an appropriate lifting device to set the RH bolts on the bottom mounting plate. Take care
drill and anchor mast (1) and the LH drill and to avoid damaging wiring and hoses.
anchor mast (2) into position. The approxi-
mate weight of the RH drill and anchor mast
(1) and the LH drill and anchor mast (2) is
1497 kg (3300 lb).

2. Secure the RH drill and anchor mast (1) using


eight bolts on the top mounting plate and ten
bolts on the bottom mounting plate. Take care
to avoid damaging wiring and hoses.
88 BI644125-00 (EN-US)
Disassembly and Assembly Section

Front Canopies - Install


Parts and Specification Information

Illustration 78

Table 32

Front Canopies

Item Qty Part Number Description Approximate Weight

1 1 4613952 Front Canopy 1075 kg (2370 lb)

2 1 4281683 Blast Shield 544 kg (1200 lb)


BI644125-00 (EN-US) 89
Disassembly and Assembly Section

Installation Procedure

Illustration 79

View of the front canopy sitting in position on the


front supports.

1. Use an appropriate lifting device to set the


front canopy (1) into position.. The approxi-
mate weight of the front canopy (1) is 1075 kg
(2370 lb).
90 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 80

2. Secure the front canopy (1) to the front super


beam using four pins.
BI644125-00 (EN-US) 91
Disassembly and Assembly Section

Illustration 81
92 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 82

3. Use an appropriate lifting device to position the


rock guard (2) into position. The approximate
weight of the rock guard (2) is 544 kg (1200
lb).

4. Secure the rock guard (2) to the front canopy


(1) using three pins.

5. Connect the cylinder.


BI644125-00 (EN-US) 93
Disassembly and Assembly Section

LH & RH Wing Catwalk Support - Install


Parts and Specification Information

Illustration 87

Table 34

Hose Reel Catwalk

Item Qty Part Number Description Approximate Weight

1 2 4614020 Wing Support, RH and LH 65 kg (30 lb)


94 BI644125-00 (EN-US)
Disassembly and Assembly Section

Installation Procedure

3 2
1 2
3 1

Illustration 88

1. Position the LH wing catwalk support (1) and


the RH wing catwalk support (2) and secure
with bolts (2) and washers (3). The approxi-
mate weight of the LH wing catwalk support (1)
and RH wing catwalk support (2) is 65 kg (30
lb).
BI644125-00 (EN-US) 95
Disassembly and Assembly Section

LH Wing Catwalk - Install


Parts and Specification Information

Illustration 89

Table 35

LH Wing Catwalk

Item Qty Part Number Description Approximate Weight

1 1 4613996 LH Wing Catwalk 280 kg (620 lb)


96 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 90

1. Use an appropriate lifting device to set the LH


wing catwalk (1) into position. The approxi-
mate weight of the LH wing catwalk (1) is 280
kg (620 lb).

2. Secure with bolts, nuts, and washers.


BI644125-00 (EN-US) 97
Disassembly and Assembly Section

RH Wing Catwalk - Install


Parts and Specification Information

Illustration 91

Table 36

RH Wing Catwalk

Item Qty Part Number Description Approximate Weight

1 1 4614654 RH Wing Catwalk 480 kg (1060 lb)


98 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 92

1. Use an appropriate lifting device to set the RH


wing catwalk (1) into position. The approxi-
mate weight of the RH wing catwalk (1) is 480
kg (1060 lb).

2. Secure with bolts, nuts, and washers.


BI644125-00 (EN-US) 99
Disassembly and Assembly Section

LH Hose Reel Catwalk - Install


Parts and Specification Information

Illustration 93

Table 37

LH Hose Reel Catwalk

Item Qty Part Number Description Approximate Weight

1 1 4614622 LH Hose Reel Catwalk 625 kg (1380 lb)


100 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 94

1. Use an appropriate lifting device to set the LH


hose reel catwalk (1) into position. The ap-
proximate weight of the LH hose reel catwalk
(1) is 625 kg (1380 lb).

2. Secure with bolts, nuts, and washers.


BI644125-00 (EN-US) 101
Disassembly and Assembly Section

RH Hose Reel Catwalk - Install


Parts and Specification Information

Illustration 95

Table 38

RH Hose Reel Catwalk

Item Qty Part Number Description Approximate Weight

1 1 4614654 RH Hose Reel Catwalk 480 kg (1060 lb)


102 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 96

1. Use an appropriate lifting device to set the RH


hose reel catwalk (1) into position. The ap-
proximate weight of the RH hose reel catwalk
(1) is 480 kg (1060 lb).

2. Secure with bolts, nuts, and washers.


BI644125-00 (EN-US) 103
Disassembly and Assembly Section

LH and RH Can Cover - Install


Parts and Specification Information

Illustration 97

Table 39

RH Hose Reel Catwalk

Item Qty Part Number Description Approximate Weight

1 2 4509748 Can Cover 10 kg (20 lb)


104 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 98
1. Use an appropriate lifting device to set the RH
and LH can covers (1) into position. The ap-
proximate weight of the RH hose reel catwalk
(1) is 10 kg (20 lb).
BI644125-00 (EN-US) 105
Disassembly and Assembly Section

Hose Reel Guard - Install


Parts and Specification Information

Illustration 99

Table 40

Hose Reel Guard

Item Qty Part Number Description Approximate Weight

1 1 4208087 Hose Reel Guard 680 kg (1500 lb)


106 BI644125-00 (EN-US)
Disassembly and Assembly Section

Illustration 100

1. Use an appropriate lifting device to set the


hose reel guard (1) into position. The approxi-
mate weight of the hose reel guard 91) is 680
kg (1500 lb).

2. Secure the hose reel guard (1) to the hose reel


with four bolts on each side.
BI644125-00 (EN-US) 107
Disassembly and Assembly Section

PTM Tables - Install


Parts and Specification Information

Illustration 101

Table 41

PTM Tables

Item Qty Part Number Description Approximate Weight

1 2 4512184 PTM Tables 1678 kg (3700 lb)


108 BI644125-00 (EN-US)
Disassembly and Assembly Section

Installation Procedure

Illustration 102

View of the mounting location of the PTM tables


(1).
BI644125-00 (EN-US) 109
Disassembly and Assembly Section

Illustration 103

1. Use an appropriate lifting device to set the


PTM tables (1) into position. The approximate
weight of the PTM tables (1) is 1678 kg (3700
lb).

2. Secure the PTM tables (1) to the front and rear


super beams with four cables and four turn
buckles.
110 BI644125-00 (EN-US)
Disassembly and Assembly Section

Cab , Groundman Assembly - Install


Parts and Specification Information

Illustration 104

Table 42

Cab, Groundman Assembly

Item Qty Part Number Description Approximate Weight

1 1 4830242 Cab, Groundman Assembly 2268 kg (5000 lb)


BI644125-00 (EN-US) 111
Disassembly and Assembly Section

Installation Procedure

Illustration 105

Illustration 106 2. Install the cab, groundman assembly (1) on the


opposite side of where the beams will be load-
1. Use an appropriate lifting device to set the cab, ed.
groundman assembly (1) into position. The
approximate weight of the cab, groundman Note: The cab, groundman assembly (1) sets in
assembly (1) is 2268 kg (5000 lb). the table with no need for any attachment.