Assembly Procedure For 6040 AC FS Machine DHX: EM030331-00 (En-Us)

EM030331-00 (en-us)
Assembly
Procedure
for
6040 AC FS
Machine
DHX
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 Dealer Service Tool Catalog" for
tools and supplies suitable to collect and
contain fluids on Caterpillar products.
Dispose of all fluids according to local
regulations and mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and
shortened component life.
3.3 ASSEMBLY MANUAL
3.3 Assembling the excavator

3.3.1 Overview ......................................................................................................................................... 3
3.3.2 Safety instructions ......................................................................................................................... 3
3.3.3 Personnel ........................................................................................................................................ 4
3.3.4 Assembly equipment ..................................................................................................................... 5
3.3.5 Modules on arrival.......................................................................................................................... 6
3.3.6 Assembly site ................................................................................................................................. 6
3.3.7 Preparation of modules for assembly .......................................................................................... 8
3.3.8 General assembly procedures ...................................................................................................... 9
3.3.9 Workflow chart of assembly procedure ..................................................................................... 12
3.3.10 Preparation of undercarriage and superstructure modules .................................................... 13
3.3.11 Undercarriage assembly ............................................................................................................. 17
3.3.12 Installation of High Voltage (HV) bracket .................................................................................. 28
3.3.13 Preparations for superstructure installation ............................................................................. 29
3.3.14 Installation of superstructure frame........................................................................................... 33
3.3.15 Installation of swing gearboxes.................................................................................................. 37
3.3.16 Connection of hydraulic lines between undercarriage and superstructure .......................... 38
3.3.17 Boom installation ......................................................................................................................... 40
3.3.18 Installation of modules and components to superstructure frame ........................................ 49
3.3.19 Stick installation ........................................................................................................................... 72
3.3.20 Final steps of boom installation ................................................................................................. 74
3.3.21 Top up operating fluids ............................................................................................................... 81
3.3.22 Electric system ............................................................................................................................. 81
3.3.23 Preparations for machine start-up ............................................................................................. 90
3.3.24 Machine start-up........................................................................................................................... 93
3.3.25 Bucket installation ....................................................................................................................... 93
3.3.26 Residual stroke............................................................................................................................. 95
3.3.27 Last preparations for machine start-up ..................................................................................... 96
3.3.28 Bucket removal and reinstallation.............................................................................................. 97
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3.3 ASSEMBLY MANUAL
Page 3.3 – 2 3746324en – (00)

3.3 ASSEMBLY MANUAL
3.3.1 Overview 3.3.2 Safety instructions
About this Assembly Manual Warnings and symbols

This Assembly Manual applies to machine type The following signs and symbols used in this
Cat 6040 FS. Assembly Manual indicate steps in the assembly
process which involve particular risk or danger to
This Assembly Manual is intended for personnel persons or to the machine.
responsible for the assembly of a machine model
6040 FS.
This symbol indicates a hazardous
It contains a description of individual assembly situation that could result in injury,
steps for the machine and the work required serious injury or death.
before and during the assembly of a component
or module.
You can find issues that go beyond those This symbol indicates a source of
described here in chapters of our Service Manual potential damage to the machine or
as well as the spare parts catalogs, and electric other property.
and hydraulic schematics.
Illustrations Safety requirements

Illustrations in this Assembly Manual show the
Everybody involved in the assembly of the
technical details required only for the respective
machine must have read and understood the
assembly step. The illustrations are not a
safety instructions and the code of conduct in
substitute for the Assembly Manual as we reserve
chapter 3.1 of the Service Manual.
the right to make technical changes. For technical
details please refer to the corresponding sections Everybody involved in the assembly process must
of the current Service Manual, Spare Parts be familiar with the local safety regulations and
Manual, electric and hydraulic schematics. special safety regulations at the assembly site.
Compliance with these regulations is mandatory
To make it easier to understand their content,
for everybody at all times.
some illustrations are simplified and therefore
differ slightly from the current assembly condition. You can find further safety instructions in chapter
1.2 of the Service Manual. They are mandatory for
Directional information everybody as well.
Directional information (right-hand, left-hand) For all safety issues, please contact the
always refers to the forward travel direction of the responsible personnel on site.
machine.
Provide safety regulations in the
Assembly duration local language and in English to
Schedule approx. twenty working days with ten ensure that everybody involved in
working hours per day for the assembly of the the machine assembly is able to
machine. understand them.
In addition, schedule approximately five working

days for commissioning and functional testing.
3746324en – (00) Page 3.3 – 3

3.3 ASSEMBLY MANUAL
Personal protective equipment and work Commissioning during assembly

clothing
Starting the machine before it is
Always wear closely fitting work clothing when completely assembled can cause
working on the machine. Baggy or loose-fitting serious injuries and/or damage to
garments may be caught in machine parts and property.
cause serious injury.
If a start-up for testing and
Wear the following personal protective equipment assembly purposes is necessary,
when working on the machine: comply with all requirements of the
 helmet machine and the assembly site.
 safety footwear
 protective gloves If it is necessary to start the machine during
assembly, the start-up must be conducted by the
 safety goggles supervisor and the machine must be operated by
 ear protection a person who has been clearly authorized to do
so.
 site specific personal protective equipment
3.3.3 Personnel
Handling of environmentally hazardous
substances Personnel required
During assembly of the machine, you will handle Experienced product experts (e.g. supplied by the
substances and materials classified as factory or dealer, please refer also to the data
environmentally hazardous according to national sheet with media Id. BI644854 "Assembly
and regional environmental legislation. These Requirements Hydraulic Shovel CAT6040 FS",
include oil, fuel, and grease. which can be downloaded from Caterpillar Service
Always follow the applicable national and regional Information System (SIS, http://sis.cat.com)):
regulations when handling such substances.  1 service engineer
 1 technician (mechanic)
Provide the regulations in the local
language and in English to ensure Additional personnel (e.g. supplied by the
that everybody involved in the customer):
machine assembly can understand  5 mechanics
them.
 1 electrician
 2 assistants
Handling of substances hazardous to  1 welder on request
health
During assembly of the machine, you will handle
substances classified as hazardous to health.
Qualification and training of personnel
These include hydraulic oil, fuel, and grease.
Avoid direct skin contact with these substances. It is mandatory that personnel have
Always follow applicable national and regional read, understood, and retained the
legislation and regulations as well as following measures and codes of
manufacturer specifications. conduct.
Provide the regulations in the local Mandatory personnel requirements:

language and in English to ensure
that everybody involved in the  Assign only fully qualified, trained, and
machine assembly is able to experienced personnel to work on or with the
understand them. machine.
 Always obey legal age restrictions.
Page 3.3 – 4 3746324en – (00)

3.3 ASSEMBLY MANUAL
 Define clearly and particularly the individual Required

responsibility of each person for operation, Qty Equipment
on days
setup, maintenance, and repair work.
Welding equipment
 Authorize the respective personnel to ignore 10
Forklift rough terrain, min.
any instructions given by a third party if these 1
7 500 kg carrying capacity
contradict the applicable safety regulations.
Power supply for equipment throughout
 Do not let persons who received only basic
instructions work on or with the machine. Table 1
Otherwise ensure that such persons are The cranes must be equipped with rigging
permanently supervised by experienced equipment, such as:
personnel.
 chains
 Assign only an experienced electrician or
trained personnel under the permanent  ropes (steel and nylon)
supervision of an experienced electrician to
 belts
work on the electric system. Ensure that work
on the electric system is carried out in  guide ropes
compliance with the applicable electrical
standards and regulations. in sufficient quantities and length.
 Assign only personnel specially trained and The rigging equipment must have the appropriate
experienced in hydraulics to work on the loading capacity and lengths and be available in
hydraulic system. sufficient quantities. The length required depends
on the angle position of welded transport lugs on
 Ensure that everybody involved in the individual modules, e.g. on the boom. The rigging
assembly process has the necessary physical equipment must match the lugs.
and intellectual abilities, such as unrestricted
An adequate quantity of supporting materials such
vision and hearing, and quick reaction
as hardwood planks, blocks, and boards, pallets,
capability.
plastic mats, etc. must also be available.
 Assign only experienced personnel who know
the valid accident prevention regulations with For further required assembly items, please refer
rigging loads and instructing the crane operator to the data sheet "Assembly Requirements
during assembly. Hydraulic Shovel CAT6040 FS", which can be
downloaded from Caterpillar Service Information
System (SIS, http://sis.cat.com).
3.3.4 Assembly equipment
Tools
The following equipment is supplied by the Assembly of the machine requires the usual
customer (s. Assembly Requirements in SIS, standard set of tools and a number of special
media Id. BI644854). tools. Section 3.2. of the Service Manual contains
a list of these tools.
Required
Qty Equipment
on days To ensure that several people can work
continuously provide four sets of standard tool
Crane with min. 100 000 kg equipment.
1-6
carrying capacity
You can download the Tools Reference List from
Crane with min. 100 000 kg the Excavator Support Portal or obtain it from your
1 - 10
carrying capacity
local dealer.
Mobile universal work platform,
We recommend that the tools listed are kept on
working height 2 to 7.5 m and 10
1 000 kg carrying capacity site, not only for assembly, but also for future
1 service work, overhauls or repairs.
Mobile equipment with 6 m
reach for installing pins, e.g.
Wheel loader, excavator, or
telehandler, required on "as
and when" basis during
assembly
Air compressor 10
3746324en – (00) Page 3.3 – 5

3.3 ASSEMBLY MANUAL
Equipment for personnel 3.3.6 Assembly site

Assembly personnel should be provided with
accommodation, break room, and wash rooms as Size and condition
well as place to store the tools. An area of at least 50 x 50 m (164 x 164 ft) will be
Medical facilities must be accessible to provide required for assembly of the machine, of which
first aid in case of an accident at work. 15 x 15 m (49 x 49 ft) must be level ground with a
maximum deviation of 1%.
The soil must have a bearing capacity of at least
3.3.5 Modules on arrival 22 N/cm2 (32 lbf/sq.in.) and good drainage (for
example compacted gravel or rocks).
After assembly and testing at Caterpillar plants,
The entire assembly site must be clean, dry, flat,
the machine is disassembled for transport.
and firm. An even and horizontal surface is
Several modules are shipped separately. For
essential for the correct inter-alignment of the
weights and dimensions of the modules please
components during assembly.
refer to chapter 2.8 “Weights of modules and
components” of the Service Manual.
Local conditions, such as the maximum load Modules arrangement on assembly site
capacity of bridges, may require the separation of
the modules into smaller units. To avoid unnecessary relocation of the modules
and cranes, unload and arrange the modules
Compare the data stated in Section 2.8 of the SM according to Fig. 1.
with the packing list. If they differ, consider the
data in the packing list. Leave sufficient space between the modules to
easily handle the parts and ensure easy access
If necessary request the packing list via Dealer for a forklift or telehandler.
Support Network (DSN) or your Regional HMS
Support. Never work under a suspended
load. Do not lift modules by crane to
Assembly steps can vary from the steps described
access the bottom side. Instead
on the following pages depending on the
place the module on stable jack
disassembly level of the machine and the special
stands or similar suitable supports
conditions at the assembly site. In this case,
of sufficient carrying capacity. Use
please contact your local dealer for additional
stands or supports with anti-slip
information.
surface or place anti-slip material
between the module and the stands
or supports.
Place the superstructure frame (4, Fig. 1) on

stands or hardwood blocks of sufficient carrying
capacity so that you can carry out work on the
underside. Comply with safety regulations at the
assembly site and legal regulations for working at
heights.
Place one of the crawlers (2 or 3, Fig. 1) on
sufficiently stable supports 100 mm above the
ground. It must remain in this position until
undercarriage assembly is completed.
Pre-assemble smaller and lighter parts at the
edge of the assembly site where you can easily
approach them without interfering with the main
assembly process.
Page 3.3 – 6 3746324en – (00)

3.3 ASSEMBLY MANUAL
Item Figure Description Item Figure Description
1 Carbody 12 Stick
2 Left crawler, complete 13 Boom cylinders
3 Right crawler, complete 14 Stick cylinders
4 Superstructure frame Crate with smaller parts

15 - 18 Fig. 1 (walkways, railings, plates,
5 Boom hoses, cables, etc.)
6 Fig. 1 Power-module
Suggested position of cranes
20 - 21
7 Counterweight at assembly-start
8 Oil cooler module 22 High Voltage bracket

9 Cab module
Table 2
10 Operator cab
11 Bucket
Fig. 1 f Modules arrangement on assembly site – 649439
Leave min. 1 – max. 1.5 m space

between the modules.
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3.3 ASSEMBLY MANUAL
3.3.7 Preparation of modules for Do not clean threaded bores with

assembly lubricants such as WD40 as this
may alter torque requirements.
Preparatory work Rework all threads completely not to
Before assembly of each module prepare the interrupt assembly procedure in
contact surfaces of the main frame and the case of a stiff thread.
relevant module according to the following
instructions. f
In general it is possible to combine this work and  To achieve the correct tension of the fixing bolts
prepare the contact surfaces, e.g., of the with the defined torque value, ensure that all
superstructure frame, in one work process – threaded bores are in perfect condition.
independently from the time when a module is  To avoid contamination during assembly,
assembled. ensure that the surfaces around and over the
In these cases you should apply a corrosion mating surfaces are clean.
protection to the contact surfaces immediately after  Immediately before assembly, carefully clean all
preparation and cover the threaded bores with a paint, dirt, grease, rust, and oil from the module
plastic cap. mating surfaces using a suitable solvent. On
these surfaces, the metal must be clean and
Prepare the modules and other components as bright after treatment.
follows:
Note: Oil based solvents such as Diesel will
 Check all parts and transport containers for leave an oily residue and are not suitable for
damage caused in transit. Document any surface treatment.
damage found as evidence for the transport
insurance in case of a claim. Provide this  To gain access to mating surfaces on the
documentation with photographs of the underside of a module, place the module on
damaged parts. sufficiently stable supports.
 Remove all packaging and corrosion inhibitors

immediately before assembly of the Do not work below a suspended
components in the corresponding module. If load.
you do not install the components immediately,
do not remove the packaging. Longer periods of Do not lift modules with a crane to
time without protection will damage or access the bottom side. Instead
contaminate contact surfaces. place the module on stable jack
stands or similar suitable supports
 Store any items that are required only for of sufficient carrying capacity.
transport, such as covers, blanking plates,
transport nuts etc. in a secure place, so that Use stands or supports with anti-
you can use them again if required. slip surface or place anti-slip
 Proceed with the utmost care when removing material between the module and
the protective film from the cylinder pin the stands or supports.
assemblies. Even the slightest damage to their
surface can cause destruction of pin  If assembly cannot take place immediately after
assemblies and bearing bushes in the future. cleaning the mating surfaces, protect them from
 Prepare all fixing parts, e.g. nuts, bolts, corrosion. Remove this protection directly
washers, spacer sleeves, etc. and check before assembly so that the mating surfaces
whether they are available in sufficient are clean, dry, and bright. If there is corrosion,
quantities. Where necessary, grease bolts (see removed it cautiously and completely.
Section “Bolt lubrication” of the Assembly  If you have to remove components (covers, bolt
Manual and Section 2.9 of the Service Manual). plates etc.) during assembly, insert the
 Carefully clean the threaded bores with removed bolts in their places again. Thus, you
compressed air. Check all threaded bores with do not lose the bolts and keep dirt from entering
corresponding bolts and rework threads if the threaded bores.
necessary. After rework, clean them again.
Page 3.3 – 8 3746324en – (00)

3.3 ASSEMBLY MANUAL
 Before assembly, clean any oil from the 3.3.8 General assembly procedures
bearings and pins and spray with an assembly
spray. Bolt tightening
 Grease all bearing bushes and pin assemblies Always fix the bolts, washers, etc. using the
before seating. Secure all pin assemblies as tightening method described in this book or in the
soon as they have been seated. Service Manual.
You can find the specified tightening method as
Important notes well as the necessary torque value for all bolts in
chapter 2.9 and chapter 17 of the Service Manual.
Copy the relevant pages and keep them
If you face problems during accessible at the assembly site.
assembly or disassembly, always
contact your local dealer. Devise a system of marking the bolts to distinguish
between pre-tightened and fully tightened ones.
Do not try to solve problems
intuitively or based on experience
from other assembly sites.
Bolt lubrication
1) Refer to chapter 2.9 of the Service Manual to
Always ensure that the modules are suspended see which bolts need to be coated with oil.
horizontally when they are assembled. The
modules must rest evenly and vertically on their 2) If required, apply a few drops of oil to the
consoles. thread (1, Fig. 2), between bolt head and
During assembly of the machine, always follow the washer (2), and below the washer (3). Do not
sequence of work steps described in this assembly dip the whole bolt in oil.
manual. The sequence of work steps has been
developed and tested by experienced specialists. If
you do not keep the sequence, you may have to
disassemble parts which you have already
assembled. This causes time losses and increases
the risk of damage to the parts.
This machine contains parts, e.g. hydraulic hoses
or handrail parts, which can easily be confused
with each other. To enable you to identify them
precisely, the number of the relevant subassembly Fig. 2 Bolt lubrication – 647239
is indicated in this manual where necessary.
Please refer to the respective number in the Spare Screwing in connecting bolts
Parts Manual to find an exact image of the When installing large modules, screw in the
respective part and its part number if applicable. connecting bolts while a module is still suspended.
All components in Caterpillar equipment are
carefully selected to operate perfectly together.
Fault-free operation and a long service life can only Do not raise the module after you
be guaranteed if genuine Caterpillar parts are started screwing in connecting
used. The warranty does not cover any damages bolts.
resulting from the use of parts which are not
genuine Caterpillar parts. 1) Lower the suspended module to 10 - 20 mm
(0.04 to 0.08 in) above its assembly position.
2) Screw all connecting bolts into the respective
bores manually as far as possible.
3) Make the last check to ensure that the
assembly position is correct.
4) Lower the suspended module another 5 – 10
mm (0.02 to 0.04 in) and again tighten the bolts
as far as possible.
3746324en – (00) Page 3.3 – 9

3.3 ASSEMBLY MANUAL
5) Repeat step 4) until the suspended module is 4) Screw all removed bolts back in to prevent
fully lowered into its assembly position and all losing them and to prevent the pin cover from
connecting bolts are hand-tight. swinging back into its normal position.
6) Tighten all bolts in accordance with chapters 5) Define from which side a pin is to be pushed
2.9 and 17 of the Service Manual. Use a (depending on equipment access, space etc.).
hydraulic torque wrench to set the exact torque
6) Attach an eyebolt (EB, Fig. 3) to the opposite
required.
end of the pin.
Ensure that the torque vs. pressure
charts are available and personnel
know how to use them to set the Do not use a chain to pull the pin.
correct torques. The dead weight of the chain can
pull out the pin unexpectedly.
Note: Mark bolts to distinguish pre-tightened from
fully tightened ones.
7) Pull out about one third of the pin (PIN, Fig. 3).
Item Figure Description
After pulling out about one third of
BB a pin, fasten a strap around the pin
Bushing
BU and secure it to the crane.
This minimizes the risk that the pin
EB Fig. 3 Eyebolt slips out of the bushing and causes
personal injury or serious damage.
PIN Pin
STR Strap
Note: Pulling can be supported by raising the pin
Table 3
(PIN, Fig. 3) slightly with the strap (STR) and the
crane.
8) Remove corrosion inhibitors from the
accessible parts of the bushing (BU, Fig. 3)
and the pin.
9) Pull the pin (PIN, Fig. 3) out until it rests only in
one bushing (BB).
Clean pins and bushings carefully.

Do not damage their surfaces.
10) Apply grease to the bushing (BU, Fig. 3). Use

only delivered genuine grease in accordance
with Caterpillar Machine Fluids
Fig. 3 Pin procedure - 649229 Recommendations SEBU 6250 in SIS.
11) Push the pin back until it rests only in the
Preparation of pins and bushings bushing (BU, Fig. 3) that you have just cleaned
Treat all pin assemblies as follows directly before and lubricated. Secure the pin to the crane.
installation: 12) Clean the second bushing (BB, Fig. 3) and the
part of the pin that was not accessible before.
1) Remove the bolts from the pin cover except for
the uppermost bolt. 13) Apply grease to the second bushing (BB, Fig.
3). Use only delivered genuine grease in
2) Loosen the uppermost bolt and tilt the pin accordance with Caterpillar Machine Fluids
cover upwards so that the bearing bushes and Recommendations SEBU 6250 in SIS.
pin are accessible.
3) Tighten the uppermost bolt to secure the pin
cover in this position.
Page 3.3 – 10 3746324en – (00)

3.3 ASSEMBLY MANUAL
The pin and bushings are now ready for This Assembly Manual refers to the use of
component installation. LOCTITE® 518TM as sealant wherever it is
Cover the bushing if you do not install the required.
component immediately.
Always cover bearing bushings
Proceed with the utmost care when
after preparation. Otherwise dirt
removing the protective film from
may penetrate the bearings during
pins and bushings. Even the
the assembly period.
slightest damage to their surfaces
can lead to their future destruction. Before applying LOCTITE® 518TM, clean the
contact surfaces of paint, oil, and grease, and of
any type of contamination.
Fitting pin covers
Cleaning hydraulic hoses
Wherever necessary, fit pin covers with a thin layer
of silicone or gasket maker as seen in Fig. 4. This Our hydraulic hoses are cleaned and closed with
prevents lubricant from being squeezed out of the blanking caps before delivery.
sides of the covers when they are closed. Hoses that are delivered with intact blanking caps
do not require cleaning.
As soon as a pin has been fitted tighten all bolts of
the respective pin covers. To prevent contamination of
hydraulic hoses, remove the
blanking caps from the hydraulic
hoses directly before fitting them.
Do not clean hoses that are
delivered with intact blanking caps.
Store the blanking caps for future maintenance

and repair work.
If a blanking cap is damaged or missing, you have
to clean the respective hose before you install it.
For this purpose, use the Hose Cleaning Group
(Caterpillar part-ID-No. 233-7192).
Fig. 4 Pin cover with silicone – 647223
Use of sealant
Always use the sealant currently

approved by Caterpillar Global
Mining HMS GmbH. For changes
and updates visit our webpage and
read General Service Information
with media-no. EM028719.
LOCTITE® 518TM is a one-part heat curable epoxy.

It is designed as non-reworkable CSP/BGA
underfill for protection of solder joint against
mechanical stress when used for hand held
electronics devices.
LOCTITE® 518TM has can be obtained from the

Caterpillar Global Mining HMS Parts Service.
3746324en – (00) Page 3.3 – 11

3.3 ASSEMBLY MANUAL
3.3.9 Workflow chart of assembly

procedure
Fig. 5 Workflow chart of assembly procedure - 649375
Page 3.3 – 12 3746324en – (00)

3.3 ASSEMBLY MANUAL
3.3.10 Preparation of undercarriage 2) Mount the lights (1, Fig. 6) onto the front of
and superstructure modules the cab module.
3) Mount the handrails (84, Fig. 7) to the
Prepare the carbody, crawler track frames, chain walkways (80).
links and segments as described in chapter 1.1.1
of this Assembly Manual. Ensure that all contact 4) Lift the stairways onto the cab module and
surfaces are free from any rests of preservative screw it tight.
spray. 5) Mount the signal horn (2, Fig. 7) to the
catwalk.
At the same time, you can install handrails and
walkways on the following modules: cab module, 6) Mount a signal horn (2). Ensure that the horn
operator cab, power (engine) module, hydraulic oil is positioned correctly; refer to the Service
cooler module and counterweight. Use Spare Letter for details.
parts manual.
Cab module
1) Assemble the walkways (80, Fig. 6) and
handrail (84) on the cab module. Tighten the
bolts according to the specified tightening
procedure.
1 Fig. 6 Lights
2 Fig. 7 Horn
80 Strap
Fig. 6
84 Handrail
Table 4
Fig. 7 Horn – 649372
Fig. 6 Walkways, handrails, lights on cab module – 649371
3746324en – (00) Page 3.3 – 13

3.3 ASSEMBLY MANUAL
Fig. 8 Installation of handrails & stairways on cab module – 649370
Page 3.3 – 14 3746324en – (00)

3.3 ASSEMBLY MANUAL
Counterweight
1) Mount three handrails (17, 41 & 42, Fig. 9 &
Fig. 10) on the counterweight top section
(CW) with the clips (22 & 43, Fig. 9) which
contains hose clamps, bolts, washers and
nuts. Join the handrails (36 & 37) with the
sockets (21 & 44).
2) Mount and connect all main lights (2, Fig. 10).
2 Fig. 10 Main light
17 Handrail
21 Socket
22 Clip
41
Fig. 9 Handrail
42
43 Clip
44 Socket
CW Counterweight
Table 5
Fig. 9 Counterweight – 649363
Fig. 10 Counterweight – 649364
3) Screw in all bolts according to section

“Screwing in connecting bolts” and chapter 2.9
of the Service Manual.
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3.3 ASSEMBLY MANUAL
Hydraulic oil cooler module Power (engine) module components

1) Install handrails before lifting the hydraulic oil 1) Assemble handrails (69 & 70, Fig. 12) with the
cooler module (OCM) into its position on the clips (73, Fig. 12), which contains hose
superstructure frame. clamps, bolts, washers and nuts, on the power
(engine) module (PM, Fig. 12):
2) Mount handrails (57 to 61, Fig. 11) on the
hydraulic oil cooler module (OCM) with the Item Figure Description
clips (56, Fig. 11), which contains hose
clamps, bolts, washers and nuts. Join the 6 Mounting plate
handrails (59 to 61, Fig. 11) with the sockets 31 Breather
(66).
31a Fig. 13 Socket
3) Screw in all bolts according to section
“Screwing in connecting bolts” and chapter 2.9 33 Plastic ring
of the Service Manual. 34 Retainer
Item Figure Description 60 Hydraulic tank
OCM Hydraulic oil cooler module 69
Handrail
56 Clip 70
Fig. 12
57
73 Clip
58
Fig. 11 PM Power (engine) module
59 Handrail
TC Transport cover
60
Table 7
61
66 Socket
Table 6
Fig. 12 Handrails assembly on power (engine) module) –

649366
2) Remove the transport covers (TC, Fig. 12)

Fig. 11 Handrails installation on hydraulic oil cooler module – from the hydraulic oil tank (60).
649365
3) Assemble the mounting plate (6, Fig. 13) for
the breather filters of the hydraulic oil tank
(60). Make sure no dirt enters the openings.
Page 3.3 – 16 3746324en – (00)

3.3 ASSEMBLY MANUAL
Fig. 15 New Breather System B - 649442
If you have version B, please proceed similarly

described in step 4) and 5) in consideration of the
parts list of GSI (ref. EM029925).
3.3.11 Undercarriage assembly
Assembly of track segments

Each of the two tracks is supplied in three
segments.
6) Connect the track segments to build one track.
7) Lay two tracks on the ground side by side with
sufficient space between them to assemble
Fig. 13 Breather filters – 648899 the machine in.
The HMS is equipped with either breather system Note: The track plates must lie with the flat edge
A (ref. to Fig. 13 and Fig. 14) or breather system (1,Fig. 16) against the travel forward direction (2)
B (Fig. 15, ref. EM029925). of the machine.
If you have version A, please proceed as
described in step 4) and 5):
4) Assemble the breathers (31, Fig. 13) to the
socket (31a).
5) Insert the plastic rings (33) to the filters and
attach the retainers (34).
Fig. 16 Aligning the track plates correctly – 644575a
Fig. 14 Previous Breather System A – 649441
3746324en – (00) Page 3.3 – 17

3.3 ASSEMBLY MANUAL
Assembly of LH crawler track frame to

carbody
Positioning the crawler frame
1) Attach the rigging hardware of both cranes to
four transport lugs (TL, Fig. 17) of one crawler
frame.
2) Lift the crawler frame above the track.
3) Lower the crawler frame onto the track.
Note: Position the crawler frame so that the track
adjuster is three plates (1.5 m) away from the end
of the track. This way, the end of the track can
later be lifted slightly for assembly. Do not connect
the track yet.
4) Remove the four transport lugs (TL, Fig. 17) Fig. 18 Cover bolts – 648905
by loosen the bolts (BT, Fig. 17). 7) Remove eight mounting bolts (18, Fig. 19) on
the track guide (24).
18 Fig. 19
Bolt
19
Fig. 18
21 Cover
24 Fig. 19 Track guide
BT Bolt
Fig. 17
TL Transport lug
Table 8
Fig. 19 Track guide bolts – 648906
8) Attach the rigging hardware of the crane to the

track guide (24, Fig. 20).
Secure the track guide against

falling down.
9) Lift the track guide (24, Fig. 20) from the

crawler frame.
Fig. 17 Transport lugs – 648904
5) Loosen four retaining bolts (19,Fig. 18) and

remove the cover(21).
6) Remove the piston accumulator inside the
track guide in a reverse procedure as
described in the Service Instruction M007968 -
Installation Procedure.
Page 3.3 – 18 3746324en – (00)

3.3 ASSEMBLY MANUAL
Fig. 20 Removal of track guide - 648907
3746324en – (00) Page 3.3 – 19

3.3 ASSEMBLY MANUAL
Preparation of mating surfaces

1) Clean the vertical and horizontal mating
surfaces (VMS & HMS, Fig. 21) of the crawler
frame and the carbody as described in section
"Preparatory work".

HMS Horizontal mating surface
Fig. 21
VMS Vertical mating surface
Table 9
Fig. 22 Sealant application on vertical surface – 648920
Fig. 23 Sealant application on horizontal surface – 648921
Fig. 21 Mating surfaces – 648908
2) Rework the threaded bores and clean them

using compressed air.
Always wear safety goggles when

3) Prepare the necessary bolts and sleeves.

4) Apply a thin layer of the sealant to the vertical
mating surface of the carbody (Fig. 22) and to
the horizontal mating surfaces of the crawler
frame (Fig. 23). Follow the instruction on
sealant of this Assembly Manual.
Page 3.3 – 20 3746324en – (00)

3.3 ASSEMBLY MANUAL
Installation of LH crawler to carbody

1) Remove the wooden protective cover from the
swing bearing (Fig. 24).
Fig. 26 Carbody positioning – 648911
Fig. 24 wooden protective - 648915

Follow the safety instructions if you
2) Attach lifting tackles to four inside lifting lugs have to adjust it manually.
(LL, Fig. 25) in the middle of the carbody.
4) When the carbody is in the correct position
Use the four lugs (LL) to lift only the
above the crawler frame, screw in the bolts
carbody. Do not use them to lift the
manually.
complete undercarriage.
5) Fasten the horizontal and vertical bolts hand
tight. Follow the safety instructions.
6) Tighten the bolts in the following sequence:
a) Start with the vertical bolts and tighten them
using a ratchet.
b) Tighten the horizontal bolts using a ratchet.
c) Loosen all horizontal bolts so that they
remain hand tight.
d) Tighten the horizontal bolts to the specified
torque (see chapter 2.9 of the Service
Manual).
e) Loosen the vertical bolts so that they remain
hand tight.
f) Tighten the vertical bolts to the specified
torque (see chapter 2.9 of the Service
Manual).
g) Tighten the horizontal and vertical bolts to
Fig. 25 Lifting lug inside the carbody – 648910
the specified angle of rotation (see chapter
3) Raise the carbody into the assembly position 2.9 of the Service Manual).
(Fig. 26). Note: Use a hydraulic torque wrench to apply the
specified torque. This will allow tightening to the
exact torque value and save time and effort. Mark
the bolts to distinguish between pre-tightened and
fully tightened ones.
3746324en – (00) Page 3.3 – 21

3.3 ASSEMBLY MANUAL
Supporting the carbody
Follow the safety instructions.
1) Raise the carbody so that it is at a slight angle

(Fig. 27).
2) Support the carbody with a stand (ST, Fig.
27). This side should be around 10 cm higher
than the other side. Check distance to the
track on the ground (DG, Fig. 27) to make
sure the crawler will fit in.
18 Fig. 29
Bolt
19
Fig. 30 Fig. 28 Reinstall of track guide – 648912
21 Cover
5) When the track guide is in the correct position
24 Fig. 28 Track guide on the crawler frame, screw in the bolts
DG Fig. 27 Distance to the ground manually.
ST Fig. 27 Stand 6) Install the track guide (24, Fig. 29) and
mounting bolts (18).
TR Fig. 31 Track
TSM Fig. 32 Transport sheet metal
Table 10
Fig. 29 Track guide bolts – 648913
7) Install the piston accumulator inside the track

guide as described in the Service Instruction
M007968 - Installation Procedure.
8) Install the cover (21, Fig. 30) and retaining
Fig. 27 Supporting the carbody – 648922 bolts (19).
3) Release the crane.
4) Lift the track guide (24, Fig. 28) on the crawler
frame.
Page 3.3 – 22 3746324en – (00)

3.3 ASSEMBLY MANUAL
Fig. 30 Cover bolts – 648914
Closing the track

The track tensioning cylinder is completely
retracted ex works and the idler is secured with
steel cables in the end position.
This steel cable needs to be removed after track
chain installation.
If the cylinder is not completely extracted (e. g. Fig. 31 Closing the track – 648916
during repairs on the track system), pressure
needs to be released and thus the cylinder can be
retracted (by external force).
Note: Remove the transport sheet metals (TSM,

Fig. 32) from the beam before installing the track.
After all bolts have been tightened, close the track
(TR, Fig. 31 & Fig. 32). Full assembly of the LH
crawler is now complete.
Fig. 32 Closing the track – 648919
3746324en – (00) Page 3.3 – 23

3.3 ASSEMBLY MANUAL
Note: If the machine has been assembled before of the track. Thus, the end of the track can be
and is now being re-assembled, check whether lifted slightly for assembly.
the shut-off valve (1, Fig. 33) of the track tension
system is closed (lever perpendicular to the hose). 4) Remove the transport lugs (TL) and bolts (BT,
Fig. 34).
Fig. 33 Shut-off valve, closed – 643466
The LH crawler is now fully assembled.

Fig. 35 Cover – 648917
Assembly of RH crawler to the carbody
Note: Leave the cover mounted on the crawler. It
Positioning RH crawler serves as support when the track is closed (21,
Fig. 35).
1) Attach the rigging hardware of both cranes to Closing the track

the four transport lugs (TL, Fig. 34) of the RH
crawler. The track tensioning cylinder is completely
retracted ex works and the idler is secured with
Item Figure Description steel cables in the end position.
This steel cable needs to be removed after track
21 Fig. 35 Cover
chain installation.
BT Bolt If the cylinder is not completely extracted (e. g.
Fig. 34 during repairs on the track system), pressure
TL Transport lug
needs to be released and thus the cylinder can be
Table 11 retracted (by external force).
Note: Remove the transport sheet metals (TSM,

Fig. 37) from the beam before installing the track.
After all bolts have been tightened, close the track
(TR, Fig. 36 & Fig. 37). Full assembly of the RH
crawler is now complete.

21 Fig. 38 Cover
SP Fig. 39 Support
TR Fig. 36 Track
Fig. 34 Transport lugs – 648909 TSM Fig. 37 Transport sheet metal
2) Lift the crawler frame above the track. Table 12
3) Lower the crawler frame onto the track.

Note: Position the crawler frame so that the track
adjuster is three plates (1.5 m) away from the end
Page 3.3 – 24 3746324en – (00)

3.3 ASSEMBLY MANUAL
Fig. 38 Cover – 648917
Fig. 39 Supporting the track – 648924
The RH crawler can be connected to the carbody.
1) Now carefully lift the closed track (Fig. 39) to

enable disassembly of the cover.
2) Support the raised track (TR, Fig. 39) using
supports (SP).
3) Now disassemble the cover (21, Fig. 38).
4) Remove the track guide (24, Fig. 39) from the
crawler frame.
3746324en – (00) Page 3.3 – 25

3.3 ASSEMBLY MANUAL
Connecting the crawler to the carbody

1) Lift the second crawler using both cranes (Fig.
40). This is the only way to align the crawler
precisely.
Use steel ropes to rig the tracks.
Do not use hooks.
Please use suitable device to
prevent steel ropes are slipping
between the chain links.

HMS Horizontal mating surface
Fig. 41
VMS Vertical mating surface
Table 13
Fig. 42 Sealant application on vertical surface – 64892
Fig. 40 Lifting the crawler – 648930
2) Prepare the mating surfaces on the crawler

and carbody as described in section
“Preparation of mating surfaces“ (Fig. 41, Fig. Fig. 43 Sealant application on horizontal surface – 648929
42 & Fig. 43).
3) Position the crawler as precisely as possible
below the supported side of the carbody. Bolt
the RH crawler to the carbody, as described in
section "
Fig. 41 Mating surfaces – 648927
Page 3.3 – 26 3746324en – (00)

3.3 ASSEMBLY MANUAL
Installation of LH crawler".
4) Now lift the complete unit.
5) Remove the supports.
6) Lower the unit onto the ground.
7) Ensure that the undercarriage is horizontal by
placing a level gauge on top of the swing
bearing. Adjust if necessary, by placing stands
between tracks and rollers.
Correct horizontal position of the
undercarriage is important for the
correct assembly of the other
modules.
Note: If the machine has been assembled before

and is now being re-assembled, check whether
the shut-off valve (1, Fig. 44) of the track tension
system is closed (lever perpendicular to the hose).
Fig. 45 Reinstall of the track guide - 648925
2) Now assemble the cover (21, Fig. 46).
Fig. 44 Shut-off valve, closed – 643466

Fig. 46 Reinstall of the cover - 648931
Reassembly of RH cover
3) Tighten the bolts using the tightening
procedure in chapter 17 of this Service
Before lifting the slider into the Manual.
assembly position ensure that the
mating surfaces are clean. 4) Lower the track slowly back down using the
steel ropes.
1) Reinstall the track guide (24, Fig. 45) on the 5) Remove the steel ropes from the track.
crawler frame.
21 Fig. 46 Cover
Table 14
3746324en – (00) Page 3.3 – 27

3.3 ASSEMBLY MANUAL
3.3.12 Installation of High Voltage

(HV) bracket
Attention:
It is essential that all applicable
safety measures and procedures are
carried out.
For more information refer to the
maintenance manual, service manual
as well as those measures outlined
by the executing parties mine
regulations and associated agencies.
Personal protective equipment must
be used as required.
Observe all local safety regulations.
Fig. 47 HV cable bracket – layout - 649379
Trained, qualified High Voltage
Electricians only are allowed to carry
out this job; machine must be
completely disconnected from Power
Supply Grid.
Attach the HV cable bracket HVCB (Fig. 47) to the

crane, lift it slightly and carefully. For weight
details refer to chapter 2.8.2. Place it to the rear of
the carbody. Tighten all fourteen bolts A1 with
bushings A2 (Fig. 47) hand tight. Use torque
wrench and the information on torque value in
chapter 2.9.1 to tighten the bolt to their required
torque. Install deflector HVG with three bolts A6
and washers A7 (Fig. 47). Fig. 48 HV cable bracket assembled to carbody - 649380
Mantle HV Junction Box HVJB with four bolts A3,
washers A4 and nuts A5 (Fig. 47) onto the
bracket. Refer also to the photo in Fig. 48
Connect the HV junction box HVJB with its base
plate and the HV cable bracket HVCB with the
carbody CB by installation of two ground strips GS
as shown in Fig. 49.

CB Carbody
Fig. 49
GS Ground strip
Fig. 47
HVC2 High voltage cable 2
Fig. 49 Fig. 49 Location of both ground straps GS – 649381
HVC3 Fig. 47 High voltage cable 3 (customer)
Fig. 48 Note: The high voltage cable 3 (HVC3, voltage
HVCB Fig. 49 High voltage cable bracket
supply, Fig. 48) has to be installed by the
HVG Fig. 47 High voltage cable guard customer after the machine is completely
Fig. 47 assembled. Please make sure the cable suits to
HVJB Fig. 48 High voltage junction box the installed brackets.
Fig. 49
SRD Fig. 49 Slipring device
Table 15
Page 3.3 – 28 3746324en – (00)

3.3 ASSEMBLY MANUAL
3.3.13 Preparations for Positioning the "soft spots"

superstructure installation
1) Check the location of the "soft spots" on the
Note: The slewing ring is already correctly outer race (OR, Fig. 51) and the inner race
assembled exfactory, please refer to chapter 5.2. (IR, Fig. 51) of the swing bearing.
The assembly steps on the undercarriage and

superstructure frame described below can be
carried out simultaneously. Clean all mating
surfaces from rests of preservative spray. Prepare
boom and power (engine) module the same way.
Preparation of the swing bearing

1) Remove all transport and corrosion protection
from the swing bearing and the bolts contact
surfaces.
2) Remove the protective caps (PRC, Fig. 50)
from the bolts and loosen the nuts. Be careful Fig. 51 Inner and outer race of the swing bearing – 648933
when the bolts fall.
Depending on the manufacturer a "soft spot" is
3) Store the protective caps and nuts in a marked with an “S” or an „F“(Fig. 52).
suitable place.

2 Lubricant cover
Fig. 58
3 Swing bearing
8 Fig. 59 Dowel pin
C Fig. 53 Plastic caps
LP Fig. 60 Lubricating pinion
IR Fig. 51 Inner race
OP Fig. 58 Opening
OR Fig. 51 Outer race
PRC Fig. 50 Protective cap
Table 16
Fig. 52 Soft spot – 648934
Chapter 5.2 of the SM contains detailed

information on soft spots as well as a drawing
showing their correct position.
Fig. 50 Protective caps on the swing bearing – 648932
3746324en – (00) Page 3.3 – 29

3.3 ASSEMBLY MANUAL
2) If necessary, turn the swing bearing until the

Cover
soft spots are at the specified angle of 90° to
one another. 1) Pre-assemble the cover (Fig. 54 - Fig. 55) on
the ground.
Cleaning and lubrication of the swing bearing
This work should be performed directly before
assembly of the superstructure frame to prevent
contamination of the mating surfaces.
1) Carefully clean and dry the machined surface
of the outer race (OR, Fig. 51) and inner race
(IR, Fig. 51) of the swing bearing as described
in section "Preparatory work".
2) Use compressed air to clean the bolt heads
and threaded bores.

3) Remove the plastic caps (C, Fig. 53) from the

bores for the lubricant injectors.
Fig. 54 Cover delivery state – 648284
Fig. 53 Lubricant injectors, teeth, seal ring – 648935
4) Inspect the machined surface for damage.

5) Lubricate the entire inner race (IR, Fig. 53) of
the swing bearing. Fig. 55 Cover assembly – 648285
2) Fill the space between the swing bearing teeth

with as much grease as possible (Fig. 56).
Use only CAT genuine product in accordance
with Caterpillar Machine Fluids
Recommendations SEBU 6250 in SIS.
Page 3.3 – 30 3746324en – (00)

3.3 ASSEMBLY MANUAL
Fig. 58 Lubricant cover - 648937
6) To center the superstructure frame correctly,

position a dowel pin (8, Fig. 59) on the outer
Fig. 56 Swing bearing teeth lubrication - 648936
race of the swing bearing when the
superstructure frame positioned above the
3) Check grease (lubricant) filling from the swing bearing.
bottom of the swing bearing. Ensure that the
lubricant runs in at least 20 mm over the
whole circumference of the swing bearing
(Fig. 57). You can find more information in
section “Inspection and servicing” of Operation
and Maintenance Manual.
Fig. 59 Dowel pin - 648938
Fig. 57 Swing bearing lubrication check – 102152
4) Lift the cover (3, Fig. 58) into assembly

position by crane and set it onto the swing
bearing (2, Fig. 58). Ensure that the openings
(OP, Fig. 58) for the swing gearbox pinions
are in the correct position at the rear of the
machine.
5) Fill the gap between the lubricant cover (3,
Fig. 58) and the swing bearing (2, Fig. 58) and
the openings (OP, Fig. 58) for the swing
gearboxes with lubricant.
3746324en – (00) Page 3.3 – 31

3.3 ASSEMBLY MANUAL
Preparation of superstructure frame

1) Raise the superstructure frame on safety
compliant blocks or stands approx. 1.2 m (4.9
ft) above ground.
Use stable jack stands or similar

suitable supports of sufficient
carrying capacity.
Use stands or supports with anti-
slip surface or place anti-slip
material between the module and
the stands or supports.
2) Clean on the bottom of the superstructure

frame:
 the threaded bores
 the contact surfaces of the swing bearing
side
 the swing bearing housing
as described in section "Preparatory work".
3) Fit the lubricating pinions (LP, Fig. 60).
Fig. 60 Lubricating pinion - 648939
Page 3.3 – 32 3746324en – (00)

3.3 ASSEMBLY MANUAL
3.3.14 Installation of superstructure 4) Lift the superstructure frame using the cranes
frame (Fig. 62).
Note: To optimize machine assembly process we

recommend you to simultaneously prepare cab
and cooler modules, boom as well as top and
bottom parts of counterweight (ballast) for further
installation steps as described in chapter 3.3.7 of
this Assembly Manual.
Note: If necessary, perform the prepositioning of

the rotary lock before installing the superstructure
frame. Lift the rotary lock (4, Fig. 75) from above
into the undercarriage (refer to 3.3.16, page 38).
1) Position the crane along the same axis as the

undercarriage to facilitate positioning of the Fig. 62 Lowering the superstructure frame - 648940
superstructure frame.
To ensure the precise alignment and positioning
2) Prepare the retaining bolts for the swing of the superstructure frame on the carbody, a
bearing using chapter 2.9 of the Service dowel (D, Fig. 63) is provided on the swing
Manual. bearing. This dowel must line up with the
corresponding bore (B, Fig. 63) on the
Do not apply oil to the top surface of superstructure frame.
the outer race of the swing bearing.
3) Apply sealant to the outer race top surface

(Fig. 61) and spread in a thin, even layer using
a putty knife. Follow the instructions on
sealant of this Assembly Manual.

B Bore
Fig. 63
D Dowel
LP Lubricating pinion
Fig. 62
SB Swing bearing
Table 17
Fig. 63 Dowel and bore – 648941
5) Position the superstructure frame over the

undercarriage.
Note: During the next assembly steps, check
continuously that the superstructure is horizontal
and adjust if necessary.
6) Slowly lower the superstructure frame. Stop
when the lubrication pinion is approx. 100 mm
(4 in) above the swing bearing (Fig. 62).
Fig. 61 Applying sealant – 643393
3746324en – (00) Page 3.3 – 33

3.3 ASSEMBLY MANUAL
Ensure that the teeth of the

lubrication pinion fit between those
of the swing bearing.
7) Continue to lower the superstructure frame

until the dowel pin (B, Fig. 63) is seated in the
respective bore on the superstructure frame.
Continuously check the position of

the bore for the dowel pin. If the
dowel pin accidently enters a
threaded bore, this might damage
the thread.
Fig. 65 Lubricant cover – 648937
8) Lower the superstructure frame as far as 10 to
12) Bolt the swing bearing lubricant cover (3, Fig.
20 mm (0.4 to 0.8 in) above the swing bearing.
65) to the superstructure frame when the
9) Screw in all bolts of the swing bearing: lift frame is suspended 10 mm above the swing
bolts with a suitable tool (Fig. 64) and tighten bearing. It would be difficult to do this later.
manually as far as possible (see “Screwing in
13) Lower the superstructure bit by bit and
connecting bolts” on p. 9).
continue to tighten the bolts of the swing
bearing manually until the superstructure
To prevent injury in case of a sudden
frame is fully lowered onto the swing bearing.
load drop, always use a tool to lift
Ensure that all bolts are screwed in before the
the bolts.
superstructure frame is fully lowered.
Do not insert your hands or fingers
into the gap under the bolts. In some cases, access to the bolts at the left
and right-hand side of the swing bearing is
easier after turning the superstructure frame
90°.
Ensure that all bolts at the front and

rear of the swing bearing are
tightened to assembly torque before
turning the superstructure frame.
Assembly torque and tightening procedure are

specified in chapters 5.2.1 and 5.2.5 of our
Service Manual.
Note: There are different torques listed: Assembly
torque for initial tightening, pre-torque and turning
Fig. 64 Swing bearing bolts – 647221 angle for installation, and inspection torque for the
100 hour service. To ensure a long service life of
10) Make the last check to ensure that the dowel the machine, follow these specifications.
pin (D, Fig. 63) and the associated bore (B)
are positioned precisely opposite each other.
11) Fully tighten the assembly bolts of the swing
bearing lubricant cover (3, Fig. 65).
Page 3.3 – 34 3746324en – (00)

3.3 ASSEMBLY MANUAL
Installation of swing bearing lubrication

lines
Note: It is important to install the swing bearing

lubrication lines before installing any other
modules.
The lubrication lines are pre-installed with the
injectors. Lubricant injectors supply lubricant to
the swing bearing. Bores for the lubricant injectors
are positioned at irregular intervals on the
superstructure frame above the swing bearing.
1) Insert the injectors in the holes of the swing
bearing lubrication system (see chapter 11.3
in the SM and LI, Fig. 66). Fig. 67 Lubricating lines on the superstructure frame - 648946
Item Figure Description 3) Ensure that the lubrication lines are laid in
such a way that they cannot be damaged
CP Fig. 67 Cover plate when the other modules are assembled.
L Fig. 68 Line
LI Fig. 66 Lubricant injector
LL Fig. 67 Lubricating line
RB Fig. 70 Retaining bolt
Table 18
Fig. 66 Lubricant injector – 648945
2) Attach the lubrication lines (LL, Fig. 67) and

cover plates (CP) to the front of the
3746324en – (00) Page 3.3 – 35

3.3 ASSEMBLY MANUAL
Swing park brake release without manual

Preparation of swing gearboxes pump
To install the swing gearbox correctly, turn the If a manual pump with pressure indicator is not
pinion in the correct position while lowering. For available, remove the swing motors and turn the
this purpose, release the swing park brake. There pinions by hand:
are two ways of doing it: with the manual pump
and without it. We recommend you always use the 1) Disassemble the swing motor above the
manual pump for swing park brake release. swing gearbox (Fig. 69). To do this, loosen
the four retaining bolts (RB, Fig. 70).
Swing park brake release with manual pump
1) Connect a manual hydraulic pump with a
pressure display to the line for the swing
brake (L, Fig. 68). To locate the swing brake
(Fig. 2) use the Spare Parts Manual.
Fig. 69 Swing gearbox & swing motor – 648289a
Fig. 68 Connecting the hand pump - 648947
2) Apply pressure to the line. The minimum

pressure is 35 bar or 40 bar. The brake is now
released. Fig. 70 Disassembling the swing motor - 648948
2) Mark the position of the swing motor and lift it

Never exceed a maximum pressure of out.
40 bar to release the swing brake.
3) Pull out the intermediate gear (IG, Fig. 70). It
Higher pressure will damage the brake.
is now possible to turn the pinion of the swing
gearbox.
Page 3.3 – 36 3746324en – (00)

3.3 ASSEMBLY MANUAL
3.3.15 Installation of swing gearboxes 7) Position the swing gearbox correctly (1, Fig.
72).
Note: Simultaneously to the installation of the
swing gearboxes (1, 2 & 3, Fig. 71 & Fig. 72) you
can prepare the cab module, hydraulic oil cooler
module, top and bottom parts of the counterweight
and the boom for further installation on the
Install the swing gearboxes (1, 2 & 3, Fig. 71 &
Fig. 72) in turns. Each of the three swing
gearboxes (1, 2 & 3) is marked to ensure its
installation in the correct position.
First install the front gearboxes (1) and then the
rear ones (2 & 3) to avoid any unnecessary
difficulties with the limited assembly space.
1) Remove the packaging from the swing
Fig. 72 Aligning the swing gearbox – 649008
gearbox.
8) Fasten all bolts hand tight and check, if the
2) Clean the assembly surfaces and pinions.
gearbox is in the correct position.
3) Attach the first swing gearbox (1) to the crane
9) Lower the gearbox (1) until it rests on the
and lift it slightly and carefully. Ensure that it
assembly surface. Make sure that the O-ring
hangs levelled.
(16) stays in place.
4) Place the enclosed O-ring (16, Fig. 71) onto
10) Tighten all bolts hand tight. Torque the first
the respective gearbox (1).
bolts crosswise in the following sequence: 1 &
Item Figure Description 13, 7 & 19, 4 & 16, 22 & 10 (Fig. 73), then the
rest bolts. Use torque wrench and the
1 Fig. 71 RH swing gearbox, front information on torque value in chapter 7.3.
2 & RH swing gearbox, rear Mark all bolts which have already been
Fig. 72 tightened.
3 LH swing gearbox, rear
Table 19
Fig. 73 Torque pattern of swing gearbox – 649009
11) Remove the manual hydraulic pump from the

swing gearbox and assemble the swing motor.
Fig. 71 Installation of swing gearboxes – 649007
12) If the swing motor has been disassembled,
5) Secure the O-ring (16, Fig. 71) on the reassemble it. Ensure that it is positioned as
assembly surface using a little lubricant. before.
6) Lower the swing gearbox to approx. 5 mm (0.2 13) Repeat step 1) to 12) with the gearboxes 2 &
in) above the assembly surface (Fig. 71). 3.10).
3746324en – (00) Page 3.3 – 37

3.3 ASSEMBLY MANUAL
3.3.16 Connection of hydraulic lines

between undercarriage and
superstructure
Note: Depending on the delivery state of the
individual machine some components can already
be installed. In this case skip the unnecessary
installation steps und proceed with the required
ones.
To prevent contamination and

damage of the machine hydraulic
system, blow all unsealed hydraulic Fig. 74 Belly plate installation – 649397
hoses with compressed air directly
before assembly. Remove transport 2) Install a rotary lock (4, Fig. 75) to the rotor
sealings from hoses and hydraulic (91).
components directly before
assembly.

Installation of travel system hydraulic

lines to the rotor
1) If there is an optional cover (belly plate) (BP,

Fig. 74) connected to the carbody, loosen the
bolts (B) of the lid (L) and slide it aside.

4 Rotary lock
Fig. 75
91 Rotor Fig. 75 Rotary lock installation – 649011
121 Fig. 79 Travel motor 3) Ensure the correct position of the rotor on the
Secondary pressure relief bottom of the travel control block. If the rotor
125 Fig. 78 is turned to 180°, the forward and backward
manifold
travel motion will be interchanged. Port 9 of
B Bolt
Fig. 74 the rotor (Fig. 76) must be on the right-hand
BP Belly plate side.
HCB Hydraulic hoses carbody
Fig. 80 Hydraulic hoses crawler
HCF
frames
L Fig. 74 Lid
LL Fig. 82 Lubrication lines
Table 20
Fig. 76 Rotor ports – 648575
Page 3.3 – 38 3746324en – (00)

3.3 ASSEMBLY MANUAL
The narrow end of the rotary lock must latch into

the cut-out (arrow, Fig. 77).
Fig. 79 Connection of pilot pressure hoses – 649400

Fig. 77 Rotor installation – 649399
7) Route all hydraulic hoses from the carbody to
4) Route all hydraulic hoses from the carbody to
both crawler frames (e.g., HCB and HCF, Fig.
the rotor. For information about the function
80).
and operation of the rotor, see chapters 8.4.9,
8.5.5, 8.5.7, and 5.9 of the Service Manual.
5) Connect high pressure hoses between rotor

(91) and secondary pressure relief manifold
(125) to the crawlers as shown in Fig. 78.
Fig. 80 Hydraulic lines carbody/track crawler frames - 649013
If you have removed the lid (L, Fig. 81) of the

optional cover (body plate, BP), reinstall it.
Fig. 78 Connection of high-pressure hoses – 649398
6) Ensure connection between undercarriage

and travel motors (121, Fig. 79). Connect pilot
pressure hoses between rotor and travel
motors.
Fig. 81 Belly plate installation – 649397
8) Connect all hydraulic hoses for the swing

circuit. Use chapter 8.5 Description of
hydraulic circuits of the Service Manual.
3746324en – (00) Page 3.3 – 39

3.3 ASSEMBLY MANUAL
9) Connect lubrication lines (LL, Fig. 82) to the 3.3.17 Boom installation
swing gearboxes.
Preparations on the superstructure
Open the pin covers (marked grey, Fig. 83) as
follows:
1) Remove the outer pin cover (marked dark
grey) on one side of the superstructure frame.
2) Remove pin covers (marked light grey) on
both sides of the superstructure frame, inside
and outside.
Note: The inside pin covers are opened to provide
a better view during alignment of the Tri-Power
rods and hydraulic cylinders.
Open the pin covers one by one following steps
3) – 6):
Fig. 82 Lubrication connection of the swing gearbox - 649014 3) Remove the bolts from the cover except for
the uppermost bolt.
10) Tighten the bolts according to the tightening
procedure described in chapter 2.9 of the 4) Loosen the uppermost bolt and tilt the pin
Service Manual. cover upwards so that bearing bush and pin
are freely accessible (see Fig. 83).
11) Connect all grease couplings.
5) Tighten the uppermost bolt to secure the pin
12) Refill nitrogen accumulators for track tension cover in this position.
system on both sides.
6) Screw in any removed bolts again to prevent
losing them and to stop the pin cover from
swinging back into its closed position.
Fig. 83 Pin covers – 649025
Page 3.3 – 40 3746324en – (00)

3.3 ASSEMBLY MANUAL
Pin installation
4) Attach two straps (STR, Fig. 84) to the part of
1) Prepare pins and bushing as described in the pin which has been pulled out and raise it
section “Preparation of pins and bushings” slightly.
(Page 10).
5) Pull out the pin until it rests only in one
2) Attach an eyebolt (EB, Fig. 84) to the end of bearing bush (BB, Fig. 84).
the pin.
Note: You can also use a special tool – pin puller
(Fig. 85):
Fasten a strap around the center of
the pin and secure it to the crane.
This minimizes the risk that the pin
suddenly slips out of the bushing
and causes personal injury or
serious damage.
Do not use a chain to pull the pin.

The dead weight of the chain can
pull out the pin unexpectedly.
3) Pull out about one third of the pin (PIN, Fig.

84).
Fig. 85 Pin puller assembly – 648576
For detailed information on its use refer to tool

Pulling the pin can be supported by operating manual with media no. M0074390 in
raising the pin slightly with the SIS web.
crane and the strap at the center of
the pin. 6) Remove corrosion inhibitors from the bushing
(BU, Fig. 84) that is now accessible and from
the accessible part of the pin (PIN, Fig. 84).
7) Grease the bushing (BU, Fig. 84) you have
Item Figure Description just cleaned. Coat the cavity (Fig. 86) with
BB Bearing bush lubricant completely.
BU Belly plate
EB Fig. 84 Eyebolt
PIN Pin
STR Strap
Table 21
Fig. 86 Cavity filled with lubricant – 649016
8) Push the pin back until it rests only in the

bushing (BU, Fig. 84) that you have just
cleaned and greased. Again, secure the pin
with a strap fastened around its center.
Fig. 84 Pulling the pin - 649230
3746324en – (00) Page 3.3 – 41

3.3 ASSEMBLY MANUAL
9) Clean the second bushing (BB, Fig. 84) and

the part of the pin that was not accessible
before.
10) Grease the second bushing (BU, Fig. 84).
11) Prepare all pin assemblies on the
superstructure the same way by repeating
steps 2) to 10).
12) Spray all pins and bearing bushes with
assembly spray.
Preparations on the boom

1) Before assembly, clean all pin assemblies and
bearings as described in section “Preparation Fig. 87 Boom components – 649017
of pins and bushings” (Page 10).
Assemble the boom with all components laid out
Always cover the bearing bushes on the ground. The assembly sequence is:
after preparation. Otherwise dirt
may enter the bearings during the Item Figure Description
assembly period.
1 Cradle (not yet installed)
2) Spray all bearing bushings and pins with Stick cylinder (not yet
assembly spray and cover them to prevent 3 installed)
Fig. 87
contamination.
Boom cylinder (not yet
4 installed)
Always cover bearing bushings after
preparation. Otherwise dirt may Table 23
enter the bearings during the
assembly period.
The following parts are mounted onto the boom

assembly on delivery:
2 TriPower steering rod

Fig. 87
5 Rocker (TriPower)
Table 22
Page 3.3 – 42 3746324en – (00)

3.3 ASSEMBLY MANUAL
Cradle 5) Place the stick cylinders near the side of the

boom they will be installed on. Place them
Note: The cradle is already correctly assembled
securely on wooden pallets which you can lift
exfactory.
with a fork lift.
1) Spray all bearing bushes and pin assemblies 6) Prepare bushings and pins of the cylinders as
on the cradle (Fig. 88) and boom with described in the corresponding section of
assembly spray. chapter 3.3.8.
2) Rig a four-legged chain to the cradle. 7) Secure the fork with a steel rope (SR, Fig. 89),
so the rod cannot slide out.
3) Lift the cradle into the installation position.
4) Insert the pins and bolt the lids to them (Fig. Item Figure Description
88). B Fig. 89 Bearing of the boom
5) Install hydraulic hoses from the cradle to the LE Lifting eye
uppercarriage. Fig. 90
RS Rope sling
SC Stick cylinder
Fig. 89
SR Steel rope
Table 24
Fig. 88 Cradle components – 649018
Installation of stick cylinders on the boom

The two stick cylinders (3, Fig. 87) are supplied Fig. 89 Stick cylinder preparation – 649019
separately and must be installed to the boom first. From here continue with one stick cylinder:
1) Lift the boom using a crane. 8) Raise the stick cylinder (SC, Fig. 89) using a
2) Set the boom on stands or supprt of sufficient fork lift to line up its bearings with the bearing
carrying capacity approx. 1 m above the of the boom (B).
ground. 9) Insert the pin and close the bearing with the
pin covers.
Use stable jack stands or similar
10) Secure the stick cylinder to the lifting eye (LE,
suitable supports of sufficient
Fig. 90) using a chain hoist or a rope sling
carrying capacity.
(RS).
Use stands or supports with anti-
11) Repeat steps 1) through 10) to fit the second
slip surface or place anti-slip
stick cylinder.
material between the module and
the stands or supports.
3) Remove the packaging material from the stick

cylinders.
4) Identify left-hand and right-hand side cylinders
using machine data sheet and serial numbers.
3746324en – (00) Page 3.3 – 43

3.3 ASSEMBLY MANUAL

2 Steering rod
4 Boom cylinder
BH Boom head bearing point
BP Boom base bearing point
FC Head front crane
GL Fig. 91 Grease line
P Pressure hose
RC Head rear crane
Fig. 90 Securing the stick cylinder – 649020 RE Rigging equipment
Installation of boom cylinders on the boom RL Rocker lock

TL Transport lock
1) Remove the packaging material from the
cylinders. Table 25
2) Identify left-hand and right-hand side cylinders

using machine data shefet and serial
numbers.
3) Prepare pins and bushings of the boom
cylinder.
Continue with one of the cylinders:
4) Raise one boom cylinder (4, Fig. 91) slightly
and remove the transport lock (TL).
5) Carefully lower the boom cylinder (4, Fig. 91)
onto the ground.
6) Repeat steps 1) through 5) to lower the
second boom cylinder. Fig. 91 Preparation and assembling of boom – 649021
7) Raise one TriPowerTM steering rod (2, Fig. 91) 10) Make sure that the piston rods and the yoke
slightly and remove the transport lock (TL). assemblies are correctly aligned.
Lower the Tri-Power rod (2) far enough to 11) Grease pin assemblies and bearing bushes.
install it easily.
12) Lift one boom cylinder into position using a
8) Secure the TriPowerTM rod (2) again in this crane and insert the pin.
position using a chain hoist.
13) Assemble the pin lid and tighten all bolts as
9) Repeat steps 7) and 8) to lower the second specified in the Service Manual.
TriPowerTM rod for easier installation.
14) Secure the boom cylinder to the boom using a
chain hoist or rope sling.
Secure cylinder piston rods of the
15) Repeat steps 12) through 14) to install the
boom cylinders using a chain hoist
second boom cylinder.
or steel the same way as with the
stick cylinders (Fig. 90) to prevent
them from sliding out.
Page 3.3 – 44 3746324en – (00)

3.3 ASSEMBLY MANUAL
Installation of the boom on the Boom installation

superstructure frame
1) Raise the boom with both cranes, one at the
Final preparations foot (rear crane, RC, Fig. 93) and one at the
1) Fill the cavities at the boom base bearing head (front crane, FC) of the boom.
points (BP, Fig. 91) and boom head (BH) with
as much grease as possible so that the time- Item Figure Description
consuming operation of filling the grease 2 Steering rod
cavity following assembly will not be Fig. 93
necessary. 4 Boom cylinder
2) Pile up grease near the bushing as indicated 5 Rocker (TriPower)

Fig. 94
(G, Fig. 92). 6 Pin
Use a service truck with a pipe of 2 BH Boom head bearing point

m length to fill in the grease. BP Boom base bearing point
Fig. 93
To avoid contamination, do not use FC Head front crane
shovels.
GL Grease line
Hole for the lubrication
HL Fig. 95
tube
P Pressure hose
RC Head rear crane
RE Fig. 93 Rigging equipment
RL Rocker lock
TL Transport lock
Table 26
Fig. 92 Grease level in cavity - 649022
3) Seal the cavity at the boom head to prevent

contamination. Remove the seal only directly
before installation procedure.
4) Also fill the cavities at the base shaft bearings
on the superstructure frame with as much
grease as possible.
5) Spray all bearing bushes and pins with
assembly spray and then cover to prevent
contamination. Fig. 93 Preparation and assembling of boom – 649021
2) Loosen the safety fastenings for the boom

Always cover the bearing bushes cylinder so that they do not interfere with
after preparation. Otherwise dirt further assembly.
may enter the bearings during the
3) Lift the boom off the ground above the
assembly period.
superstructure and then slowly lower the
boom until it is suspended in the required
position (Fig. 94) and the foot bearings line up
with the bushings of the superstructure frame.
3746324en – (00) Page 3.3 – 45

3.3 ASSEMBLY MANUAL
7) Release the rear crane that is holding the

Lower the boom into the bearing boom foot (RC, Fig. 94). Keep the front crane
bushes from above. attached to the boom head (FC).
If you move it in from the front it 8) Mount the lubrication lines for the boom base
may tilt and get stuck. pin assembly on both sides of the
9) Remove any excessive grease.
4) When lowering the boom, make sure that the
TriPower rods (2, Fig. 94) slide into the
intended position of the superstructure frame.
Installation of TriPowerTM steering rods on the
5) Now insert the pin (6) on the boom foot. superstructure frame
1) Use suitable rigging equipment (RE, Fig. 96)
to attach the first TriPowerTM rod to the rear
crane.
2) Use the rigging equipment and the rear crane
to ensure that the TriPowerTM rod (2) slides
into its required position on the superstructure
frame.
3) Use the front crane to lower and raise the
boom head to assist with the alignment.

2 Steering rod
6 Fig. 96 Pin
RE Rigging equipment
Table 27
Fig. 94 Boom installation – 649023
6) Fit pin covers (see corresponding passage of

chapter 3.3.8). Ensure that the bearing cover
is positioned correctly: the hole for the
lubrication tube (HL, Fig. 95) must be at the
top.
Fig. 96 Installation of steering rod – 649028
4) Insert the pin (6, Fig. 96).

Fig. 95 Closing the bearing cover – 649024 5) Remove the rigging equipment (RE) from the
rod.
Page 3.3 – 46 3746324en – (00)

3.3 ASSEMBLY MANUAL
6) Fit the pin covers as described in the

corresponding section of chapter 3.3.8 and Installation of boom cylinders on the
tighten all bolts in accordance with the superstructure frame
specified tightening method. Shims
7) Proceed in the same way with the second Fabrication tolerances may cause too much axial
TriPower rod. play at the bearing points of the boom cylinders.
Removal of the rocker lock The play between cylinder yoke (CY, Fig. 98) and
The following steps need to be carried out before cylinder fork (CF) must be at least 1 mm on both
fixing the boom cylinders to the superstructure sides and must not exceed 2 mm.
frame: To adjust the play and to center the cylinder yoke
4) Secure the rocker lock (RL, Fig. 97) with a belt (CY, Fig. 98) in the cylinder fork (CF), it may be
and the rear crane to prevent it from falling. necessary to fit shims (SH) on both sides of the
yoke.
5) Manipulate the boom head with the front crane
to take the weight off the rocker lock. Item Figure Description
6) Pull out the rocker lock. CY Cylinder yoke
7) Leave the front crane attached to support the CF Cylinder fork
boom head. Fig. 98
SH Shims
PIN Pin
Table 28
Fig. 97 Rocker lock - 649029
Fig. 98 Cylinder fork with shims - 649030
3746324en – (00) Page 3.3 – 47

3.3 ASSEMBLY MANUAL
Selection of shims
Boom cylinder installation
The shipment includes several different shims. To
Install the two boom cylinders one after the other:
determine the thickness of the shims needed,
measure the cylinder yoke (A, Fig. 99) and the 1) Lift the first boom cylinder (2, Fig. 100) into
relevant cylinder fork (B). position using the rear crane.
Calculate as follows: 2) Install the shims on the bearing bushings of
the boom cylinder and insert the pin (PIN, Fig.
 Thickness of cylinder yoke including bearing
100).
bushing (A)
3) Install the pin covers and tighten all bolts in
 Internal gap of the cylinder fork (B) accordance with the tightening method
 Formula: (B - A) / 2 = size of the shim specified in chapter 2.9 of the Service Manual.
Note: You need two shims of this size, one on 4) Remove safety ropes between the cylinder rod
each side of the cylinder yoke. and cylinder liner and open cylinder ports.
5) Repeat steps 1) through 4) to fit the second
boom cylinder.
6) If you connect the hoses later, close the
cylinder ports.
The boom is now held by the boom cylinders
and the TriPowerTM rods.
7) Release the front crane.

2 Boom cylinder
Fig. 100
PIN Pin
Table 29
Fig. 99 Bearing position – 644663
Fig. 100 Installation of boom cylinder – 649031
Page 3.3 – 48 3746324en – (00)

3.3 ASSEMBLY MANUAL
3.3.18 Installation of modules and

components to superstructure
frame
Ensure that all modules and components of
superstructure listed in Table 30 and shown in
Fig. 101 are either installed or ready for
installation.
Preparation of power (engine) module

Complete power module preparation as described
in this Assembly Manual before fitting the power
module to the superstructure frame. However,
varying site conditions and crane schedules may
call for a different approach in some cases. It is
possible to carry out the following work alongside
the assembly of the undercarriage and the
To ensure working safety on the

superstructure fit handrails,
walkways, steps and gratings before
lifting the power module into place.
1 Lubrication (pumps) module

Hydraulic oil tank breathers
2
(installed)
3 Vise
4 On-board crane
Fig. 101
5 Horn (installed)
6 On-board crane set (optional)
7 Working lights
8 Mirror
9 AC platform
Table 30
3746324en – (00) Page 3.3 – 49

3.3 ASSEMBLY MANUAL
Fig. 101 Uppercarriage components - 649368
Page 3.3 – 50 3746324en – (00)

3.3 ASSEMBLY MANUAL
Installation of hydraulic access ladder
Assemble platforms and handrails

before lifting the ladder into place to
ensure working safety at heights.
1) Secure the hydraulic access ladder (Fig. 102)

in the delivery state.
FP Fig. 103 Fixing points
SEA Fig. 104 Service arm
Fig. 103 Installation of hydraulic access ladder – 649034
Table 31
5) Insert the bolts at all fixing points (FP, Fig.
103) and tighten them according to the
specified tightening method (see Service
Manual for details).
Note: Connect lubricating and hydraulic lines for
the ladder after the cab module has been
installed.
Installation of power (engine) module on

1) Remove all packaging material from the
service arm (SEA, Fig. 104) but do not lower it
yet.
Fig. 102 Hydraulic access ladder in delivery state - 649033
2) Remove the packaging material from the

ladder and platform.
3) Clean all mating surfaces on the platform and
on the power module and prepare all bolts
and sleeves.
4) Use a crane to carefully lift the ladder into the
installation position (Fig. 103).
Fig. 104 Service arm – 649035
2) Secure all loose cables and hoses on the

module so that they do not interfere with the
assembly work.
3) Make sure that all machined mating surfaces
and bolt holes in both the power module and
the superstructure frame have been cleaned
according to the instructions (see Section
3.3.1 in the Service Manual). If necessary,
rework the threads.
4) Prepare all bolts and sleeves according to the
specifications (see Section 2.9 in the Service
Manual).
3746324en – (00) Page 3.3 – 51

3.3 ASSEMBLY MANUAL
5) Apply a thin layer of sealant to the eight

mating surfaces on the superstructure frame
(dashed circles, Fig. 105).
Follow the instructions on sealant of this
Assembly Manual.
Fig. 106 Lowering the service arm - 649369
Fig. 105 Mating surfaces on the superstructure

frame – 649040
6) Raise the engine (power) module using two

cranes and align it horizontally.
Ensure that no hoses or cables are

crushed or damaged when setting
the power module onto the
7) Carefully position the power module in its end

position.
8) Insert the bolts, start tightening them manually
while the power module is still suspended.
9) Fully lower the power module.
10) Tighten the bolts as far as possible by hand.
11) Remove the rigging material.
12) Tighten the bolts in accordance with Section
2.9 of the Service Manual.
13) Slowly lower the service arm (SEA, Fig. 106).
Page 3.3 – 52 3746324en – (00)

3.3 ASSEMBLY MANUAL
Installation of hydraulic oil cooler module

1) Clean the mating surfaces (dashed circles,
Fig. 107) of the hydraulic oil cooler module
and the superstructure frame, as described in
section "Preparatory work".
Fig. 108 Mating surfaces on cab module – 649038
2) Clean the mating surfaces on the

superstructure frame (circles with dashed
Fig. 107 Mating surfaces on hydraulic oil lines, Fig. 109), as described in section
cooler module – 649039 "Preparatory work".
2) Prepare all bolts and sleeves required for
installation of the module.
3) Apply sealant to the prepared surfaces on the
superstructure frame. Follow the instructions
on sealant of this Assembly Manual.
4) Attach the hydraulic oil cooler module to a
crane and raise it. Ensure it is suspended
horizontally.
5) Lift the module into its assembly position.
6) Insert the bolts. Start them according to
chapter 3.3.8 of this Assembly Manual. When
the module is fully lowered, tighten bolts
according to the specified tightening
procedure (see Section 2.9 of the Service Fig. 109 Mating surfaces on superstructure frame – 649041
Manual).
Installation of cab module 3) Apply sealant to all mating surfaces on the
superstructure frame. Follow the instructions
1) Clean the mating surfaces and threaded bores on sealant of this Assembly Manual.
on the operator cab module (circles with
dashed lines, Fig. 108), as described in 4) Prepare all bolts and sleeves for assembly.
section "Preparatory work". 5) Lift the cab module into its final position.
Ensure that the module is suspended
horizontally. Use chain blocks or chains with
shorteners if necessary.
Note: While the module is lifted into its end
position, the cables and hoses (C & H, Fig. 110)
of the engine module must be fed through the
opening in the lower right corner and into the
operator cab module.
3746324en – (00) Page 3.3 – 53

3.3 ASSEMBLY MANUAL
Item Figure Description Installation of lubrication and air conditioning

C&H Fig. 110 Cable and hose platform
STW Fig. 111 Stairway 1) Remove the packaging material from the
platform (Fig. 112).
Table 32
2) Clean all mating surfaces as described in the
corresponding section of the Assembly
Manual.
3) Install plates (PL, Fig. 112).

HR Handrail
PL Plate
Fig. 112
SB1
Support brackets
SB2
Table 33
Fig. 110 Cable and hoses btw power (engine) & cab modules –
649042
Lower the module from above.

Do not swing it into position
from a side.
6) Insert the bolts and fasten hand-tight.

7) Tighten all bolts as specified in the Service
Manual.
8) Assemble the stairways (STW, Fig. 111)
between the cab module and the engine
Fig. 112 Lubrication & AC platform – 649044
module.
4) Loosen the support brackets (SB2, Fig. 112)
on the power (engine) module and turn 180°.
5) Raise the platform using a crane. Make sure it
is suspended horizontally.
6) Install the platform between the cab module,
the oil cooler module and the power module.
The support brackets (SB1, Fig. 112) are
located on the hydraulic oil cooler module and
the cab module.
7) Insert the mounting pins, secure the lock nut
with the splints as well as the front spacers
with washers and secure bolts (Fig. 112).
Note: In case you have to install air conditioning

system (AC) do not install handrail (HR, Fig. 112)
to the platform.
Fig. 111 Stairways btw cab & engine modules - 649376
Page 3.3 – 54 3746324en – (00)

3.3 ASSEMBLY MANUAL
Installation of hydraulic and electric lines

between power (engine) module and
Start the installation of the hydraulic lines from the

lower level and continue to the upper level:
 pilot hoses between rotor and the engine

module (Fig. 118);
 high pressure hoses (grey colored, Fig. 113)

between swing gearboxes and main pumps;

Fig. 113 High pressure hoses btw swing gearboxes and main
Pilot pressure control
25 pump – 649374
Fig. 118 manifold
 walkway grid on top of the superstructure
26 Auxiliary manifold frame (Fig. 114);
High pressure filter &
30 & 32
control block
91 Rotor
Return oil lines from
91-1 & 91-2 rotor 91 to the
Fig. 115 manifolds 25 & 26
92 RH travel valve
Return oil line from
92-1
RH travel valve 92
High pressure lines
92-2
from main pumps
Pilot pressure lines
from RH travel valve
92-3 & 92-4 Fig. 118
92 to Pilot pressure
control manifold 25 Fig. 114 Walkway grid - 649219
93 LH travel valve
Return oil line from LH
93-1
Fig. 115 travel valve 93
High pressure lines
93-2
from main pumps
Pilot pressure lines
from LH travel valve
93-3 & 93-4 Fig. 118
93 to Pilot pressure
control manifold 25
Table 34
3746324en – (00) Page 3.3 – 55

3.3 ASSEMBLY MANUAL
 hydraulic hoses between high pressure filters

and rotor (Fig. 115);
Fig. 116 High pressure hoses from high pressure filter manifold
to main pumps - 649378
 Connect hydraulic hoses (grey colored, Fig.

117) from rotor (91) and travel valves (92 &
93) to the attachment control manifold (160 &
Fig. 115 High pressure hoses from rotor to hydraulic tank and
high-pressure filter manifold - 649377
161);
 high pressure hoses (93-2 & 93-2, Fig. 116)

from main single pumps (s. Table 34) through
control block (30) and high pressure filter (32,
Fig. 116) in the power module to the travel
valves (92 & 93, Fig. 115) and return line
hoses (93-1 & 92-1, Fig. 115) on the
superstructure frame. Connect them from
below.
Fig. 117 High pressure hoses btw rotor & boom cradle –
649396
 Connect electric lines between the attachment

and the rear of the cab module (Fig. 118).
Page 3.3 – 56 3746324en – (00)

3.3 ASSEMBLY MANUAL
Fig. 118 Pilot pressure hoses from travel motors to travel control manifold - 649397
3746324en – (00) Page 3.3 – 57

3.3 ASSEMBLY MANUAL
Installation of operator cab

1) Remove the transport and packaging material 4) Place plates (PL, Fig. 121) and top section of
from the operator cab. the cab mount assembly onto the mounting
surfaces (dashed circles in Fig. 120).
2) Lift the transport cover (TC, Fig. 119) from the
upper section of the cab module.
AC Antenna cable
BC Bus cable
Fig. 123
C Connector
CC Camera cable
MS Fig. 121 Mounting surface
OP Fig. 123 Opening
PL Fig. 121 Plate
TC Fig. 119 Transport cover
Table 35
Fig. 119 Lifting transport cover – 649405
3) Clean the four mounting surfaces on top of

the cab module (dashed circles, Fig. 120) and
on the operator cab. Fig. 121 Cab installation on cab module - 649201
5) Check the correct seat of the plates.

6) Lift the operator cab using a crane (Fig. 121).
Make sure it is suspended horizontally and
that the angle between the rigging and the
roof is no less than 45°.
7) Lower the operator cab onto the mounting
surfaces (MS, Fig. 121).
8) Start bolts while the cab is still suspended a
few mm above the mounts.
9) Fully lower the cab when bolts and mounts
align.
Fig. 120 Mounting surfaces for the rubber dampers – 649406

10) Tighten the four bolts according to the
specified tightening method.Affix the large
rear mirror (RM, Fig. 122) to the center bar
(BAR) of the railings.
Page 3.3 – 58 3746324en – (00)

3.3 ASSEMBLY MANUAL
Do not remove the protective film Counterweight installation

from the mirror before the machine
is put into operation to prevent its 1) Attach two handrails (HR, Fig. 124) to the
damage during further assembly counterweight and connect them using the
steps. sleeves (SL).
CW Fig. 126 Counterweight
HR Fig. 124 Handrail
RL Fig. 125 Rear light
SFR Fig. 126 Superstructure frame
SL Fig. 124 Sleeve
Table 36
Fig. 122 Operator cab, final work - 649401
12) Install electric lines between the operator cab

and the cab module. Guide three connectors
(C, Fig. 123), antenna cable (AC), three bus
cables (BC), and camera cable (CC, optional)
downwards and wiping line through the
opening (OP) and into the cab module.
Fig. 124 Rails installation – 649402
2) Fit railings around the counterweight.

3) Attach two rear lights (RL, Fig. 125) to both
sides of the counterweight.
Fig. 123 Electric lines btw cab & cab module - 649203
Fig. 125 Rear lights - 649403
3746324en – (00) Page 3.3 – 59

3.3 ASSEMBLY MANUAL
4) Clean the contact surfaces on the

superstructure frame and the counterweight
as described in chapter 3.3.7 of this Assembly
Manual.
5) Prepare all bolts and sleeves required for
assembly.
6) Apply a thin layer of sealant to the contact
surfaces on the superstructure frame. Follow
the instructions on sealant of this Assembly
Manual.
7) Use a crane to raise the counterweight (CW,
Fig. 126) above its intended position on the
superstructure frame (SFR). Ensure that it is
suspended horizontally.
Fig. 127 Counterweight sections fixing bolts – 649407
Fig. 126 Installation of the counterweight - 649406
8) Slowly lower the counterweight onto the

9) Tighten bolts (Fig. 127) which retain the
counterweight in its position on the
superstructure frame to their final torque
(chapter 2.9 of the Service Manual).
Page 3.3 – 60 3746324en – (00)

3.3 ASSEMBLY MANUAL
Lubrication pump module

To prevent personal injury move
away from hanging components. EB Eyebolt
Fig. 129
LL Lubrication line
LPM Lubrication pump module
For more information about the lubrication system,
read chapter 11 of the Service Manual. PF Fig. 128 Platform
1) Prepare existing drill holes on the power PM Power module

module (PM, Fig. 128) for assembling the SEA Service arm
platform (PF, Fig. 128) of the lubrication pump
module (LPM, Fig. 128). 2 Base Plate
Fig. 129
2) Attach lifting tackles to the eyebolts (EB, Fig. 37 Sleeve
129). 38 Bolt
3) Raise the platform (PF) using a crane. Ensure Table 37
that it is suspended horizontally.
4) Carefully lower the platform (PF) to the
specified drill holes of the power module (PM)
slide into their drill holes position.
5) Attach the lubrication pump module (LPM) to
the power module (PM, Fig. 128).
6) Secure the platform (PF, Fig. 129) using the
bolts (38, Fig. 129) and sleeves (37, Fig. 129).
7) Connect the lubrication line (LL, Fig. 129) to
the service arm (SEA, Fig. 129).
8) Connect the pressure connection (PH, Fig.
129) for pilot pressure and the return
connection (RH, Fig. 129) of the hydraulic tank
to the connection points of the power module Fig. 128 Lubrication pump module - 649408
(PM).
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3.3 ASSEMBLY MANUAL
Fig. 129 Lubrication pump module connections – 649415
Page 3.3 – 62 3746324en – (00)

3.3 ASSEMBLY MANUAL
9) Connect the main line A (AS, Fig. 130) and the

main line B (BS, Fig. 130) of lubricant pump
module (LPM, Fig. 130) to the lubrication lines
of the boom.
10) Route the other ends of the lines to the boom.
11) Connect main line A (AS, Fig. 130) and the
main line B (BS, Fig. 130) to the connection
points (C1 and C2, Fig. 131) on the boom.
Item Figure Function
C1
Fig. 131 Connection points of the boom
C2
BS
Fig. 130 Main lubrication line
AS
Table 38
Fig. 130 Lubrication pump module connections – 649141
Fig. 131 Lubrication lines on the boom – 649233
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3.3 ASSEMBLY MANUAL
Routing of High Voltage HV Cable from Motor

Module to Junction Box
The HV cable HVC1 (Fig. 132) is in the motor

module preassembled and connected on one end,
the other end needs to be routed from the motor
module (Fig. 133) to the rotor RT (Fig. 132, Fig.
133 & Fig. 134), passing it (Fig. 135) and
continuing into the vertical entry of the slip ring
device SLD (Fig. 132 & Fig. 135), where it needs
to be connected (Fig. 136) according to the
electric schematic.

Fig. 132 Routing of HV cable 1, coming from the motor
CB Fig. 137, Fig. 139 Carbody module, entering the rotor - 649382
Fig. 133, Fig. 137,
CL1 Clamping Set 1
Fig. 139
Fig. 134, Fig. 135,
CL2 Clamping Set 2
Fig. 137, Fig. 138
CL3 Fig. 134, Fig. 135 Clamping Set 3
CL4 Fig. 151 Clamping Set 4
Fig. 132, Fig. 133,
HVC1 Fig. 134, Fig. 135, High Voltage Cable 1
Fig. 138
Fig. 132, Fig. 135,
HVC2 Fig. 137, Fig. 139, High Voltage Cable 2
Fig. 138
High Voltage Cable 3
HVC3 Fig. 132, Fig. 138
(Customer)
High Voltage Cable
HVCB Fig. 139, Fig. 138
Bracket
High Voltage Junction Fig. 133 Routing of HV cable 1 in motor module to the rotor -
HVJB Fig. 132, Fig. 138
Box 649383
Fig. 140, Fig. 141, Pin for Retainer on
P
Fig. 143 Slipring Device
Fig. 135, Fig. 140,
RET Retainer
Fig. 141, Fig. 142
Fig. 132, Fig. 134,
RT Fig. 135, Fig. 138, Rotor
Fig. 140, Fig. 142
Fig. 132, Fig. 135,
SRD Fig. 137, Fig. 140, Slipring Device
Fig. 141, Fig. 143
SST Fig. 140 Superstructure
Table 39
Fig. 134 HV cable 1 enters the rotor (bird’s eyes view) -

649384
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3.3 ASSEMBLY MANUAL
Another HV cable HVC2 must be mantled to

connect the slip ring device SLD (horizontal outlet;
Fig. 132; Fig. 136 & Fig. 137) with the high
voltage junction box HVJB (Fig. 132 & Fig. 138)
according to the electric schematic.
Customers responsibility is to lay their local high
voltage cable HVC3 from the mine power station
to the high voltage junction box HVJB, located on
the cable bracket (Fig. 138).
Fig. 137 Routing of HV cable 2, coming from slipring device,

entering the carbody - 649387
Fig. 135 Routing of HV cable 1, location of retainer –
649385
Fig. 138 Routing of HV cables - 649389
It must be ensured, that the HV cables will be

clamped and assembled in a workmanlike
manner, using clamping sets CL1 to CL4 as
shown in Fig. 133, Fig. 134, Fig. 135, Fig. 137,
Fig. 139 and Fig. 138.
The rotor RT in the superstructure and the slipring

device SRD in the carbody will be connected with
the retainer RET (Fig. 140 to Fig. 143). It must be
ensured, that the fork shape on the bottom of the
retainer RET fits onto the pin P on the slipring
device as shown in Fig. 141.
Fig. 136 Slip ring device, both covers dismantled - 649386
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3.3 ASSEMBLY MANUAL
Fig. 139 Routing of HV cable 2, leaving the carbody, entering

the HV cable bracket - 649388
Fig. 142 View from the bottom in direction to rotor RT, showing
the retainer RT - 649392
Fig. 140 Assembly of retainer RET to connect rotor RT with

slipring device SRD - 649390
Fig. 143 Bird’s eyes view, showing the slipring device in the
carbody, retainer needs to be assembled to get fixed
by the pin P - 649404
Fig. 141 Enlargement out of Fig. 140 - 649391
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3.3 ASSEMBLY MANUAL
Air conditioning (AC) system Item Figure Function

Depending on optional equipment chosen, the EB Fig. 145 Eyebolt
machine can be equipped with one or two air
conditioning systems. In the case of two air HH1
conditioning systems, there are two evaporator Fig. 148 Heating hoses
HH2
units in the cab and there are two condenser units
(CU, Fig. 147) next to the lubricant container. LT Fig. 145 Lubricant container
1) Affix support brackets (SUP, Fig. 144) for the SUP Fig. 144 support bracket
platform (PF, Fig. 145) to the oil cooler module Table 40
and the cab module.
2) Remove packaging material from the platform
(PF).
3) Prepare bearing points (BP1 and BP2, Fig.
145 and BP3, Fig. 146) between the oil cooler
module and the cab module for assembly of
the platform.
4) Install eyebolts (EB, Fig. 145) as shown on the
platform (PF).
5) Attach lifting tackles (LT, Fig. 145) to the
eyebolts (EB).
6) Raise the platform using a crane. Ensure that
it is suspended horizontally.
7) Carefully lower the platform to the specified Fig. 144 Support bracket - 649137
point between the oil cooler module and the
cab module so that both bearing points (BP1,
Fig. 145 and BP2, Fig. 145 & Fig. 146) slide
into their bearing position (BP3).
8) Secure the platform using the pins designed
for this purpose.
9) Attach the condenser unit to a crane using the
four transport lugs. Ensure that it is
suspended horizontally.
10) Install the condenser unit (CU, Fig. 147) on
the platform (LC).

Fig. 145 Rail installation – 649138
BP1
Fig. 145
BP2 bearing point
BP3 Fig. 146
CU Condenser unit
CUL1 Fig. 147

Condenser unit lines
CUL2
CP1
Fig. 149 Connection points
CP2
CUL1 Fig. 146 Support bracket - 649139

Fig. 147 condenser unit line
CUL2
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3.3 ASSEMBLY MANUAL
Fig. 149 Air conditioning system connections on the operator

Fig. 147 Air conditioning system – 649416 cab – 649147
11) Connect heating hoses (HH1, Fig. 148) 13) Connect cooling hoses between the
coming from the power module to the condenser unit lines (CUL1 and CUL 2, Fig.
connection points (CP1, Fig. 149) on operator 147) to the corresponding connections on the
cab as well as AC hoses coming from the operator cab.
condenser unit.
Fig. 148 lines 1 – 649146
12) Connect heating hoses (HH2, Fig. 148) of the

air conditioning system to the connection
points (CP1 and CP2, Fig. 149) on the
operator cab.
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3.3 ASSEMBLY MANUAL
On-board crane (optional) 6) Align the on-board crane.

1) Loosen the bolts and remove the dummy 7) Insert the bolts and tighten according to the
cover (DC, Fig. 150). specified tightening procedure.
Item Figure Function Crane power unit

BO Fig. 151 Boom 1) Lower the crane power unit (Fig. 152) into the
DC required position on the counterweight.
Fig. 150 Dummy cover
M 2) Insert the bolts and tighten them using the
Mounting
specified tightening procedure.
MA Fig. 151 Mounting assembly
OBC On-board crane
Table 41
Fig. 152 Crane power unit installation – 649409
3) Connect all hydraulic lines from the power unit

to the on-board crane (Fig. 153).
Fig. 150 Dummy cover – 649148
2) Install mounting assembly (MA, Fig. 151) to

the plates at the dummy cover.
3) Install shackles with the corresponding
mounting (M) to the mountings (MA).
4) Install lock bracket assembly (LBA) to the
platform.
5) Raise the on-board crane (OBC, Fig. 151)
using an assembly crane and move it into the
installation position.
Fig. 153 Hydraulic lines btw on-board crane & its power unit
- 649411
4) Read sections “Operation” and “Inspection

and Servicing” concerning on-board crane
and its power unit in Operation and
Maintenance Manual. If necessary read
supplier documentation as well.
5) Start the on-board crane.
6) Lower the boom (BO, Fig. 151) of the crane
Fig. 151 On-board crane installation – 649149 into the lock bracket (LBA) to secure it.
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3.3 ASSEMBLY MANUAL
Fire extinguisher Installation of lubrication and hydraulic oil

lines for hydraulic access ladder
Install the fire extinguisher on the left next to the
operator cab doors (FE, Fig. 154). 1) Connect hydraulic lines to the hydraulic
access ladder cylinder (Fig. 156).
Fig. 156 Hydraulic lines for access ladder cylinder – 649156

Fig. 154 Fire extinguisher – 649151
2) Mount the lubricant distributor block (LDB,
Grease collectors Fig. 157) onto the rear of the access ladder.
Install two collectors (GC, Fig. 155) to catch the Item Figure Function
used grease coming from boom pin inside the
HCL Fig. 159 Hydraulic control lines
LDB Fig. 157 Lubricant distributor block
OV Fig. 158 Operation valve
PRS Proximity switch
Fig. 160
SAS Service arm switch
Table 42
Fig. 157 Lubrication lines of hydraulic access ladder – 649153
Fig. 155 Assembly of the grease collectors – 649168 3) Install lubrication lines to the corresponding
connection points and tighten the nuts
according to the specification.
4) Mount the operation valve (OV, Fig. 158) for
the hydraulic access ladder onto the left
handrail of the engine module.
Page 3.3 – 70 3746324en – (00)

3.3 ASSEMBLY MANUAL
Fig. 158 Operation valve for hydraulic access ladder - 649154

Fig. 160 Proximity switch for hydraulic access ladder – 649158
5) Connect hydraulic control lines (HCL, Fig.
159) to the valve (OP).
Fig. 161 Service arm switch - 649440
Fig. 159 Hydraulic lines of access ladder valve - 649157
6) Install proximity switch (PRS, Fig. 160) for

access ladder and service arm switch (SAS,
Fig. 161). Connect electric lines of the ladder
using information of chapter 9.4 of the Service
Manual.
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3.3 ASSEMBLY MANUAL
3.3.19 Stick installation 4) On the same side of the stick, fit an eyebolt
(EB, Fig. 163) to one of the threaded bores for
1) Ensure that the stick is level. the pin cover.
2) Remove the pin cover (PC, Fig. 162) from the 5) Prepare pin and bearing bushings as
stick. described in section “Preparation of pins and
Item Figure Function bushings” (Page 10) of this Assembly Manual.
EB Fig. 163 Eyebolt 6) Pull out the pin to the side with the two
eyebolts (EB, Fig. 163) until it rests only in one
LD Fig. 167 Lubrication distributor bushing. Secure the pin with a steel rope (SR)
LL Fig. 162 Lifting lugs between the eyebolts (EB) so that it cannot
slide out further.
PIN Fig. 163 Pin
PC Fig. 165 Pin cover When taking out the pin ensure that
PP
its surface is not damaged.
Protection plates
Fig. 162
SHC Stick head cavity
SR 7) Install cylinder protection plates (PP, Fig. 162)
Fig. 163 Steel rope
on the brackets provided.
TU1
Fig. 165 Tube 8) Fill the stick head cavity (SHC, Fig. 162) with
TU2 lubricant as described in section Preparing
Table 43 bushings and pins for boom installation. Seal
the cavity.
9) Grease the pin and all bearings.
10) Attach rigging material to the lifting lugs (LL,
Fig. 162).
Note: It is important, that the stick is suspended
horizontally when lifted. This may be difficult to
achieve as the stick will be unbalanced due to the
pin protruding on one side. To compensate for this
use chain shorteners or shackles of different
sizes.
11) Lift the stick with a crane (Fig. 164).
Fig. 162 Components of the stick – 649234
3) Determine from which side the pin (PIN, Fig.

163) will be pushed. On this side of the pin, fit
an eyebolt (EB) to the pin face.
Fig. 164 Lifting the stick – 644605
12) Maneuver the stick into its installation position

Fig. 163 Securing the pin – 649235 from above or from the front.
Page 3.3 – 72 3746324en – (00)

3.3 ASSEMBLY MANUAL
Ensure that the stick does not

swing and hit the bearing bushings.
13) Line up the bearing bushings of stick and

boom and push in the pin (PIN, Fig. 163).
14) Lower the stick until it is suspended
perpendicularly by its own weight.
15) Release the crane.
16) Remove the eyebolts (EB, Fig. 163).
17) Install the pin covers (PC, Fig. 165).
Fig. 166 Hydraulic connections on the stick – 649237
Fig. 165 Pin cover installation - 649236
18) Tighten the bolts in accordance with the

specified tightening method (chapters 2.9 and Fig. 167 Hydraulic and lubrication lines – 649238
17 of the Service Manual).
19) Connect hydraulic hoses between tube (TU1, Installation of stick cylinders to the stick
Fig. 166) and hose bracket (HB) and between 1) Remove pin covers from the fork of one of the
hose bracket (HB) and bucket cylinder (BC). stick cylinders.
20) Connect hydraulic hoses (HH) between the 2) Loosen blanking plates from the cylinder ports
tube (TU2, Fig. 166) and the bucket cylinder for venting. Extend the cylinder by securing a
(BC). chain hoist with one end on the fork (FE, Fig.
21) Install lubrication distributor (LD, Fig. 167) and 168), the other end on the stick top chord
hydraulic tubes (TU1 & TU2, Fig. 167) for the lifting lugs (LL, Fig. 162).
bucket cylinders on the rear of the stick. 3) Just before lining up fork and stick bushings
prepare the fork pin and bushings as
described in section “Preparation of pins and
bushings” (Page 10).
4) Line up cylinder fork bushings (FE, Fig. 168)
and stick bushings (STB).
5) Ensure that the orientation of the fork is
correct. The fork lubrication holes (LH, Fig.
169) must point to the ground, not to the stick.
Turn fork if necessary.
6) Push in the pin and install the pin covers.
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3.3 ASSEMBLY MANUAL
7) Tighten the bolts in accordance with the 3.3.20 Final steps of boom installation
specified tightening method (see Service
Manual, chapter 17). Installation of lateral walkways
8) Remove the chain hoist. 1) To install walkways on the rear section of the
9) Repeat steps 1) to 8) to install the second boom, prepare the bolts and sleeves.
stick cylinder. 2) Remove paint from contact surfaces.
10) If applicable, install two additional main lights 3) Affix the railings (RAI, Fig. 170) to the
on the boom. walkways.
Item Figure Function 4) Secure rigging hardware to the walkway so
FE Fig. 168 Fork end that the walkway is suspended parallel to the
contact surface of the boom. Use different
LH Fig. 169 Lubrication holes length lifting gear, if necessary.
STB Fig. 168 Stick bushing 5) Lift the walkway (WW, Fig. 170) onto the
Table 44 boom.
6) Screw in the bolts as described in Screwing in
connecting bolts on p. 9 and specified in
chapter 2.9 of the Service Manual.
RAI Railing
Fig. 170
WW Walkway
Table 45
Fig. 168 Lining up the cylinder forks – 649239
Fig. 170 Assembly of side walkways – 649241
Fig. 169 Fork orientation - 649240
Page 3.3 – 74 3746324en – (00)

3.3 ASSEMBLY MANUAL
Connection of lubrication tubes on the

attachment
1) Connect all lubrication tubes (Fig. 171, Fig.
172 & Fig. 173).
Fig. 171 Boom lubrication lines - 649243
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3.3 ASSEMBLY MANUAL
Fig. 172 Stick lubrication lines - 649259
Page 3.3 – 76 3746324en – (00)

3.3 ASSEMBLY MANUAL
Fig. 173 Back wall lubrication lines - 649260
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3.3 ASSEMBLY MANUAL
Connection of hydraulic lines Note: Tighten bolts on both ends of the hoses.
Connect hydraulic hoses (HH, Fig. 174) on the 1) Connect the high-pressure hoses to the
boom top between boom cradle and rotor. cylinders (pFig. 176).
 on the boom cylinders (BC): hose (H1) on the
Item Figure Function rod side, hose (H2) on the piston side
BC pFig.  on the stick cylinders (SC): hose (H4) on the
Boom cylinder
176 rod side, hose (H3) on the piston side
HH Fig. 174 Hydraulic hose
2) Connect all lubrication tubes to the bearings of
H1 – H4 pFig. Hose the cylinders.
SC 176 Stick cylinder pFig. 176 High pressure hoses on the boom - 649242
Table 46
Fig. 174 Hydr hose connection btw cradle & rotor – 649412
Note: If necessary, remove the grid (arrow in Fig.

175) from its support bracket. Then re-install the
grid.
Fig. 175 Grid - 649261
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3.3 ASSEMBLY MANUAL
Installation of hydraulic oil cooling lines

For information about function and operation of
the hydraulic oil cooling system read chapter 8.5
of the Service Manual.
To install all hydraulic lines for the hydraulic oil
cooling system, take the following steps:
1) Connect hydraulic hose (HH1, Fig. 177) from
LH fan pump (FP1) via hydraulic hose (HH3)
to fan motor (FM1).
2) Connect hydraulic hose (HH2, Fig. 177) from
RH fan pump (FP2) via hydraulic hose (HH4)
to fan motor (FM2).
3) Connect hydraulic hose (HH5) from hydraulic
tank (60) via hydraulic hose (HH7) to
hydraulic oil cooler (H02).
tank (60) via hydraulic hose (HH8) to
hydraulic oil cooler (H01).
tank (60) to oil cooler hydraulic tank (OCH).
FM1 & FM2 Fan motor

FP1 & FP2 Fan pump
HH1 – HH9 Fig. 177 Hydraulic hose
HO1 & HO2 Hydraulic oil cooler
OCH Oil cooler hydraulic tank
Table 47
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3.3 ASSEMBLY MANUAL
Fig. 177 Hydraulic oil cooling system connections - 649413
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3.3 ASSEMBLY MANUAL
3.3.21 Top up operating fluids 3.3.22 Electric system

Top up all and check the level of all machine Connectors and sockets that are to be connected
operating fluids using chapter “Inspection and to each other are marked with the same number.
Servicing” of Operation and Maintenance Manual. See electric schematics for detailed information
Always use only the fluids approved and about the electric system.
recommended by Caterpillar Global Mining HMS
GmbH (e.g., SEBU 6250). For this purpose, refer
to current publications in SIS Web. Main lights and maintenance lights
Top up and check the level of the hydraulic 1) Connect the main lights (1 to 5, Fig. 178) to
accumulators using chapter 8.6 “Pressure the pre-installed cables on the outside of the
checking and setting” of the Service Manual as superstructure.
well as current technical publications in SIS Web. Note: Two additional main lights (optional) can be
fitted on the boom. They are not included in Table
48.
2) Install and connect the maintenance lights (6
to 12, Fig. 178) inside the modules.

1 Front oil cooler module
2 Front left operator cab roof
3 Front cab module
4 Rear counterweight
5 Rear operator cab roof
6 Inner cab module
Fig. 178
7 Service station
8 LH power module walkway
9 Counterweight
10 RH power module walkway
11 Rear LH oil cooler module
12 Inner oil cooler module
Table 48
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3.3 ASSEMBLY MANUAL
Fig. 178 Location of main lights and maintenance lights - 649414
Page 3.3 – 82 3746324en – (00)

3.3 ASSEMBLY MANUAL
In the cab module CAN bus

Plug connectors (1 and 3, Fig. 179) into the CAN bus connectors are color coded. Fig. 180
corresponding sockets on the underside of the shows how to connect them. See electric
operator cab. Plug in connector (2) if available. schematics for more information.
See Table 49 for details. 1) Use the cable with green markings to connect
CAN bus II from pedals and joysticks to the
main electric cabinet -X1.
Item Description Connection
2) Connect the three CAN bus cables from the
1 –X180 Air conditioning system operator cab as follows:
2nd air conditioning  the CAN bus I cable (yellow) to the main
2 –X181
system (optional) electric cabinet -X1 (9, Fig. 189).
3 –X102 Operator cab platform  the two on-board diagnostics cables (blue
Forward travel
and red) to the drive controller cabinets
4 -X30 (red) and -X40 (blue) in the power
direction
module.
Table 49
3) Connect one CAN bus I cable (yellow) to the
main electric cabinet –X1 and to the socket on
the underside of the drive controller cabinet -
X30 in the power module.
4) Connect one CAN bus I cable (yellow)
between the drive controller cabinet –X30 and
the drive controller cabinet –X40.

1 Pedals and joy sticks
Board Control System (BCS)
2
monitor
Fig. 179 El. connection btwn cab module and operator cab
3 Resistors on X61 terminal
– 646859
4 main electric cabinet –X1
5 Cab module
6 RH drive controller
Fig. 180
7 RH engine
8 Drive controller, LH
9 LH Engine
BL RH engine bus, blue
GN CAN bus II, green
RD LH engine bus, red
YE CAN bus I, yellow
Table 50
3746324en – (00) Page 3.3 – 83

3.3 ASSEMBLY MANUAL
Fig. 180 CAN BUS connection - 647242
Page 3.3 – 84 3746324en – (00)

3.3 ASSEMBLY MANUAL
Horn and mirror equipment to the respective socket on the

right-hand side of the superstructure frame.
1) Attach the wiring harness –X111 for the horn
(HRN, Fig. 181) and the mirror heating (MH) 3) Connect connector –X121 (CON3, Fig. 184)
to the M8 threaded studs (TST) and plug the to the power supply for the proportional valves
connector into the socket (SCK) under the of the attachment.
walkway. 4) Connect connectors (CON4 and CON5, Fig.
In countries with a warm climate the mirror 184) to the corresponding positions (2 and 8,
heating can be blanked off. Fig. 189) on the main electric cabinet -X1 in
2) Connect the two ends of the wiring harness to the cab module.
the signal horn (HRN, Fig. 181) and to the
mirror (MR). Item Figure Description
3) Also connect the horn at the right-hand side of 2

Fig. 189
the oil cooler module. 8
Item Figure Description CON1 Fig. 183 Connector
HRN Horn CON2 –

Fig. 184
CON5
MH Mirror heating
TB Fig. 183 Terminal box
MR Fig. 181 Mirror
Fig. 182
SCK Socket
TST Threaded stud
Table 51
Fig. 181 Horn and mirror connection – 649176
Lubrication system terminal box

1) Connect connector –X109.1 (CON1, Fig. 183)
to the terminal box (TB, Fig. 183) for the
lubrication system.
2) Connect connector –X108 (CON2, Fig. 184)
of the wiring harness for the proximity switch
of the stick lubrication system and other
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3.3 ASSEMBLY MANUAL
DB Fig. 185 Distribution box

SCK Fig. 186 Socket
Table 52
Fig. 183 Lubrication terminal box – 649177
Fig. 185 Air conditioning system distribution box - 649180
2) Plug connector –X185 (CON6, Fig. 186) of the

cable (CBL3, Fig. 186) into the socket (SCK,
Fig. 186) on the condenser.
Fig. 184 Lubrication system cables – 649178

Fig. 186 Condenser connections - 649181
Air conditioning system (optional)

1) Guide a cable (1, Fig. 179) from the cab Oil cooler module
module up into the operator cab. Connect it The wiring harness for the hydraulic oil cooler
(CBL1, Fig. 185) to the distribution box (DB). module is installed on the superstructure and
The cable is used to supply power to the air coiled up for shipment.
conditioning. 1) Plug connector –X107 (CON7, Fig. 187) into
If a dual air conditioning (optional) is installed, the socket (SCK). Attach the harness to the
there is an additional cable (CBL2, Fig. 185) module with the P-clamps provided (as seen
and an additional distribution box in (ADB, Fig. on Fig. 187).
185). In this case repeat step 1 to connect
them.
7 Fig. 189
Item Figure Description connector
CON7
ADB Additional distribution box Fig. 187
SCK socket
CBL1 Fig. 185
Cable Table 53
CBL2
CON6 Fig. 186 Connector
Page 3.3 – 86 3746324en – (00)

3.3 ASSEMBLY MANUAL
Hydraulic access ladder

1) Install a wiring harness (WH, Fig. 188) behind
the walkway (WW).
AP Attachment point
CON8 Connector
SB Fig. 188 Switch box
WH Wiring harness
WW Walkway
Table 54
Fig. 187 Hydraulic oil cooler module connection – 649182
2) Guide the other end of the wiring harness into

the cab module and plug the connector into
socket –X105 (7, Fig. 189).
Fig. 188 Hydraulic stairway electrical connection – - 649183
2) Guide the wiring harness to the rear of

walkway and stairway to the attachment point
(AP, Fig. 188).
3) Install the switch box (SB, Fig. 188) and
sensor in the proper position when the engine
is running, and the ladder can be hydraulically
controlled and stopped in the top position.
4) Plug the connector (CON8) into the socket on
the outer left wall of the cab module.
3746324en – (00) Page 3.3 – 87

3.3 ASSEMBLY MANUAL
Main electric cabinet -X1

1) Remove protective film from the wiring
harness connectors and plug them into the
corresponding sockets at the left-hand side of
the main electric cabinet –X1.
2) Guide the –X1 wiring harness through the
cable gland (12, Fig. 189) at the side of the
main electric cabinet –X1. Connect the
individual lines to the corresponding terminals
according to the terminal diagram and electric
schematics.
3) Connect the connectors as seen in Table 55
and Fig. 189.
Table 55 refers to Fig. 189.
Item Designation Connection

1 -X101 Operator cab platform
Plugs between cab module
2 -X122 & boom and for attachment
valves Fig. 189 Main electric cabinet connections – 646858
3 -X160 BCS in operator cab

4 -X161 BCS in operator cab Swing gearbox sensors
5 - 1) Connect pressure sensors (PS) using Table
6 -X130 LH pump gearbox 56 and Fig. 190. RH front swing motor has a
temperature sensor (TS) attached to it.
7 -X140 RH pump gearbox LH rear swing motor has pressure sensors
8 -X105 Swing motors / gearboxes (PS).
9 -X73 Hydraulic oil cooler 2) Connect all contamination switches (CS, Fig.
190) on all swing motors.
10 -X109 Lubrication terminal box
The items in Table 56 refer to Fig. 190.
11 BUS Operator cab
12 -X110 Engine switch box Item Description Function
Cable gland for X1 wiring PS -2B17, -2B18 Pressure sensors
13
harness
TS -2B19 Temperature sensor
14 -X100 LH & RH drive controllers
Table 55 CS -5B9 to -5B11 Contamination switches
Table 56
Page 3.3 – 88 3746324en – (00)

3.3 ASSEMBLY MANUAL
Connecting to ground
All modules in the machine must be connected to
each other by ground cables. Install the ground
cables as follows:
1) Between the superstructure frame, power
module and counterweight:
 (GC2, Fig. 191) on the superstructure
frame
 (GC1) on the counterweight
GC1
Fig. 191
GC2
GC3
Fig. 192
GC4
Ground cables
GC5
Fig. 193
GC6
GC7
Fig. 194
GC8
Table 57
Fig. 190 Swing gearbox sensors - 649184
Fig. 191 Ground connection 1 - 649185
2) Between the superstructure frame, power

module, and oil cooler module:
 (GC4, Fig. 192) on the superstructure
frame
 (GC3, Fig. 192) to (GC6, Fig. 193) on the
cab module
Proceed in the same way to connect the
hydraulic oil cooler module to the ground.
3746324en – (00) Page 3.3 – 89

3.3 ASSEMBLY MANUAL
3.3.23 Preparations for machine start-

up
1) Check the whole electric system. Ensure that
it is installed in accordance with the electric
schematic and terminal diagrams.
Ensure that the battery isolator

switch is switched off. Use
lockout-tagout procedure.

Fig. 192 Ground connection 2 – 649186
1 Fig. 197 Shut off valve
21 Cover plate
Fig. 196
24 Track guide
BAT1
Fig. 195 Batteries
BAT2
SL Fig. 195 Supplied lead

Table 58
2) In the power module remove the cover of the

batteries. They are located under the electric
cabinet behind the hydraulic tank.
3) Use the supplied leads (SL, Fig. 195) to
connect the batteries (BAT1 and BAT2) in
series.
Fig. 193 Hydr. access ladder, power module - cab module

interface 2 – 649187
3) Between the cab module and operator cab

threaded bolts (GC7 and GC8, Fig. 194) at
the upper left-hand side in the cab module.
Fig. 195 Connecting the batteries - 649189
4) Connect the rest of the six batteries in sets

similarly, i.e. three and four, five and six in
series.
5) Connect the three sets of batteries in parallel.
6) Ensure that all hydraulic hoses have been
connected in accordance with hydraulic
schematic and the relevant sections of this
Fig. 194 Ground connection 3 – 649188 assembly manual.
Page 3.3 – 90 3746324en – (00)

3.3 ASSEMBLY MANUAL
7) Carry out the procedures according to

Ensure that all hydraulic and
Operation and Maintenance Manual, Part 3
electric lines are installed
Inspection and servicing, Plan V. Check the
correctly. Otherwise you´ll
oil level and the condition of other operating
damage people and machine.
equipment or resources.
8) Check the pre-charge pressure of the
hydraulic accumulators according to the 16) Remove the cover plate (21, Fig. 196) under
Service Manual, Part 2.4 Pressure Setting. the crawler center support to gain access to
the track tensioning housing.
Open the gate valves in the suction
lines of the hydraulic pumps before
starting the machine for the first
time. Otherwise you will damage the
hydraulic system.
9) Ensure that all pumps have been bled

(chapter 8.2 of the Service Manual).
10) Turn the battery isolator and starter isolator
switches on.
11) Switch the reset switch (a green button) on
the -X1 main cabinet in the cab module on.
12) Switch on ignition and allow the BCS to boot.
Use the BCS to detect any faults in the wiring
installation and take corrective action.
Fig. 196 Cover - 649190
Note: Most wiring problems during assembly
are caused by bent pins or wrong connected
harnesses.
Ensure that the BCS shows no active fault
messages before starting the engines for the
first time.
13) Run the engine for 3 – 5 minutes during the
first start-up, then shut down and check all
fluid levels. Top up where necessary.
14) Use the extension function of the bucket
cylinders to bleed them.
Do not extend the cylinders too far,

as the foot pin is not yet secured,
and hoses can be damaged.
15) Bleed air from the hydraulic system and all

cylinders as described in chapter 8.2 of the
Service Manual. This ensures the soft
operation of the cylinders.
Note: You may need to top up hydraulic oil
several times while bleeding the hydraulic
system and cylinders.
By starting the machine, the hydraulic cylinder is
filled with oil and the air forced out of the system.
3746324en – (00) Page 3.3 – 91

3.3 ASSEMBLY MANUAL
17) Open the shut-off valve (1, Fig. 197) of the

track tensioning system (lever parallel to the
line).
18) Secure the shut-off valve in this position using
a cable tie or similar.
Fig. 197 Shut off valve – 643389
19) Close the housing by replacing the cover plate

(21, Fig. 196).
20) Repeat the same procedure for the other
track.
Always lubricate the bearing points
before the first commissioning.
Otherwise pin assemblies and
bearing bushes can run dry and
may be seriously damaged.
Ensure that cylinder assemblies
can extend and retract safely when
you start up the shovel.
Page 3.3 – 92 3746324en – (00)

3.3 ASSEMBLY MANUAL
3.3.24 Machine start-up Before bucket assembly

 Ensure that the working area is
Before starting the machine for the clean and level;
first time, ensure that the gate
valves in suction line of the  Ensure that the clam is resting
hydraulic pumps are opened. in a horizontally level position.
Support it with beams of
1) Start the machine. hardwood to keep it from
rocking.
2) Slowly move the cylinders in and out as
described in section “Inspection and 1) Clean the bushings (BU1 to BU3, Fig. 198), of
Servicing” of the Operation and Maintenance back wall (BW) and clam (CL). Clean and
Manual. This will fill the cylinders with prepare the corresponding pins.
hydraulic oil, the system will be ventilated, and
control will become softer. 2) Lubricate the bushings (BU1 to BU3, Fig.
198).
3) Where necessary, switch the machine off and
refill the tank. Then proceed as described 3) Attach a suitable 4-legged chain to the lifting
below. lugs (LL1 to LL4, Fig. 199) on the back wall
and raise it slowly.
Note: A great quantity of oil is consumed when
filling the cylinders. Therefore, always check the 4) Position the back wall (BW, Fig. 198) above
oil level in the hydraulic oil tank. the stationary clam (CL).
4) Ensure that the machine stands on the level Pressure locks or drops may cause
ground, lower the boom completely and sudden movements of the clam
switch off the engine. cylinders.
3.3.25 Bucket installation To prevent personal injury, stay
clear of the bucket assembly. Use
Before continuing with installing a bucket, ensure suitable auxiliary equipment.
that
To join back wall and clam:
 All hydraulic and electrical connections
5) Lower the back wall onto the clam until the
between the superstructure frame and the
hinge bores (BU1 to BU3, Fig. 198) line up.
modules are connected.
 The machine has been started and all 6) Insert the pins on both sides.
necessary functions (see chapter 3.3.23 7) Slowly lower the back wall until it rests on the
“Preparations for machine start-up”) have clam.
been tested.
 The cylinders have been bled properly (very Stay clear of the bucket assembly
important for their smooth operation during as it may rock when the center of
bucket installation). gravity shifts.
Normally a 6040 FS bucket comes fully 8) Remove the lifting gear.

assembled, i.e. clam and back wall are
connected. In this case continue with step 9)
below.
Otherwise remove packaging material and
corrosion inhibitors as described in 3.3.7
“Preparation of the modules for assembly” on
Page 8 and continue with step 1) below.
3746324en – (00) Page 3.3 – 93

3.3 ASSEMBLY MANUAL
Note: If the machine is not level, the bucket

Item Figure Description must have the same slope as the machine.
Machine and bucket must be parallel.
BP Fig. 200 Bearing point
10) Remove packaging material and corrosion
BU1 – BU3 Bushing inhibitors as described 3.3.7 “Preparation of
BW Fig. 198 Back wall the modules for assembly” on Page 8.
CL Clam
11) Remove rubber flaps (RF, Fig. 199).
12) Remove the pin cover (PC, Fig. 200) and pull
LL1 – LL4 Fig. 199 Lifting lugs
out the pin (PIN) so that it is only held by one
PC Pin cover bearing bushing (see p. 10 for details). To
Fig. 200 prevent the pin from falling out secure it with
PIN Pin additional support slings (SL).
PL Plates
Fig. 199
RF Rubber flaps
SL Fig. 200 Sling

Table 59
Fig. 200 Bucket preparation – 649246
13) Clean the bearings and pin according to

“Preparation of pins and bushings” (Page 10)
and spray them with assembly spray.
14) The stick, boom, and travel functions of the
machine can now be used to move the stick
into position.
Fig. 198 Back wall, installation and removal – 649244
15) Remove the sealing material from the stick
head cavity.
16) Align the bearing bushings of the bucket and
stick.
17) Push the pin into the bearing points.
18) Install the pin covers and tighten the bolts in
accordance with the specified tightening
method (see chapter 2.9 of the Service
Manual).
19) Reinstall the rubber flaps (RF, Fig. 199).
Fig. 199 Bucket – 649245
9) Place the bucket in front of the machine using

a crane. Ensure that it is as level as the
machine.
Page 3.3 – 94 3746324en – (00)

3.3 ASSEMBLY MANUAL
Installation of the bucket cylinders on the 3.3.26 Residual stroke

bucket
It is important that the clam cylinders (CLC, Fig.
1) Remove one pin cover from each bottom fork
202) are not fully extended when the bucket is
of the bucket cylinders.
completely closed. Otherwise the piston head can
2) Pull the pins out so that they are held by only hit the piston ring with major force inside the
one bearing bushing and clean them (see cylinder and cause damage.
“Preparation of pins and bushings” on Page
The difference between the maximum possible
10).
stroke and the actual stroke is called residual
3) Spray the bearing points and pins with stroke.
assembly spray.
Always check the residual stroke
4) Extend the bucket cylinders (BC, Fig. 201) and
before operating the bucket for the
move the stick (ST) to align the forks at the
first time.
bearing points (BP, Fig. 200) of the bucket
rear panel. Repeat such checks regularly
during the machine life and take
If necessary, use the travel forward function
corrective action if necessary.
and the stick float function simultaneously to
move the stick in and to have the bucket
cylinders suspended right above the bucket To measure the clam cylinder residual stroke
bearing points (BP, Fig. 201).
1) Close the bucket as seen in Fig. 202.
Item Figure Description 2) Ensure that the clam (CL, Fig. 202) touches the
BP Bearing point back wall (BW) along the full width of the
bucket.
BC Fig. 201 Bucket cylinder
ST Stick
Table 60 BW Back wall
CL Clam
Fig. 202
CLC Clam cylinder
DST Distance
EDG Edge
Fig. 203
RF Rubber flaps
Table 61
Fig. 201 Bucket assembly – 649247
5) Insert the pins and screw on the pin covers in

Manual).
6) Connect hydraulic hoses and install missing
lubrication tubes between stick and bucket.
The machine is now ready for test operation.
Fig. 202 Residual stroke – 649248
3) Remove the rubber flaps (RF, Fig. 203).
3746324en – (00) Page 3.3 – 95

3.3 ASSEMBLY MANUAL
4) Measure the distance (DST, Fig. 202) using a 3) Check the lubricant fill level of the swing
tape measure. bearing: turn the superstructure 360° and
check whether the lubricant has spread across
5) Compare the measured distance (DST, Fig.
the entire height of the swing bearing. If
202, residual stroke) with the specifications in
necessary, top up the lubricant through the
our Service Information. Refer to Media-No.
opening in the swing bearing cover (see the
EM027833, which can be downloaded from
"Inspection and Maintenance" chapter in the
Caterpillar Service Information System (SIS,
Operation and Maintenance Manual).
http://sis.cat.com).
4) Install the switch box (4, Fig. 204) and sensor
for the proximity switch of the hydraulic access
ladder. Raise the hydraulic access ladder
slowly until it is in the top position. Adjust the
sensor until the yellow LED in the switch is on,
i.e. the switch is energized. Fix the sensor in
this position.
5) The excavator is now ready for machine start-
up, commissioning, and functional testing.
Fig. 203 Residual stroke 1 - 649249
If the residual stroke exceeds the distance

specified in the Service Information with Media-
No. EM027833, apply material to the edge of the
bucket (EDG, Fig. 203). In this case, please
contact the service department of Caterpillar
Global Mining HMS for additional information or
see DSN and/or our Service Manual, chapter 20
“Welding for maintenance and repair”.
3.3.27 Last preparations for machine

start-up
Carry out the following steps after bucket
installation, when the machine is completely Fig. 204 Main electric cabinet connections – 646858
assembled:
1) Check oil, lubricant, and coolant levels.
2) At all main bearing points (boom base, boom
head), disconnect the lubrication lines and fill
the bearing points with lubricant using an
external lubrication pump. This eliminates the
time-consuming filling procedure using the
machine lubrication pump.
If the bearing points are not

sufficiently lubricated prior to the
first commissioning, the pin
assemblies and bearing bushings
can run dry and be seriously
damaged.
Page 3.3 – 96 3746324en – (00)

3.3 ASSEMBLY MANUAL
3.3.28 Bucket removal and

reinstallation
Bucket removal
Before removal ensure that
 the working area is clean
and level;
 the bucket back wall is in a
vertical position and the full
width of the clam touches
the ground.
Fig. 205 Connection between bucket and bucket cylinder –

Preparation 649250
1) Place the bucket on level ground. The stick, 4) Remove lubrication lines from the bucket
bucket cylinders and bucket back wall should cylinder foot fork.
be vertical. 5) Pull the bucket cylinder foot pins towards the
2) The full width of the clam should contact the outside (open pin cover side) until the forks
ground below. If necessary, use the machine are no longer pinned to the bucket and the
bucket function to push some ground out of pins rest in only one bushing.
the way. If the surface to rest the bucket on 6) Now the bucket cylinders foot side should now
and the machine are parallel it is easier to no longer be connected to the bucket. Start
uniformly take the weight off the bucket main the machine and retract the bucket cylinders
pin. (BC, Fig. 205)) about 500mm.
3) Remove the outer pin covers (PC, Fig. 205) of 7) Push the bucket cylinder foot pins back in so
both bucket cylinder foot connections. Loosen that they rest in both bushings. Replace the
the pin covers on the inner side to prevent a pin covers (PC) to secure the pins. Retract the
vacuum when pulling pins. bucket cylinders (BC) completely to get them
out of the way.
8) Secure the bucket cylinders in such a way that
BC Fig. 205 Bucket cylinder they cannot creep down during bucket
removal.
9) Ensure that the hydraulic system has been de-
HH Hydraulic hoses pressurized (see chapter 8.2 of the Service
Fig. 205
PC Pin cover Manual).
10) Disconnect the hydraulic hoses (HH) from the
PIN Fig. 206 Pin
hydraulic manifold in the bucket back wall.
RF Fig. 205 Rubber flaps Leave the other ends connected to the pipes
on the stick bottom chord. Seal open hoses
SL Fig. 206 Sling with adequate blanking plugs.
Table 62
Note: The hoses must be sealed well to
prevent oil from leaking out when the machine
is operated in step 14). s
11) Disconnect the two main lubrication lines
between stick bottom chord and bucket back
wall.
12) Remove the rubber flaps (RF, Fig. 205)
covering the clam cylinder cavity.
13) Remove the bucket main pin covers (PC, Fig.
205).
3746324en – (00) Page 3.3 – 97

3.3 ASSEMBLY MANUAL
14) Start the machine and manipulate the Removal of the bucket back wall
attachment in such a way that the pin has no
weight resting on it. Always support the side walls of the
15) Pull the pin (PIN, Fig. 206) until it is supported bucket clam for transport and for
in only one side of the bearing point (BP) and welding (to prevent distortion under
the stick is no longer pinned to the bucket. To heat influence).
prevent the pin from falling out on the ground
secure it with additional support slings (SL).
1) Support the side walls of the clam with
16) Move the attachment so that it is well clear of
sufficiently sturdy U-bars or similar (U, Fig.
the bucket.
207).
To prevent personal injury move Item Figure Description

away from hanging components.
BU1 – BU3 Bushing
Fig. 210
BW Back wall
17) To ensure unobstructed work on the bucket,
CL Fig. 207 Clam
move the machine away from the bucket.
Alternatively swing 90 degrees. This will ease CLC Clam cylinder
the reinstallation if the same bucket is installed
again later. FK Fork
Fig. 208
18) Reinsert the pin (PIN, Fig. 206) and close the FP Fork pins
pin covers (PC).
LBL Lubrication lines
19) Protect the pin from weather impacts and
damage with suitable material. LL1 - LL4 Fig. 209 Lifting lugs
SW Fig. 207 Side walls
PL Fig. 209 Plate
PRP Pin retainer plates

Fig. 208
SL Sling
U Fig. 207 U-bars

Table 63
Fig. 206 Pin between stick and bucket – 649246
Fig. 207 Clam support – 649257
2) Weld the bars to the side walls (SW, Fig. 207)

and the bottom of the clam (CL). Refer to the
Repair Welding Manual.
Page 3.3 – 98 3746324en – (00)

3.3 ASSEMBLY MANUAL
3) Remove the rubber flaps (RF, Fig. 209) from

both sides of the bucket if they have been
reattached after bucket removal.
4) Open the plates (PL, Fig. 209) on both sides
of the bucket back wall.
Pressure peaks or drops may cause

sudden movements of the clam
cylinders.
To prevent personal injury, stay
clear of the clam and bucket
assembly. Use suitable auxiliary
equipment.
Fig. 209 Bucket – 649245
5) Remove any lubrication lines (LBL, Fig. 208)
connected to the clam cylinder fork.
6) Remove pin retainer plates (PRP, Fig. 208).
7) Attach a sling (SL, Fig. 208) to the clam
cylinder (CLC). Raise the clam cylinder with a
crane until the sling is tight.
8) Remove the fork pins (FP, Fig. 208).
9) To prevent damage to the clam cylinders,
support them by beams of hardwood.
Fig. 210 Back wall, installation and removal – 649244
Fig. 208 Clamshell cylinder - 649258
10) Repeat steps 5) - 9) to remove the clam

cylinder on the other side.
11) Attach a 4-legged chain of suitable capacity to
the 4 lifting lugs (LL1 to LL4, Fig. 209) on the
bucket back wall. Use a crane to raise the
back wall off the hinge pin connecting back
wall and clam until the back wall is in a nearly
horizontal position.
12) Remove the hinge pins with suitable auxiliary
equipment.
13) Raise the bucket back wall (BW, Fig. 210) and
place it aside.
3746324en – (00) Page 3.3 – 99

3.3 ASSEMBLY MANUAL
Bucket reinstallation Item Figure Description
BC Fig. 212 Bucket cylinder

Before reinstallation
 Ensure that the working area is
clean and level; CL Fig. 215 Clam
 Ensure that the clam is resting CLC Clam cylinder

in a horizontally level position.
Support it with beams of FK Fig. 213 Fork
hardwood to keep it from FP Fork pins
rocking.
HH Fig. 212 Hydraulic hoses
 Check the installation
components for damage and LBL Fig. 213 Lubrication lines
take corrective action if
necessary. LL1 - LL4 Fig. 214 Lifting lugs
PC Pin cover
Fig. 211
1) Clean the bushings (BU1 to BU3, Fig. 210), of PIN Pin
the back wall (BW) and clam (CL). Clean and
PL Fig. 214 Plate
prepare the corresponding pins.
2) Lubricate the bushings (BU1 to BU3, Fig. PRP Fig. 213 Pin retainer plates
210). RF Fig. 212 Rubber flaps
3) Attach a suitable 4-legged chain to the lifting
SL Fig. 211 Sling
lugs (LL1 to LL4, Fig. 209) on the back wall
and raise it slowly. SW Side walls
Fig. 215
4) Position the back wall (BW, Fig. 210) above U U-bars
the stationary clam (CL).
Table 64
Pressure locks or drops may cause

sudden movements of the clam
cylinders.
To prevent personal injury, stay
clear of the bucket assembly. Use
suitable auxiliary equipment.
To join back wall and clam:

5) Lower the back wall onto the clam until the
hinge bores (BU1 to BU3, Fig. 210) line up.
6) Insert the pins on both sides.
7) Slowly lower the back wall until it rests on the
clam.
Fig. 211 Pin between stick and bucket – 649246
Stay clear of the bucket assembly
as it may rock when the center of 11) Install the pin cover on the opposite side of the
gravity shifts. bucket pin bushing leaving a gap. When you
push in the pin, the pin cover will stop the pin
and the air can escape through the gap.
8) Remove the lifting gear.
12) Fill the stick head cavity with lubricant as
9) Remove the main pin covers (PC, Fig. 211). described in section “Preparation of pins and
10) Pull out the pin (PIN, Fig. 211) until it is bushings” (Page 10) or remove the sealing
supported in only one bucket bushing (BP). To material.
prevent the pin from falling out secure it with
additional support slings (SL).
Page 3.3 – 100 3746324en – (00)

3.3 ASSEMBLY MANUAL
13) Manipulate the attachment to line up the bores 22) Insert the fork pin (FP, Fig. 213) and install the
in stick and bucket as described in chapter pin retainer plate (PRP).
3.3.25 Bucket installation.
23) Connect lubrication lines (LBL, Fig. 213) to the
14) Push in the pin and install pin covers in clam cylinder forks (FK).
Manual).
15) Connect the clam supply hoses (HH, Fig. 212)
between stick bottom chord and attachment
control manifold (see hydraulic schematics).
Fig. 213 Clamshell cylinder - 649258
24) Install the cover plates (PL, Fig. 214)

25) Install the rubber flaps (RF, Fig. 214).
Fig. 212 Connection between bucket and bucket cylinder –

649250
16) Connect main lubrication lines (LBL, Fig. 213)

from the stick bottom chord to the bucket back
wall.
17) Attach a sling (SL, Fig. 213) to one clam
cylinder (CLC) and raise it slowly with a crane.
Remove the hardwood beam previously used
to support the cylinder.
18) Activate clam cylinder extension slowly until
the fork (FK, Fig. 213) and clam bearing points
line up. One of the clam cylinders will extend Fig. 214 Bucket – 649245
before the other. Start with this cylinder.
26) Remove the welded support beams (U, Fig.
In case the second clam cylinder begins to 215) from the clam using a cutting torch and
extend, ensure that it cannot damage ports or grind smooth. If hard facing strips were
components: secure the fork of the second removed in the factory to accommodate the
clam cylinder to the cylinder with a steel cable. support bars, these strips need to be welded
19) Insert the fork pin (FP, Fig. 213) and install the into place to complete the buckets hard facing.
pin retainer plate (PRP). Refer to the welding instructions supplied in
chapter 20 of the Service Manual.
20) Attach sling (SL, Fig. 213) to the second
cylinder (CLC) and raise it with the crane. 27) Check contact surfaces of the clam and back
Remove the hardwood beam previously wall. This procedure is described in our
supporting the cylinder. Service Information. Refer to Media-No.
EM027833, which can be downloaded from
21) Remove the steel cable from the second Caterpillar Service Information System (SIS,
cylinder. Repeat the procedure described in http://sis.cat.com).
step 14) to align clam cylinder fork (FK, Fig.
213) and clam bearing point.
3746324en – (00) Page 3.3 – 101

3.3 ASSEMBLY MANUAL
Ensure that the bucket parts close

completely, otherwise you will
damage the clam cylinders.
Fig. 215 Clam support – 649257
Page 3.3 – 102 3746324en – (00)

Assembly Procedure For 6040 AC FS Machine DHX: EM030331-00 (En-Us)

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Assembly Procedure For 6040 AC FS Machine DHX: EM030331-00 (En-Us)

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EM030331-00 (en-us)

3.3 Assembling the excavator

3.3.2 Safety instructions ......................................................................................................................... 3

3.3.3 Personnel ........................................................................................................................................ 4

3.3.4 Assembly equipment ..................................................................................................................... 5

3.3.5 Modules on arrival.......................................................................................................................... 6

3.3.6 Assembly site ................................................................................................................................. 6

3.3.7 Preparation of modules for assembly .......................................................................................... 8

3.3.8 General assembly procedures ...................................................................................................... 9

3.3.9 Workflow chart of assembly procedure ..................................................................................... 12

3.3.10 Preparation of undercarriage and superstructure modules .................................................... 13

3.3.11 Undercarriage assembly ............................................................................................................. 17

3.3.12 Installation of High Voltage (HV) bracket .................................................................................. 28

3.3.13 Preparations for superstructure installation ............................................................................. 29

3.3.14 Installation of superstructure frame........................................................................................... 33

3.3.15 Installation of swing gearboxes.................................................................................................. 37

3.3.17 Boom installation ......................................................................................................................... 40

3.3.18 Installation of modules and components to superstructure frame ........................................ 49

3.3.19 Stick installation ........................................................................................................................... 72

3.3.20 Final steps of boom installation ................................................................................................. 74

3.3.21 Top up operating fluids ............................................................................................................... 81

3.3.22 Electric system ............................................................................................................................. 81

3.3.23 Preparations for machine start-up ............................................................................................. 90

3.3.24 Machine start-up........................................................................................................................... 93

3.3.25 Bucket installation ....................................................................................................................... 93

3.3.26 Residual stroke............................................................................................................................. 95

3.3.27 Last preparations for machine start-up ..................................................................................... 96

3.3.28 Bucket removal and reinstallation.............................................................................................. 97

3746324en – (00) Page 3.3 – 1

Page 3.3 – 2 3746324en – (00)

3.3.1 Overview 3.3.2 Safety instructions

About this Assembly Manual Warnings and symbols

Illustrations Safety requirements

In addition, schedule approximately five working

3746324en – (00) Page 3.3 – 3

Personal protective equipment and work Commissioning during assembly

Provide the regulations in the local Mandatory personnel requirements:

Page 3.3 – 4 3746324en – (00)

 Define clearly and particularly the individual Required

3746324en – (00) Page 3.3 – 5

Equipment for personnel 3.3.6 Assembly site

Place the superstructure frame (4, Fig. 1) on

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Item Figure Description Item Figure Description

3 Right crawler, complete 14 Stick cylinders

4 Superstructure frame Crate with smaller parts

8 Oil cooler module 22 High Voltage bracket

Fig. 1 f Modules arrangement on assembly site – 649439

Leave min. 1 – max. 1.5 m space

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3.3.7 Preparation of modules for Do not clean threaded bores with

 Remove all packaging and corrosion inhibitors

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Clean pins and bushings carefully.

10) Apply grease to the bushing (BU, Fig. 3). Use

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Store the blanking caps for future maintenance

Fig. 4 Pin cover with silicone – 647223

Always use the sealant currently

LOCTITE® 518TM is a one-part heat curable epoxy.

LOCTITE® 518TM has can be obtained from the

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