BLOCK 2111044 - Caterpillar

Image1.33.1
23. Refer to Image1.34.1 and Image1.37.1. Place and weld the appropriate front boom pivot gusset plate (119) on the front side of boom (117). Ensure drain hole (107) is oriented to the top.
Image1.34.1
24. Refer to Image1.35.1 and Image1.38.1. Weld hose guides 118a & 118b on the front of the boom (117).
Image1.35.1
25. Inspect welds using the magnetic particle or dye-penetrant inspection methods to assure there are no cracks or deformities. If any cracks or deformities exist, grind to remove affected area and repeat the weld and inspection procedures.
26. Mask the surfaces or parts which are unaffected before painting.
27. Clean, prime and paint the affected areas.
Front and Rear Boom Pivot Plate Weldment
Image1.37.1
Hose Guide Weldment
Image1.38.1
28. Using suitable slings and a hoist or crane with a minimum lift capacity of 10,000 lb (4536 kg), turn boom over to the bottom side by repositioning the slings and set on level ground or supports.
Note: Verify that the sling does not interfere with the extend/retract cylinder or any hydraulic tubes.
29. Refer to Image1.40.1. Using slings, balance the boom assembly, lift and carefully guide the boom into place. Align the frame pivot bores with the boom assembly pivot bores. Install boom pivot pin (110) and lock bolt.
Image1.40.1
30. With the sling still in place, install the compensating cylinder pin, (109) and lock bolt.
31. With the sling still in place, install the lift/lower cylinder pin, (108) and lock bolt.
32. Refer to Image1.41.1. Uncap and connect the previously labeled extend/retract cylinder hoses (111) to the appropriate tube connection.
Image1.41.1
33. Uncap and connect the previously labeled tilt hoses (112) and auxiliary hoses (113) to the appropriate tube connection.
34. Connect all electrical connections to the boom assembly.
35. Refer to the appropriate Service Manual, install the boom angle sensor rod. The sensor will require re-calibrating before the machine is placed back in service.
36. Remove slings and supports.
37. Refer to Image1.42.1 and Image 1.42.2. Clean the boom holes (120), and surrounding area at the rear of the first boom section. Verify all holes are clean and free of any cleaning residue. Apply Silicone, Dow Corning 700 Industrial Grade or equivalent, completely filling the upper cavity (1) of the three Boom plugs (115) P/N 513-5090.
Image1.42.1
Image1.42.2
38. Refer to Image1.43.1 and Image1.43.2. Install Plugs (115) in each of the three boom holes. Drive each Plug (115) flush with the top of the boom plate. Clean any excess silicone from around each plug.
Image1.43.1
Image1.43.2
39. Properly connect the battery.
40. Start the engine and operate all of the boom functions several times, ensure proper operation.
41. Retract and lower the boom assembly and shut off engine.
42. Check for fluid leaks. Check the hydraulic fluid level in the tank and add as required.
43. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine.
44. Remove the Do Not operate Tag from both the ignition key switch and the steering wheel.
45. Return the machine to service.