REHS3315

CATERPILLAR 15 November 2006

Special Instruction
02645076

NOTICE
Installation of Ripper (S/N: 404) When a hoist is used to lift any part or assembly
stand clear of the rea. Always make sure the hoist
S M C S Code: 6310
has the correct capacity. Approximate weights of the
components are shown in the chart.
Track-Type Tractor
D6K (S/N: DHAI-Up; FBH1-Up)
Weights
Table of Contents Table 1

Introduction 1 Approximate Weights

Safety 1 Item Weight
Weights 1
Installation of Ripper 2 Tooth Group 33 kg (75 lb)(i)
Necessary Parts 2 Carriage Assembly 365 kg (805 Ib)
Installation Procedure 3
Lower Link 142 kg (315 Ib)
Introduction Upper Link 29 kg (65 lb)(2)

Mounting Group 100 kg (220 Ib)

This Special Instruction provides the procedure for
installation of the Ripper Cylinder Group 82 kg (180 Ib)
(1) Weight for One Ripper Tooth
Note: Each section contains the related parts list. (2) Weight for One upper Link

After assembly is complete, prepare the machine for

service.

Read the Information and understand the Information

in this publication before you perform any procedures.

Safety

A WARNING
Do not attempt to assemble this machine until you
have read and understand the assembly instruc-
tions. Improper procedures could result in injury
or death.

NOTICE
Do not let any dirt or foreign material get into the
hydraulic system during assembly or maintenance
operation. Keep the oil in the hydraulic system at the
correct level to prevent pump cavitation.

1
Installation of Ripper Table 3
240-1471 Ripper
Necessary Parts
Item Part Description Quantity
Table 2 Number

240-1476 Ripper IVIounting Group 20 2K-0703 Bar 1

Item Part Description Quantity 21 3B-8489 Hydraulic 11
Number Fitting

1 9N-4449 Spacer 12 22 3K-8510 Pin 1

2 9N-4450 Spacer 4 23 4K-3004 Bearing 2

3 193-3074 Spacer 4 24 9N-4449 Spacer 6

4 193-3075 Spacer 10 25 9N-4450 Spacer 2

5 240-1486 Bracket 1 26 193-3074 Spacer 4

Assembly 27 193-3075 Spacer 10.
6 240-1487 Bracket 1 28 240-1472 Link 1
Assembly Assembly
7 240-1490 Pin 2 240-1477
29 Carriage 1
8 240-1491 Pin 2 Assembly

9 240-1494 Bracket 1 30 240-1478 Link 2

Assembly Assembly

10 240-1495 Bracket 1 31 240-1490 Pin 2

Assembly 32 240-1491 Pin 2
11 6K-8987 Dowel 2 3B-5325
33 Cotter 1
12 6V-7744 Locknut 2 6V-7744
34 Locknut 2
13 7X-2575 Bolt 8 7X-2543
35 Bolt 2
14 8T-1482 Washer 8 Bolt
36 8T-4139 2
15 81-4167 Washer 8 37 81-4223 Washer 18
16 81-4198 Bolt 2 38 8T-4244 Nut 10
17 81-4244 Nut 2 81-4648 Bolt
39 8
18 81-5041 Bolt 2
40 8T-7930 Bolt 2
19 81-5878 Bolt 8
Table 4
227-0842 Ripper Lift Cylinder
Item Part Description Quantity
Number
41 230-4873 Cylinder 1
Assembly
42 1P-4576 Flange 4
43 8T-4196 Bolt 8
44 8T-4121 Hard 8
Washer
45 5H-4018 Cover 2
46 4J-5267 Seal 2

2
Table 5
253-1698 Ripper Lines Gp
Item Part Description Quantity
Number
47 1L-5081 Spacer 1
48 5P-8501 Padlock 1
Group
49 9M-2904 HoseClamp 2
50 112-4368 Shieid 4
51 130-1977 Shieid 4
52 130-9192 Grommet 2
53 253-7673 Hose As 1
54 253-7674 Hose As 1
55 148-8418 Reducer 2
56 4J-5267 0-Ring Seal 2
57 5P-7466 Clip 1
58 5P-7467 Clip 1
59 5P-8112 Grommet 1
60 6V-8556 Nut 2
61 8T-4121 Hard 8
Washer
62 8T-4186 Bolt 7
63 8T-6466 Bolt 1

Table 6
8J-1434 Ripper Tooth
Item Part Description Quantity
Number
64 3B-5325 Cotter 2
65 2K-6413 Pin 1
66 9J-6586 Shank 1
67 136-8308 Pin 1
68 6Y-0309 Tip 1
69 114-0359 Retainer
Assembly

Installation Procedure

Note: Clean all parts. Remove paint from any mating

surfaces.

1. Remove the drawbar from the machine (if

equipped).

Note: The weight of the drawbar is 89 kg (200 Ib).

3
lllustration 1 gOi 3 2 7 5 6 9

2. Install two dowels (11) in the machine frame for

the lower links. The dowels should be installed to
a depth of 25.0 1.5 mm (0.98 0.06 inch).

3. Use bolts (-13) and washers (14) in order to install

bracket assemblies (9) and (10). Use spacers (1)
and (2), a s required. Tighten bolts (13) to a torque
of 900 100 N m (665 + 75 Ib ft).

4. Use bolts (18) and nuts (17) in order to install pins

(7). Do not tighten the bolts at this time.

5. Use bolts (19) and washers (15) in order to install

bracket assemblies (5) and (6). Use spacers (3)
and (4), a s required. Tighten bolts (19) to a torque
of 900 100 N m (665 75 Ib ft).

6. Use bolts (16) and locknuts (12) in order to install

pins (8). Do not tighten the bolts at this time.

A
 26, 27, 32
38, 40
lllustration 2
7. Use fittings (21), pins (8), bolts (16), and locknuts
(12) in order to install link assemblies (28) to
bracket assemblies (5) and (6). Tighten bolts (16)
to a torque of 60 12 N m (44 9 Ib ft). Install
the other end of link assemblies (28) to carriage
assembly (29), using pins (32), bolts (35), spacers
(26) and (27), and locknuts (34). Install cotter (33).
Note: Insert pins (8) into bracket assemblies (5) and
(6). Be sure that the holes in the pins and the holes
in the bracket assemblies are aligned horizontally
Insert pins (32) into carriage assembly (29). Be sure
that the holes in the pins and the holes in the carriage
assembly are aligned vertically
5
24, 25
gOl328389
8. Use fittings (21), pins (7), bolts (18), spacers
(24) and (25) and nuts (17) in order to install link
assemblies (30) to bracket assemblies (9) and
(10). Use spacers (24) and (25), a s required.
Tighten the bolts (18) to a torque of 105 20 N m
(77 15 ft). Use pins (31), bolts (40), and nuts (38)
in order to install the other end of link assemblies
(30) to carriage assembly (29).
Note: Insert pins (7) into bracket assemblies (9) and
(10). Be sure that the holes in the pins and the holes
in the bracket assemblies are aligned horizontally
Insert pins (31) into carriage assembly (29). Be sure
that the holes in the pins and the holes in the carnage
assembly are aligned vertically
9. Put stands or blocks under carriage assembly (29)
in order to hold the carriage in a level position
during assembly
10. Use bearings (23), fittings (21), bolts (39), nuts
(38), and washers (37) in order to instal the head
end-of cylinder (41) to carriage assembly (29).
Tighten bolts (39) to a torque of 105 20 N m
( 8 0 15 Ib ft).

gOl328699
lllustration 3

11. Remove flanges (42), bolts (43), washers (44),

covers (45) and seis (46) from cylinder assembly
(36).

Note: Covers (45) and seis (46) are for shipping

and storage.
7
 56, 60 56, 60
lllustration 5
12. Remove two plugs and two seis from tubes at
rear of machine. These items are for shipping and
storage.
Note: Items that are not numbered are part of the
lines group for the ripper. The items are already on
the machine.
13. Connect hose assemblies (53) and (54) to the
hydraulic lines at the rear of the machine. Use
reducers (56), and nuts (61).
14. Install hose assembly (53) to the rod end of
cylinder assembly (41 ), using seal (56), flanges
(42), shields (50), bolts (62) and washers (61).
Note: Install hose clamp (49) on hose assembly
before connecting the hose assembly to the head
end of the cylinder assembly. Do not tighten the hose
clamp at this time.
8
gOl328877
15. Install shields (51) and grommet (52) on hose
assembly (53). Tighten hose clamp (49).
16. Install hose assembly (54) to the head end of
cylinder assembly (41), using seal (56), flanges
(42), shields (50), bolts (62) and washers (61).
Note: Install hose clamp (49) on hose assembly
before connecting the hose assembly to the head
end of the cylinder assembly. Do not tighten the hose
clamp at this time,
17. Install shields (51) and grommet (52) on hose
assembly (54). Tighten hose clamp (49).
18. Use grommet (59), clips (57) and (58), spacer
(47), washer ( 6 1 ) and bolt (63) in order to attach
hose assembly (54) to cylinder assembly (41).
19. Remove support under carriage assembly (29).
Raise or lower the carriage assembly .in order
to align the holes in the cylinder rod eyes with
the holes in link assembly (30). Connect cylinder
(41) to carriage assembly (29) with fittings (21),
pins (22), bar (20), bolts (36), and washers (37).
Tighten bolts (36) to a torque of 105 20 N m
(80 15 Ib ft).

Note: Insert pins (27) into carriage assembly (33).

Be sure that the holes in the pins and the holes in the
carriage assembly are aligned horizontally

20. Tighten all hose clamps. Check all connections

for leaks and make repairs, if necessary.

21. Check the oil level in the hydraulic tank and fill
the tank, if necessary. Cycle the cylinder in both
directions in order to purge air from the lines and
from the cylinder. Refill the hydraulic tank to the
F U L L mark.

23. Make sure that carriage assembly (29) is well

supported. Install ripper tip (68) with retainer (69)
and pin (67).

24. Prepare the machine for operation. Refer to

Operation and Maintenance Manual for further
Information.