Caterpillar Cat 215B EXCAVATOR (Prefix 4FC) Service Repair Manual (4FC00001 and up)

1
Service Repair Manual
Models 215B EXCAVATOR
2
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Product EXCAVATOR Model 215B EXCAVATOR
4FC Configuration 215B SA EXCAVATOR 4FC00001-UP
(MACHINE) POWERED BY 3304 ENGINE
Disassembly and Assembly 215 EXCAVATOR VEHICLE
SYSTEMS Media Number -SENR2172-00 Publication
Date -01/02/1982 Swing Drive SMCS - 5459-16
5459-11 5459-12 5459-15
Date Updated -11/10/2001

• Remove Swing Drive
• start by
• remove swing motor
• remove swing brake
• 1. Lower the level of the hydraulic tank below
  the sight gauge level.

1. Disconnect hose assembly (1) from the hydraulic
   tank.
2. Install one 5/8"-11 NC and one 1/2"-13 NC forged
   eyebolt in the swing drive as shown.
3. Fasten a hoist to the swing drive.
4. Remove the bolt and clip (4) from the swing drive.

3

1. Remove the two bolts and clamp (2) that hold the
   brake cable in position.
2. Remove four bolts (3) that hold the swing drive
   to the upper frame.
3. Lift the swing drive until the pinion on the
   output shaft is above the hole in the upper
   frame. Remove the swing drive. The weight of the
   swing drive is 520 lb. (234 kg).

Install Swing Drive
1. Install one 5/8"-11 NC and one 1/2"-13 NC
forged eyebolt in the swing drive. Put 4S9416
Anti- Seize Compound on the finished surfaces of
the cartridge. Fasten a hoist and put the swing
drive in position on the upper frame. Install
the four bolts (1) that hold the swing drive to
the upper frame.

• Install clamp (2) and the two bolts that hold the
  clamp.
• Install the clip and bolt (3) to the swing drive.
• Connect hose assembly (4) to the hydraulic tank.
• Fill the hydraulic tank to the correct level
  after installation of the swing motor. end by
• install swing brake
• install swing motor

Disassemble Swing Drive
4
start by a) remove swing drive
1. Drain the oil from the swing drive. Fasten a
hoist and put the swing drive in position on tool
(A).
2. Remove five bolts (1) that hold bearing cage
(2) to the swing drive cover.
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3. Remove O-ring seal (3) and shims (4) from
bearing cage (2).
4. Remove the four bolts that hold bearing cage
(5) in place. Install two 5/8"-11 NC forcing
screws and remove bearing cage (5) and the shims.
5. Remove bearing cup (6) from the bearing cage
with tooling (B). Remove O-ring seal (7) from the
bearing cage.
6. Remove the six bolts that hold bearing cage
(8) to the swing drive cover. Install two 1/2"-13
NC forcing screws and remove bearing cage (8)
and shims (9) from the swing drive cover.
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7. Remove bearing cup (10) from the bearing cage
with tooling (C). Remove O-ring seal (11) from
the bearing cage.
8. Turn the bearing cage over and remove lip type
seal (12) from the bearing cage with tooling (D).

1. Remove the bolts from swing drive cover (13).
2. Install three eyebolts (14), one each 3/8"-16 NC,
   7/16"-14 NC and 1/2"-13 NC in the swing drive
   cover. Fasten a hoist and remove the cover. The
   weight of the cover is 78 lb. (35 kg).

11. Turn cover (13) over and remove bearing cup
(15) with tooling (C).
12. Remove gear (16) from the housing assembly.
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13. Install tooling (E) and remove bearing cone
(17) from gear (16). Remove gear (18).
14. Remove bearing cone (19) with tooling (F)
from gear (16).
15. Remove gear (20) from the housing.

1. Remove the bearing cones from each side of gear
   (20) with tooling (F).
2. Remove gear (21) from gear shaft (20).

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18. Remove pinion gear (22) from the housing.
19. Remove the bearing cones from pinion gear
(22) with tooling (E).
20. Remove bolts (23), locks (24), retainer (25)
and the shims from the output shaft.
21. Install a 5/8"-11 NC forged eyebolt in the
output shaft. Fasten a hoist to hold it in place.
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22. Remove twelve bolts (26) that hold cartridge
assembly (27) to the housing. Remove the
cartridge assembly. The weight of the cartridge
assembly is 200 lb. (90 kg).
23. Remove gear (28) from the output shaft with
tooling (H).
24. Remove three bolts (29), the lock and
retainer (30). Remove the O-ring seal.
25. Remove pinion (31), O-ring seal (32),
retainer (33) and Duo-Cone seal (34).
26. Install tooling (J) and push the shaft out of
the bearing cone. Remove the bearing cone from
the cartridge.
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27. Remove shaft (35) and bearing cone (36) from
the cartridge.
28. Remove bearing cone (36) from shaft (35) with
tooling (K).

1. Remove bearing cup (37) from the cartridge with
   tooling (L).
2. Remove the bearing cup from the other end with
   tooling (C).

31. Remove bearing cups (38), (39) and (40) with
tooling (G) from the housing.
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Assemble Swing Drive
1. Make sure all parts are clean. Inspect all
O-ring seals for damage and make replacement if
needed.
2. Heat bearing cone (2) to a maximum temperature
of 275F (135C). Start the bearing cone on
shaft (1). NOTE The bearing cone will be pushed
into correct position when the pinion is
installed.
3. Install Duo-Cone seal (3) with tool (A) in
retainer (4). NOTE The rubber seals and all
surfaces that make contact with the seals must be
clean and dry. After installation of the seals,
put oil on the contact surfaces of the metal
seals.
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4. Install O-ring seal (5) in retainer (4).
Install the retainer on the shaft.
5. Put 2P2506 Anti-Seize Compound on the shaft
and pinion splines. Install pinion (7) on the
shaft. Install retainer (6) on the pinion.
6. Use a press and push the bearing cone and gear
into position on the shaft. NOTE The pinion and
bearing cone are in correct position when the
retainer is against the end of the shaft.
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7. Remove retainer (6). Put lubrication on the
O-ring seal and install O-ring seal (8). Install
the retainer. Install the lock and three bolts
that hold the retainer. Tighten the bolts a small
amount.
8. Lower the temperature of bearing cup (9).
Install the bearing cup in cartridge (10).

• Turn the cartridge over. Lower the temperature of
  bearing cup (12). Install the bearing cup in the
  cartridge.
• Install Duo-Cone seal (11) with tooling (A) in
  the cartridge.
• NOTE The rubber seals and all surfaces that make
  contact with the seals must be clean and dry.
  After installation of the seals, put oil on the
  contact surfaces of the metal seals.

15
11. Lower cartridge (10) into position on the
shaft.
12. Heat bearing cone (12) to a maximum
temperature of 275F (135C). Put the bearing
cone in position on the shaft.
13. Install the gear on the shaft. Put three
pieces of solder (13) with a diameter of .059 in.
(1.50 mm) on the end of the shaft between the
bolt holes as shown. Install retainer (14) and
the three bolts that hold the retainer. Tighten
the bolts to 60 lb.in. (6.8 Nm). Remove the
bolts and the retainer. Measure the thickness of
the solder.
16
Put the retainer and bolts in position on the
shaft to hold the gear in position while the
unit is put on tool (B). The gear can fall off
the shaft if the bolts and retainers are not
used to hold it and serious personal injury be
the result.

1. Fasten a hoist to the cartridge and put the
   cartridge in position on tool (B). Install shims
   (15) that are the same thickness as the average
   thickness of the solder minus .004 to .007 in.
   (0.10 to 0.18 mm).
2. Install retainer (14) on the end of the shaft.
   Install the lock and two of the bolts that hold
   the retainer in place. Tighten the two bolts a
   small amount. Put a 5/8"-11 NC forged eyebolt in
   the other bolt hole.

16. Tighten the pinion bolts on the other end of
the shaft to a torque of 222 20 lb.ft. (298
25 Nm). Bend the locks.

1. Lower the temperature of bearing cups (16) and
   install the bearing cups in the swing drive
   housing.
2. Put 7M7260 Liquid Gasket on the surfaces that
   make contact with the cartridge assembly and
   housing.

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19. Fasten a hoist to the cartridge assembly and
put it in position in the housing.
20. Install the twelve bolts (17) that hold the
cartridge to the housing. Tighten bolts to a
torque of 200 20 lb.ft. (270 25 Nm).
21. Put a brass bar (18) that is 4 1/2 in. (11.4
cm) in length and 1 1/2" (3.81 cm) in diameter
between the housing and gear. Remove the eyebolt
and install the last bolt. Tighten bolts (19) to
a torque of 222 20 lb.ft. (298 25 Nm). Bend
the locks except for one. NOTE Make five
revolutions of the output shaft with a torque
wrench. Check the torque needed to keep the
shaft in rotation. The torque must be 13 3
lb.ft. (18 4 Nm). Make an adjustment to the
shims if needed. Bend the lock.
22. Heat bearing cones (20) and (22) to a maximum
temperature of 275F (135C). Install the cones
on pinion gear (21).
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23. Install gear (21) in the housing.

1. Heat bearing cone (25) to a maximum temperature
   of 275F (135C). Install the cone on gear (24).
2. Turn the gear over and install gear (23).
3. Heat bearing cone (22) to a maximum temperature
   of 275F (135C). Install the cone on the gear.

27. Install gear (24) into swing drive housing.
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1. Heat bearing cone (28) to a maximum temperature
   of 275F (135C). Install the cone on gear (27).
2. Turn the gear over and install gear (26).

1. Heat bearing cone (25) to a maximum temperature
   of 275F (135C). Install the cone on gear (27).
2. Install gear (27) in the swing drive housing.

1. Lower the temperature of bearing cup (29).
   Install the cup in the cover.
2. Clean the old gasket material from the contact
   surfaces of the cover and case. Put 7M7260
   Liquid Gasket on the surfaces.

34. Install three eyebolts (30) one each, 3/8"-16
NC, 7/16"-14 NC and 1/2"-13 NC in the swing drive
cover. Fasten a hoist and put cover (31) in
position on the housing. Install the bolts that
hold the cover to the housing.
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35. Lower the temperature of bearing cup (32).
Install the cup in bearing cage (33). Install the
lip type seal with the lip of the seal toward
the top of the cage with tooling (C). Put oil on
the lip of the seal.
36. Put cage (33) in position on the cover
without the shims and O-ring seal. Install two
bolts 180 apart. Tighten the bolts evenly to a
torque of 60 lb.in. (6.8 Nm) while gear (27) is
turned. Measure the gap between the cage and
cover at the two bolt locations with a feeler
gauge.
37. Install shims (35) that are the same
thickness as the average gap measured plus .000
to .0008 in. (0.00 to 0.02 mm). Install O-ring
seal (34) on the cage. Put the cage in position
on the cover. Install the bolts that hold the
cage in position and tighten the bolts to a
torque of 100 20 lb.ft. (135 14 Nm).
38. Lower the temperature of bearing cup (36).
Install the cup in bearing cage (37).
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39. Install cage (37) without shims and O-ring
seal. Install two bolts 180 apart. Tighten the
bolts evenly to a torque of 60 lb.in. (6.8 Nm)
while pinion gear (21) is turned. Measure the gap
between the cage and the cover at the two bolt
locations with a feeler gauge.
40. Install shims (39) that are the same
thickness as the average gap measured plus .002
to .0032 in. (0.05 to 0.08 mm). Install O-ring
seal (38) on the cage. Put the cage in position
on the cover and install the bolts that hold it
in place.
41. Install cage (40) without shims and O-ring
seal. Install two bolts 180 apart. Tighten the
bolts evenly to a torque of 60 lb.in. (6.8 Nm).
Measure the gap between the cage and the cover at
the two bolt locations with a feeler gauge.
42. Install shims (41) that are the same
thickness as the average gap measured plus .000
to .0012 in. (0.00 to 0.03 mm). Install O-ring
seal (42) on the cage. Put the cage in position
on the cover and install the bolts that hold it
in place.
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43. Fill the swing drive with oil to the correct
level. end by a) install swing drive
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Product EXCAVATOR Model 215B EXCAVATOR
4FC Configuration 215B SA EXCAVATOR 4FC00001-UP
(MACHINE) POWERED BY 3304 ENGINE
Disassembly and Assembly 215 EXCAVATOR VEHICLE
SYSTEMS Media Number -SENR2172-00 Publication
Date -01/02/1982
Date Updated -11/10/2001
Swivel Group SMCS - 5060-16 5060-11 5060-12
5060-15 Remove Swivel Group NOTE Put
identification on all the oil lines for
installation purpose.

• Disconnect oil lines (1), (2), (3) and (5) which
  go to the main control valves.
• Disconnect oil line (4) which goes to the
  hydraulic tank.
• NOTE Put plugs in the oil line to keep oil in.

VIEW FROM UNDER MACHINE 3. Disconnect parking
brake oil lines (6) and (7). Disconnect track
motor return lines (8) and (9) from the rotor.
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4. Disconnect oil lines (10), (11), (12) and (13)
for the track motors from the rotor.
5. Remove the two bolts that hold bracket (14) in
place. Remove the bracket.
6. Install two 3/8"-16 NC forged eyebolts in the
swivel group. Fasten a hoist to the swivel group.
Remove eight bolts (15) and remove the swivel
group. The weight of the swivel group is 170 lb.
(77 kg).
Install Swivel Group
1. Install two 3/8"-16 NC forged eyebolts in the
swivel group. Fasten a hoist and put swivel
group (1) in position on the machine. Install the
eight bolts that hold the swivel group in place.
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VIEW FROM UNDER MACHINE 2. Install bracket (2)
as shown. Install the two bolts that hold it in
place.
3. Connect oil lines (3), (4), (5) and (6) for
the track motors to the rotor.

1. Connect track motor return lines (7) and (10).
   Connect parking brake oil lines (8) and (9).
2. Connect oil line (14) which goes to the hydraulic
   tank.

6. Connect oil lines (11), (12), (13) and (15) to
the swivel group which go to the main control
valves.
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Disassemble Swivel Group
start by a) remove swivel group
1. Remove bolts (1) and cap (2) from the swivel
housing. Remove the O-ring seal from the cap.

1. Remove three screws (3) and remove retainer (4)
   from the rotor.
2. Turn the swivel housing over and remove the
   fittings.

27

1. Make two 1/2"-13 NC threaded rods 24 in. (610 mm)
   long. Put the rods in position on the swivel
   housing with four 1/2" flat washers and nuts.
   Install tooling (A) on the rods. Use 1/2" flat
   washers and nuts to hold tooling (A) in place.
2. Remove rotor (5) from the housing.

6. Remove seal (6) from the housing. Remove seven
inner seals (7) and the seven outer seals from
the housing.
Assemble Swivel Group
28

• Install the seven out seals (rubber) and seven
  inner seals (plastic) (2) in the swivel housing.
• Install seal (1) in the swivel housing.
• NOTE Seal (1) does not have a rubber seal behind
  it. Put lubrication on the seals.
• Put rotor (3) in position in swivel housing (4).
  Make two 1/2"-13 NC threaded rods 24 in. (610
  mm) long. Put the rods in position on the swivel
  housing with four flat washers and nuts. Install
  tooling (A) on the rods. Use four 1/2" flat
  washers and nuts to hold tooling (A) in place.
• Install the rotor as shown.

5. Install fittings (5) and (6) in the rotor.
6. Turn the swivel housing over as shown. Install
retainer (7) on the rotor. Install the three
screws that hold the retainer in place.
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7. Install O-ring seal (8) in cap (9). Install
cap (9) on the swivel housing. Install the bolts
that hold the cap to the housing.
8. After assembly the rotor must be turned so
that the center line of the smallest flat side
(10) of the rotor is in alignment with the
center line of fittings (11) in the swivel
housing as shown. end by a) install swivel group
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Licensees.
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Product EXCAVATOR Model 215B EXCAVATOR
4FC Configuration 215B SA EXCAVATOR 4FC00001-UP
(MACHINE) POWERED BY 3304 ENGINE
Disassembly and Assembly 215 EXCAVATOR VEHICLE
SYSTEMS Media Number -SENR2172-00 Publication
Date -01/02/1982
Date Updated -11/10/2001
Track Motor Guards (If So Equipped) SMCS -
7162-11 7162-12 Remove Track Motor Guards (If
So Equipped)
1. Remove the bolts that hold covers (1), (2) and
(3). Remove the top three covers.

1. Put a floor jack in position under the lower
   guard assembly. Remove seven bolts that hold
   lower guard (4) to the carbody.
2. Remove the lower guard. The weight of the guard
   is 200 lb. (90 kg).

Install Track Motor Guards (If So Equipped)
31
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1. Put lower guard (1) in position with a floor
jack and install the seven bolts that hold it in
place.
2. Install three top covers (2), (3) and (4) in
number sequence as shown.
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Previous Screen
Product EXCAVATOR Model 215B EXCAVATOR
4FC Configuration 215B SA EXCAVATOR 4FC00001-UP
(MACHINE) POWERED BY 3304 ENGINE
Disassembly and Assembly 215 EXCAVATOR VEHICLE
SYSTEMS Media Number -SENR2172-00 Publication
Date -01/02/1982
Date Updated -11/10/2001
Track Motors SMCS - 5058-11 5058-12 Remove
Track Motors 1. Remove the top covers from over
the track motors. Make reference to REMOVE TRACK
MOTOR GUARDS.
2. Disconnect drain hose assembly (1) and the
inlet and outlet hose assemblies (2) and (3). Put
plugs in the openings in the hose assemblies and
the track motor.

1. Fasten a hoist to track motor (4). Remove two
   bolts (5) that hold the track motor to the
   parking brake.
2. Remove motor (4). The weight of the track motor
   is 105 lb. (47.3 kg).

Install Track Motors
34

• Install O-ring seals (1) and (2) on track motor
  (3). Inspect the O-ring seals for damage and make
  replacements if needed.
• Fasten a hoist and install the track motor on the
  parking brake. Install the two bolts that hold
  the track motor in place. Remove the top drain
  fitting and fill the motor case with SAE 10 W
  hydraulic oil.
• NOTICE
• Do not start the engine until the motor is filled
  with oil.

4. Remove the plugs from the hose assemblies and
the track motor.

• Connect the drain hose assembly (4).
• Connect the inlet and outlet hose assemblies (5)
  and (6) to the track motor.
• NOTE Make sure the O-ring seals are in place on
  the inlet and outlet hoses.
• Install the top covers over the track motors.
  Make reference to INSTALL TRACK MOTOR GUARDS.

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Licensees.
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