Caterpillar Cat 212 WHEEL-TYPE EXCAVATOR (Prefix 5DC) Service Repair Manual Instant Download

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Product EXCAVATOR Model 212 EXCAVATOR
5DC Configuration 212 EXCAVATOR WHEEL-TYPE
5DC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
VEHICLE SYSTEMS Media Number -SENR4321-01 Publicat
ion Date -01/06/2005
Date Updated -19/07/2005
SENR43210037
Swivel-Hydraulic SMCS - 5060-010 5060-017 Remove
And Install Swivel-Hydraulic

• Start By
• a. remove electrical swivel
• Drain hydraulic tank.
• Remove bottom belly plate on undercarriage.

3. Disconnect four main hydraulic lines (1) and
(2) from bottom of swivel. Disconnect three
hydraulic lines (3) at tee.
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4. Disconnect six hydraulic lines (4). Remove
four bolts (5) and secure bracket and lines back
out of the way.
5. Remove four main hydraulic lines (6) from top
of swivel. Remove two hydraulic lines (7) from
swivel. Disconnect hydraulic hose (8).

• Attach tooling (A) and remove three bolts (9).
  Remove swivel. The weight of the swivel is 64 kg
  (140 lb).
• NOTE The following steps are for the
  installation of the swivel.
• Position swivel in excavator and install three
  bolts (9).
• Connect hydraulic hose (8). Attach two hydraulic
  lines (7) to swivel. Attach four main hydraulic
  lines (6) to top of swivel.
• Install four bolts (5) and connect six hydraulic
  lines (4).
• On bottom of swivel install three hydraulic lines
  (3) and four main hydraulic lines (1) and (2).
• Install bottom belly plate on undercarriage.
• Fill hydraulic tank.
• End By
• a. install electrical swivel

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Disassemble And Assemble Swivel-Hydraulic
Start By a. remove swivel

• NOTE The following photos and text is TYPICAL
  and is not meant as an exact illustration for the
  disassembly of the 206 or 212 Swivel. However,
  the same procedures do apply.
• Remove two hydraulic fittings (1) and (3) from
  cover (2).
• Remove four bolts (4) and remove cover (2).

1. Remove two bolts (8) and remove cover (7).
2. Remove two bolts (5) and bracket (6). Remove
   three bolts and cover (9).

1. Remove small swivel housing (12) from rotor (11).
2. Remove four set screws (10) and rotor (11).

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7. Attach tooling (A) to housing (13) and
carefully separate housing (13) from rotor (14).
8. Remove seal ring (15), five washer seals (16)
and one ring (17) from swivel housing (13).
9. From small swivel housing (12) remove wiper
(18), seal (19), flat rubber seal (20), ring
(21), seal (22) and wiper (23). NOTE The
following steps are to assemble the swivel.
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• In the small swivel housing (12), install wiper
  (23), seal (22), ring (21), flat rubber seal
  (20),
• seal (19) and wiper (18).
• In swivel housing (13), install ring (17), five
  washer seals (16) and ring (15).
• With tooling (A) slide housing (13) over rotor
  (14).
• Install cover (9) with three bolts. Install rotor
  (11), small swivel (12) and secure with four set
  screws (10).
• Install cover (7) with two bolts (8).
• Install bracket (6) with two bolts (5).
• Install cover (2) with four bolts (4).
• Install hydraulic fittings (3) and (1). End By
• a. install swivel

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Product EXCAVATOR Model 212 EXCAVATOR
5DC Configuration 212 EXCAVATOR WHEEL-TYPE
5DC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
VEHICLE SYSTEMS Media Number -SENR4321-01 Publicat
ion Date -01/06/2005
Date Updated -19/07/2005
SENR43210038
Duo-Cone Seals SMCS - 7561-016 Assembly And
Installation Of Conventional Duo-Cone
Seals Introduction This instruction gives the
procedure for installing Conventional Duo-Cone
Seals. It is most important that correct assembly
and installation procedures are followed when
Duo- Cone Seals are used. Many of the Duo-Cone
Seals failures are the direct result of one or
more mistakes made during assembly or
installation of the seal components. NOTICE Keep
all parts clean from contaminants. Contaminants
put into the system may cause rapid wear and
shortened component life.
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1. Seal
2. Rubber Toric Ring
3. Housing Retaining Lip
4. Housing Ramp
5. Seal Ring Housing

1. Seal Ring Face
2. Seal Ring Ramp
3. Seal Ring Retaining Lip
4. Installation Tool.

NOTICE Never permit oil to get on the toric rings
or ramps before both seal rings are put together
in their final assembled position (Step 10).
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Avoid prolonged skin contact with isopropyl
alcohol. Avoid breathing the vapors in enclosed
areas without adequate ventilation and do not
smoke. Do no use near open flame or welding
operations or other heated surfaces exceeding
482 C (900 F).
1. Use isopropyl alcohol with a clean cloth or
paper towels to remove any oil film, dust or
other foreign matter from toric rubber rings (2)
and from ramps (4) and (7) and lips (3) and (8)
of both seal rings (1) and housings (5).
2. Put toric ring (2) on seal ring (1), at the
bottom of seal ring ramp (7) and against
retaining lip (8). NOTICE
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Make sure that toric ring (2) is straight on seal
ring (1) and is not twisted. Be careful when you
work on the rubber toric ring. Nicks, cuts and
scratches can cause leaks.
NOTICE Do not use Stanisol or any other liquid
that leaves an oil film or does not evaporate
quickly.
3. Put installation tool (9) onto seal ring (1)
with toric ring (2). Lower the rings into a
container with isopropyl alcohol until all
surfaces of toric ring (2) are wet.
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4. With all surface of toric ring (2) wet, us
installation tool (9) to position seal ring (1)
and toric ring (2) squarely against housing (5)
as shown. Use sudden and even pressure to pop
(push) toric ring (2), under retaining lip (3) of
housing (5).
5. Check assembled height (A) in at least four
places, 90 apart. The difference in height
around the ring must not be more than 1 mm (.04").

• If small adjustments are necessary, do not push
  directly on seal ring (1) use installation tool
  (9).
• Toric ring (2) can twist if it is not wet all
  around during installation or if there are burrs
  or fins on retaining lip (3) of housing (5).
• NOTICE
• Misalignment, twists and bulges of the toric ring
  will cause Duo-Cone Seal failures. If correct
  installation is not obvious, remove seal from
  housing and repeat steps 3 thru 6.

IMPORTANT Toric rings (2) must never slip on the
ramps of either seal rings (1) or seal ring
housings (5). To prevent slippage, wait a minimum
of two minutes to let the isopropyl alcohol
evaporate before further assembly. Once correctly
in place, the toric ring must roll on the ramps
only.
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8. Wipe seal faces (6) of seal rings (1) clean.
Use a lint free cloth or paper towel. No
particles of any kind are permissible on the
sealing surfaces. Even a small piece from a paper
towel can hold the seal faces apart and cause
leakage.
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9. Use an applicator, a disposable tissue or a
clean finger, to distribute a thin film of clean
oil evenly on the seal faces. Do not to get any
oil on the rubber toric rings.
10. Make sure both housings (5) are in correct
alignment and are concentric. Move the parts
slowly and carefully toward each
other. NOTICE Do not slam seals together. High
impact can scratch or break the seal components.
11. Once in place, fasten all parts tightly.
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Product EXCAVATOR Model 212 EXCAVATOR
5DC Configuration 212 EXCAVATOR WHEEL-TYPE
5DC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
VEHICLE SYSTEMS Media Number -SENR4321-01 Publicat
ion Date -01/06/2005
Date Updated -19/07/2005
SENR43210039
Steering Cylinder SMCS - 7561-016 Remove And
Install Steering Cylinder

1. Using tool (A) and (B), disconnect tie rod from
   steering cylinder rod.
2. Disconnect and plug two hydraulic lines (1).
   Remove eight bolts (3) and two end caps (2).

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3. Remove cylinder rod (4) and O-ring (5).
4. Remove retaining ring (6).
5. Remove two sets of split rings (7) from each
side of the piston.
6. Remove ring (8) and remove rod (4) from piston.
7. Remove seal (9), seal (10) and ring (11).
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• Inspect cylinder (12) and replace liner if
  necessary.
• NOTE The following steps are for to install the
  steering cylinder.
• Install seal (9), seal (10) and ring (11).
• Slide rod (4) into piston and install ring (8).
• Install two sets of split rings (7) on each side
  of piston. (A small amount of grease will hold
  rings in place in the groove).
• Install retaining ring (6).
• Slide piston and rod (4) assembly into cylinder
  and install two new O-ring seals (5).
• Replace two end caps (2) and secure with eight
  bolts (3).
• Connect two hydraulic lines (1) and connect two
  tie rods to cylinder rod ends with tools (A) and
  (B).
• NOTE See Specification Service Manual for
  correct procedure to adjust the tie rods and the
  maximum steer angle.

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Product EXCAVATOR Model 212 EXCAVATOR
5DC Configuration 212 EXCAVATOR WHEEL-TYPE
5DC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
VEHICLE SYSTEMS Media Number -SENR4321-01 Publicat
ion Date -01/06/2005
Date Updated -19/07/2005
SENR43210040
Steering Knuckle And Bearings SMCS -
4321-010 Remove And Install Steering Knuckle And
Bearings
Start By a. remove front final drive (see 206
212 Disassembly And Assembly, Power Train,
SENR4322)
1. Remove eight bolts (1) and two hydraulic lines
(2).
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1. Remove two bolts (3) and bracket (4).
2. Remove four bolts (5) and trunnion (6).
3. Attach tooling (A) and remove four bolts (7) and
   trunnion (8).
4. Remove knuckle (9).

6. Remove axle (10).
7. Remove seal (11).
8. Remove upper and lower cup bearings (12).
9. From trunnions (6) and (8), remove cone
bearings (13). NOTE The following steps are for
the installation of the steering knuckle and
bearings.
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• Install cone bearings (13) onto trunnions (6) and
  (8).
• Install new upper and lower cup bearings (12).
• Install new seal (11).
• Install axle (10).
• Position knuckle (9) to axle housing and install
  bottom trunnion (8) with four bolts (7).
• Remove tooling (A) and install trunnion (6) with
  four bolts (5).
• NOTE For proper bearing preload, see
  Specification Service Manual, and select
  appropriate shim from the parts book.
• Install bracket (4) with two bolts (3).
• Connect two hydraulic lines (2) with eight bolts
  (1). End By
• a. install front final drive (see 206 212
  Disassembly And Assembly, Power Train, SENR4322)

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Product EXCAVATOR Model 212 EXCAVATOR
5DC Configuration 212 EXCAVATOR WHEEL-TYPE
5DC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
VEHICLE SYSTEMS Media Number -SENR4321-01 Publicat
ion Date -01/06/2005
Date Updated -19/07/2005
SENR43210041

• Downshift Control Valve
• SMCS - 3178-017 3178-010
• Remove And Install Downshift Control Valve
• NOTE The following steps show the down shift
  control valve being removed after the
  transmission and differential have been removed.
  The valve may be removed without removing the
  transmission and differential.
• Start By
• remove axle
• remove drive motor
• remove transmission and differential

1. Mark and remove two hydraulic lines (1) and
(2). Remove four bolts (3) and four nuts (4).
Remove housing (5).
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2. Loosen two locknuts (6) and remove two oil
supply pistons (7). Remove plug (8) and
centrifugal valve (9). Remove valve body (10)
from shaft.

• Remove centrifugal valve seat (13) from shaft.
  Remove retaining ring (14) and shims (12). Remove
  bearing carrier (11).
• NOTE The following steps are to install the
  downshift control valve.
• Install bearing carrier (11) with four nuts (4).
• Install shims (12) and retaining (14). Adjust end
  play between shims (12) and retaining ring
• (14) to a maximum of .20 mm (.008 in) by adding
  or subtracting shims.
• Install centrifugal valve seat (13) onto shaft.
  Use grease to hold it in place.
• Replace valve body (10). be sure large collar of
  valve body is toward the transmission and
  differential.
• Install right side oil supply piston (7) first to
  insure alignment of the valve. Torque to maximum
  15 Nm (11 lb ft).
• Install left side oil supply piston (7) next to
  insure alignment of the valve. Torque to maximum
  15 Nm (11 lb ft).
• Install two locknuts (6). Torque to a maximum 28
  Nm (21 lb ft).
• Install centrifugal valve (9) and plug (8).
  Torque to maximum 46 Nm (34 lb ft).
• Place housing on transmission and differential
  and install four bolts (3). Torque to a maximum
  of 49 Nm (36 lb ft).
• Connect two hydraulic lines (1) and (2). End By
• a. install transmission and differential

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b. install drive motor c. install
axle Disassemble And Assemble Downshift Control
Valve Start By a. remove downshift control valve
1. Remove retaining ring (1) and seal (2). Remove
four hydraulic fittings (3). Check and replace
O -ring seals if needed.
2. Remove plug (4), seal (5), bushing (6), piston
(7), washer (8), keeper (9), washer (10),
spring (11) and washer (12). 3. Remove plug (13),
seal (14), spring (15) and piston (16). NOTE The
following steps are to assemble the downshift
control valve.
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• Install piston (16), spring (15), seal (14), and
  plug (13).
• Install washer (12), spring (11), washer (10),
  keeper (9), washer (8), piston (7), bushing (6),
  seal
• (5) and plug (4).

6. Install four hydraulic fittings (3). Install
seal (2) with tool (A) and install retaining ring
(1). End By a. install downshift control valve
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Product EXCAVATOR Model 212 EXCAVATOR
5DC Configuration 212 EXCAVATOR WHEEL-TYPE
5DC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
VEHICLE SYSTEMS Media Number -SENR4321-01 Publicat
ion Date -01/06/2005
Date Updated -19/07/2005
SENR43210042
Hydraulic Rotary Joint SMCS - 5060-017
5060-010 Remove And Install Hydraulic Rotary Joint
Start By
1. Remove the access cover. Disconnect and plug
seven hydraulic lines (1).
2. Disconnect and plug seven hydraulic lines (2).
Loosen bolts (3) and remove three bolts (4).
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3. Install tool (A) and attach to a hoist. Remove
rotary joint (5). NOTE Install in reverse order.
Disassemble And Assemble Hydraulic Rotary Joint
Start By a. remove hydraulic rotary
joint NOTICE Keep all parts clean from
contaminants. Contaminants put into the system
may cause rapid wear and shortened component life.

1. Remove two hydraulic fittings (1) and (3).
2. Remove four bolts (4) and remove cover (2).

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1. Remove two bolts (8) and remove cover (7).
2. Remove two bolts (5) and bracket (6). Remove the
   three bolts and cover (9).

1. Remove small rotary joint housing (12).
2. Remove four set screws (10) and rotor (11).

7. Attach tooling (A) to housing (13) and
carefully separate housing (13) from rotor (14).
28
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.ebo
oklibonline.com