390F Excavator Counterweight Removal and Installation Caterpillar

Counterweight Removal and Installation for Standard Machines

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Unexpected machine movement can cause injury or death. In order to avoid possible machine movement, move the hydraulic lockout control to the LOCKED position and attach a Special Instruction, SEHS7332, "Do Not Operate" or similar warning tag to the hydraulic lockout control.

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Personal injury or death can occur from a counterweight falling during removal or installation. Do not allow personnel under or around the counterweight during removal or installation. Make sure that the lifting device is in good condition and is capable of handling the weight of the counterweight.

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Personal injury or death can occur from a counterweight falling during removal or installation. Before you remove the counterweight mounting bolts, read and understand the instructions and warnings in the Operation and Maintenance Manual.

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Make certain personnel are clear of cable when there is a load on it. Cable can break and cause personal injury.

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Personal injury or death can occur from a counterweight falling during removal or installation. Before you begin the Removal Procedure, make sure that the support blocks are installed and tightened properly.

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Crush Hazard. Read and Understand the Operation and Maintenance Manual before performing maintenance on equipment. Could cause serious injury or death.

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Unexpected machine damage and personal injury or death can occur from any machine operation without counterweight bolt tightened properly. Make sure to tighten the counterweight mounting bolts when the counterweight is installed.

Machines Equipped with Standard Counterweight

Counterweight Removal

Reference: Refer to Operation and Maintenance Manual, "Specifications" for specific weight information.

Note: Before you remove the counterweight, disconnect the wiring for the rear view camera. Refer to Operation and Maintenance Manual, "Camera Harness - Disconnect and Connect" for more information.

1. Position the machine on a surface that is hard and level. Lower the work tool to the ground.

2. Move the hydraulic lockout control to the LOCKED position.
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   Illustration 1	g03485178

3. Fasten a proper rated wire cable with shackles to the link on the counterweight. Use an appropriate lifting device to tension the cable.

4. Lift the counterweight enough so that there is no load on the retaining Links.
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   Illustration 2	g03437997

5. Remove six counterweight mounting bolts and washers. Inspect the bolts for damage. If the bolts are damaged, replace the bolts.
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   Illustration 3	g03438036

6. Separate the counterweight from the machine. Lower the counterweight onto suitable supports.

Counterweight Installation

Perform the installation procedure in reverse order.

Note: Temporarily tighten the six counterweight mounting bolts. Decrease the tension on the lifting cable. Make sure that the counterweight is correctly positioned on the retaining pins. Tighten the counterweight mounting bolts horizontal to a torque of 2800 ± 350 N·m (1990 ± 220 lb ft).

Machines Equipped with Counterweight Removal System

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IMPROPER OPERATION OF THE COUNTERWEIGHT REMOVAL SYSTEM CAN RESULT IN SERIOUS INJURY OR DEATH. DO NOT OPERATE THIS SYSTEM UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUAL.

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Before you remove the counterweight, check for signs of hydraulic oil leaking from the Counterweight Removal System. An oil leak may be a sign of a potential system failure and needs to be corrected before removing the counterweight mounting bolts. A hydraulic leak, along with other factors, can result in personal injury or death.

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When the removal cylinder is used to lower the counterweight, the counterweight can wedge against the machine frame which stops the downward movement of the counterweight. Since the removal cylinder continues to retract and the counterweight stopped, slack in the chain for the removal cylinder occurs. The counterweight can suddenly fall due to the slack in the chain which could result in personal injury or death. Monitor the lowering of the counterweight when the counterweight is being lowered with the removal cylinder. If the removal cylinder is retracted and the downward movement of the counterweight stops, stop the lowering procedure and correct the wedging of the counterweight against the machine frame.

Counterweight Removal

Reference: Refer to Operation and Maintenance Manual, "Specifications" for specific weight information.

Note: Before you remove the counterweight, disconnect the wiring for the rear view camera. Refer to Operation and Maintenance Manual, "Camera Harness - Disconnect and Connect" for more information.

1. Position the machine on a surface that is hard and level.

2. Position the upper structure parallel to the tracks. Lower the work tool to the ground.

3. Start the engine. Adjust the engine speed to one-third of full throttle engine speed.
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   Illustration 4	g00104545

4. Move the hydraulic lockout control to the LOCKED position. Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls.
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   Illustration 5	g03640796

5. Remove two bolts from the top of the counterweight cover plate.

6. Open the rear access door on the right side of the machine.
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   Illustration 6	g03485316
   (1) Switch (2) Control lever (3) Stop valves (A) CLOSED position (B) OPEN position

7. Place stop valves (3) in OPEN position (B).

8. Move switch (1) upward to the ON position.

9. Move control lever (2) upward to support the counterweight and relieve the weight on the counterweight mounting bolts. This will keep the counterweight from possibly sliding off when the counterweight mounting bolts are removed. There should be a slight tension on the chains.
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   Illustration 7	g06510567

10. There should be a slight tension on the chains. Inspect both chains to verify condition and that they are not seized or binding. Monitor chain tension for 5 minutes to verify no leaks and no excessive drift is present indicating service is  required before system use. Contact your AVSpare dealer if service is required.
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    Illustration 8	g06553479

11. Remove bolts (4) from the counterweight.

12. Reinstall bolts (4) and tighten by hand until the bolts are fully engaged.

    Note: Do not use tools to reinstall bolts (4).

13. Loosen bolts (4) two full revolutions.

    Note: Do not remove bolts (4) from the counterweight.

14. Remove remaining bolts (5).

15. Remove bolts (4) by hand.

    Note: Do not use tools to remove bolts (4).

    Note: If unable to remove bolts (4) by hand, the counterweight removal system may not be appropriately supporting the weight of the counterweight. Adjustment of the linkage, or additional support, may be required to safely remove the final two bolts.

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    Illustration 9	g06553503
    (6) Counterweight (7) Retaining pin

16. Move control lever (2) upward to raise the counterweight (6) until access to the retaining pins (7) can be gained.
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    Illustration 10	g06553686
    (8) Retaining pin (9) Extension

17. Use a ratchet wrench and an extension (9) to rotate each retaining pin (8). Retaining pins (8) require 90^° of rotation. The retaining pins (8) are now in the UNLOCKED position.
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    Illustration 11	g06553652
    (10) Counterweight

18. Move control lever (2) downward to lower counterweight (10) onto supports on the ground.
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    Illustration 12	g06553700
    (6) Counterweight (11) Chains (12) Pins (13) Nuts (14) Cotter pins

19. Remove cotter pins (14). Loosen nuts (13).

20. Remove pins (12) to disconnect chains (11) from counterweight (6).
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    Illustration 13	g06553706
    (11) Chain (15) Bracket (16) Washer (17) Bolt (18) Pin (19) Bolt (20) Washer

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    Illustration 14	g03485485

21. Pin (18) should be located in the storage box. Remove pin (18) from the storage box.

22. Install pin (18) into chains (11).

23. Install bolts (19) and washers (20) to attach pin (18) to bracket (15).

24. At the end of pin (18), install washer (19) and bolt (20).
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    Illustration 15	g03485518

25. Fasten a proper rated wire cable with shackles to the link on the counterweight. Use an appropriate lifting device to tension the cable.
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    Illustration 16	g03438601

26. Lift the counterweight enough so that there is no load on the retaining Links.
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    Illustration 17	g03438036

27. Use an appropriate lifting device to put the counterweight on suitable supports.

Counterweight Installation

Perform the installation procedure in reverse order.

Note: Make sure that you remove pin (14), bolt (17), washer (16), bolt (19), and washer (20). Return these parts to the storage box.

Note: Before you install the counterweight mounting bolts, make sure that the retaining pins are in the LOCKED position and that the counterweight is securely held on the retaining pins. There should be a slight amount of slack on the chains.

Tighten the counterweight mounting bolts horizontal to a torque of 2800 ± 350 N·m (1990 ± 220 lb ft).