R1700G Load Haul Dump Machine Systems Caterpillar

Assembly Procedure

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

Note: Ensure that the pin bores in the ejector bucket, lift arm assembly and tilt link are free of dirt and debris.

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Illustration 1	g01402320

1. Apply Tooling (M) to the bore of ejector cylinder (1) .

2. Attach a suitable lifting device to ejector cylinder (1). The weight of the ejector cylinder is approximately 52 kg (115 lb).

3. Install ejector cylinder (1) to the ejector bucket. Align the bores of the ejector cylinder and the ejector bucket.

4. Install the ejector cylinder pin and shims.

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Illustration 2	g01102509

5. Install three caps (21) .

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Illustration 3	g01102511

6. Install three bungs (22) .

7. Apply Tooling (J) to the inside diameter and the outside diameter of the collets.

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Illustration 4	g01102517
Typical example

8. Install collet (20) .

9. Install the collet on the other side.

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Illustration 5	g01193250

10. Apply Tooling (J) to the threads of bolt (19) prior to assembly. Install bolt (19) and the washer.

    Note: The collet on one side must not extend farther than the other when the bolt is tight.

11. Tighten bolt (19) to a torque of 370 ± 50 N·m (275 ± 37 lb ft). After the bolt is tight, hit collet (20) on each side with a heavy hammer until the torque on the bolt is less than 200 N·m (150 lb ft).

12. Tighten bolt (19) again to a torque of 370 ± 50 N·m (275 ± 37 lb ft). Hit each collet again until the torque for the bolt is less than 285 N·m (210 lb ft).

13. Tighten bolt (19) to a final torque of 370 ± 50 N·m (275 ± 37 lb ft).

    Note: At the end of 50 service hours, repeat Step 11 through Step 13.

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Illustration 6	g01402296

14. Install Tooling (A) in order to support ejector cylinder (1) in the horizontal position.

15. Install clip (17) .

16. Connect hose assemblies (15), (16) and (18) .

17. Repeat Step 1 through Step 16 for the other ejector cylinder.

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Illustration 7	g01338657

18. Lower the temperature of bearing (14) to −75° ± 5°C (−103° ± 9°F). Use Tooling (K) to install bearing (14) to a depth of 9.5 ± 1 mm (0.37 ± 0.04 inch) below the surface of the bore.

19. Use Tooling (L) to install lip seal (13). Install lip seal (13) with the sealing lip towards the outside of the main ejector plate assembly.

20. Repeat Step 18 and Step 19 for the other side of the main ejector plate assembly.

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Illustration 8	g01338656

21. Attach a suitable lifting device to lower ejector plate assembly (11). The weight of lower ejector plate assembly (11) is approximately 175 kg (385 lb).

22. Apply Tooling (J) to the bores of lower ejector plate assembly (11) and main ejector plate assembly (7) .

23. Align the bores of lower ejector plate assembly (11) and main ejector plate assembly (7) .

24. Use two people to install the hinge pin. The weight of the hinge pin is approximately 25 kg (55 lb).

25. Apply Tooling (J) to the threads of bolts (12) prior to assembly.

26. Install two bolts (12), and the washers. Tighten bolts (12) to a torque of 430 ± 60 N·m (315 ± 45 lb ft).

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Illustration 9	g01429058

27. Install Tooling (C), Tooling (D) and, a suitable lifting device to ejector plate (7). The weight of the main ejector plate assembly with the lower ejector plate assembly attached is approximately 1275 kg (2810 lb).

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Illustration 10	g01338655

28. Apply Tooling (M) to the bores of the ejector bucket and the bores of the main ejector plate assembly.

29. Align the bores of the ejector bucket with the bores of the main ejector plate assembly.

30. Install shims (10) (not shown) as required between the ejector bucket and the main ejector plate assembly.

31. Install pin (9) .

32. Apply Tooling (J) to the threads of bolt (8) prior to assembly.

33. Install bolt (8), and the washer.

34. Repeat Step 30 through Step 33 for the other side of the ejector bucket.

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Illustration 11	g01338651
Typical example

35. Apply Tooling (M) to the bore of the ejector cylinder.

36. Align the bores of the main ejector plate assembly with the bore of the ejector cylinder.

37. Install shims (5) as required.

38. Install pin (6) .

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Illustration 12	g01103423

39. Install three caps (23) to the collets.

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Illustration 13	g01103424

40. Install three bungs (24) to the collets.

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Illustration 14	g01338648
Typical example

41. Apply Tooling (J) to the inside diameter and the outside diameter of the collets.

42. Install collet (4). Install the collet to the other side.

43. Apply Tooling (J) to the threads of bolt (3) .

44. Install bolt (3) and the washer.

Note: The collet on one side must not extend farther than the other when the bolt is tight.

45. Tighten bolt (3) to a torque of 370 ± 50 N·m (275 ± 37 lb ft). After the bolt is tight, hit the collet on each side with a heavy hammer until the torque on the bolt is less than 200 N·m (150 lb ft).

46. Tighten bolt (3) again to a torque of 370 ± 50 N·m (275 ± 37 lb ft). Hit each collet again until the torque for the bolt is less than 285 N·m (210 lb ft).

47. Tighten bolt (3) to a final torque of 370 ± 50 N·m (275 ± 37 lb ft).

    Note: At the end of 50 service hours, repeat Step 45 through Step 47.

48. Install cover plate (2) .

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Illustration 15	g01338208
Rear view of the ejector bucket

49. Remove Tooling (A) from ejector cylinder (1) .

50. Repeat Step 35 through Step 49 for the other ejector cylinder.

51. Lubricate the ejector cylinder bearings. Refer to Operation and Maintenance Manual, "Ejector Cylinder Bearings - Lubricate".

52. Lubricate the main ejector plate assembly bearings. Refer to Operation and Maintenance Manual, "Ejector Plate Bearings - Lubricate".

53. Fill the hydraulic tank with oil to the correct level. Refer to Operation and Maintenance Manual, "Hydraulic System Oil Level - Check".

End By: Remove the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".