R1600H Load Haul Dump Machine Systems Caterpillar

Hydraulic Tank - Assemble

Usage:

Specifications

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Illustration 1	g02828896

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Table 1
Specification for 230-9789 Hydraulic Tank Gp
Item	Qty	Part	Specification Description
1	12	9J-6379 Disc Spring	Assembled height is 2.0 mm (0.08 inch).
			Test force 270.5 ± 54.1 N (60.81 ± 12.16 lb).
			Outside diameter 125 mm (4.9 inch).
2	2	132-6277 Liquid Level Gauge As	Torque to 10 ± 2 N·m (88 ± 18 lb in).
3	2	9J-9842 Bolt	Torque to 56 ± 3 N·m (41 ± 2 lb ft).
4	2	3G-2815 Stud	Torque to 108 ± 14 N·m (80 ± 10 lb ft).
5	1	3S-9733 Spring	Length under test force 76.6 mm (3.02 inch).
			Test force 15.74670 ± 12.89984 N (3.54 ± 2.9 lb).
			Free length after test 78.2 mm (3.08 inch).
6	1	8T-4906 Sealant	Cross the ends of the Sealant to complete the seal, as shown.
7	1	7B-3039 Spring	Length under test force 26.2 mm (1.03 inch).
			Test force 15.6 ± 1.2 N (3.50 ± 0.27 lb).
			Free length after test 36.6 mm (1.44 inch).
8	1	9J-7031 Drain Plug	Torque to 68 ± 7 N·m (50 ± 5 lb ft).

Assembly Procedure

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Table 2
Required Tools
Tool	Part Number	Part Description	Qty
B	138-7575	Link Bracket	2

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

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

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Illustration 2	g03733091

Install seven O-ring seals (67) to block (66).
Position block (66).
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Illustration 3 g03733097
Install two bolts (65).
Install the O-ring seal to cover (64). Install cover (64) and four bolts (63).
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Illustration 4 g03733099
Install seven O-ring seals (62) to block (61).
Position block (61).
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Illustration 5 g03733100
Install two bolts (58).
Install the O-ring seal to cover (60). Install cover (60) and four bolts (59).
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Illustration 6 g03733101
Install twelve O-ring seals (57) to block (56).
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Illustration 7 g03733102
Position block (56).
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Illustration 8 g03733104
Install two bolts (53).
Install the O-ring seal to cover (55). Install cover (55) and four bolts (54).
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Illustration 9 g03732600

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Illustration 10 g03733106
Install O-ring seal (48) on drain plug (47). Install drain plug (47) in drain valve body (46).
Tighten drain plug (47) to a torque of 68 ± 7 N·m (50 ± 5 lb ft).
Install O-ring seal (49), valve (50), spring (51) and valve guide (52).
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Illustration 11 g03732599
Install drain valve assembly (46) and two locknuts (45).
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Illustration 12 g03732596
Install baffle tube (43) and two bolts (44).
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Illustration 13 g03733107

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Illustration 14 g03732590

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install the O-ring seal to cover (40). Install valve (41), spring (42), cover (40) and two bolts (39).
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Illustration 15 g03733108
Install two studs (36) to filter base (35). Tighten two studs (36) to a torque of 108 ± 14 N·m (80 ± 10 lb ft).
Install ten O-ring seals (37).
Install two O-ring seals (38).
Position filter base (35) on the outside of the cover.
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Illustration 16 g03732587
Install two bolts (34) that hold filter base (35).
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Illustration 17 g03733114
Install sealant (68) to baffle (32) overlap the ends of sealant (68) in order to complete the seal.
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Illustration 18 g03732586
Install baffle (32) and six bolts (33).
Install gasket (30).
Install gasket (31).
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Illustration 19 g03732585
Install Tooling (B) and a suitable lifting device to cover (28). The weight of cover (28) is approximately 75 kg (165 lb).
Position cover assembly (28) and install seventy bolts (29) and the locknuts.
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Illustration 20 g03732584
Install two bolts (24) to liquid level gauge (25). Install O-ring seal (27) to two bolts (24).
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Illustration 21 g03732583
Install liquid level gauge (25). Tighten two bolts (24) to a torque of 10 ± 2 N·m (88 ± 18 lb in).
Install bracket (26).
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Illustration 22 g03733109
Install O-ring seal (21) on bolt (15).
Install bolt (15) to cover (16). Install retaining ring (22) (not shown) on bolt (15).
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Illustration 23 g03733159
Install O-ring seal (23).
Install six disc springs (20). Install the disc springs in pairs with the outside diameters in contact with each other.
Install spacer (19) and retaining ring (18).
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Illustration 24 g03732579

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Illustration 25 g03732578
Install element (17) and cover (16). Tighten bolt (15) to a torque of 56 ± 3 N·m (41 ± 2 lb ft).
Repeat Step 33 through Step 38 for the other filter assembly.
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Illustration 26 g03732577
Install strainer (13) and O-ring seal (14) to filler (12).
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Illustration 27 g03732576
Install ball (10), plate (9) and gasket (8) to cap (11).
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Illustration 28 g01099374
Install O-ring seals (5), (6) and (7) on breaker relief valve (4).
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Illustration 29 g01099373
Install breaker relief valve (4).
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Illustration 30 g01099372
Install element (3).
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Illustration 31 g01091821
Install cover (2) and snap ring (1).