- Load Haul Dump
- R1600H (S/N: 9SD1-336)
Introduction
This Special Instruction covers the procedure to rework the brake accumulators on the above R1600H Load Haul Dump Machines.
This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.
Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.
Safety Section
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.
Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
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Personal injury can result from removing hoses or fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved. |
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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. |
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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock link between the front and rear frames before working on machine. |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
Reference Section
Reference: Disassembly and Assembly, UENR1457, "R1600H Load Haul Dump Machine Systems".
Reference: Systems Operation Testing and Adjusting, UENR1453, "R1600H Load Haul Dump Braking System".
Required Parts
| Required Parts | ||
|---|---|---|
| Qty | Part Number | Part Description |
| 2 | Elbow | |
| 1 | Bolt | |
| 1 | Sleeve | |
| 1 | Clip | |
| 2 | Hard Washer | |
| 2 | O-Ring Seal | |
| - | 476-0947 | Software |
| 2 | Hydraulic Accumulator Gp | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Hose As | |
| 1 | Clamp As | |
| 2 | Bracket | |
| 1 | Clip | |
| 10 | Washer | |
| 10 | Bolt | |
| 2 | Bolt | |
Machine Preparation
Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.
- Move the machine to a hard level surface away from operating machines and away from personnel.
- Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
- Stop the engine.
- Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".
- Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.
- Release system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".
Procedure
- Remove and discard Item (1) through Item (6), the bolts, and the washers.
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Illustration 2 g06094271 - Remove and discard two tapping blocks (7).
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Illustration 3 g06098080 (8) M12 x 1.75
(9) 3/8 - 16 UNC
(A)320 mm (12.60 inch)
(B)84 mm (3.30 inch)
(C)327 mm (12.90 inch)
(D)277 mm (10.90 inch)
(E)185 mm (7.30 inch)
(F)385 mm (15.20 inch)
(G)135 mm (5.30 inch)
(H)60 mm (2.40 inch)
(J)50 mm (2.0 inch)
(K)75 mm (2.90 inch) - Drill and tap 10 holes (8) and one hole (9).
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Illustration 4 g06177477 (10) 509-4373 Clamp As
(11)6V-3668 Bolt
(12)6V-8178 Washer
(13)510-0854 Bracket - Install Item (10) through Item (13).
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Illustration 5 g06177478 (14) 492-1974 Hydraulic Accumulator Gp
(15)6V-4248 Bolt
(16)3E-4353 Hard Washer
(17)030-7947 Elbow
(18)3J-1907 O-Ring Seal - Install two 492-1974 Hydraulic Accumulator Gp (14), using Item (15) through Item (18).
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Illustration 6 g06177479 (19) 504-6328 Hose As
(20)504-6333 Hose AsShow/hide table
Illustration 7 g06177480 (19) 504-6328 Hose As
(20)504-6333 Hose AsShow/hide table
Illustration 8 g06177481 (19) 504-6328 Hose As
(20)504-6333 Hose As
(21)502-1174 Hose As
(22)502-1173 Hose As
(23) ClipShow/hide table
Illustration 9 g06177482 (22) 502-1173 Hose As
(24)351-4320 Clip
(25)5K-8451 Clip
(26)085-8091 Bolt
(27)211-9084 Sleeve - Install Item (19) through Item (27). Refer to Illustration 6 through Illustration 9.
Note: Clip (23) is relocated to where hole (9) was drilled.
Note: Ensure 504-6328 Hose As (19) and 504-6333 Hose As (20) are pulled tight and do not contact the frame. Refer to Illustration 8.
- Charge the accumulators. Refer to Systems Operation Testing and Adjusting , Brake Accumulator - Test and Charge.
- Purge air from the braking system. Refer to Systems Operation Testing and Adjusting , Braking System Air - Purge.
- Flash the Power Train ECM with the latest software.
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Table 2 Part Number Description 476-0947 Software Note: Go to SIS Web, "Service Software Files" to obtain the new Power Train software.
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| Illustration 1 | g06094286 |
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(1) Hose As
(2) Hose As (3) Hose As (4) Hose As (5) Clamp As (6) Accumulator As | |
Pressure Sensor (Brake Accumulator Oil)
Note: The alert indicator pressure has changed.
The Power Train Electronic Control Module (Power Train ECM) receives input signals from pressure sensors in the braking system. If a braking system failure occurs and the accumulator oil pressure is lost, the Power Train ECM will engage the parking brake.
Alert Indicator
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| Illustration 10 | g03038716 |
| (1) Brake accumulator oil pressure sensor for the alert indicator and brake application | |
The brake accumulator oil pressure sensor is installed in the brake accumulator charging valve. The brake accumulator charging valve is on the left side of the rear frame.
The pressure of the parking brake oil corresponds to the voltage signal of the sensor. The changes in voltage represent changes in the parking brake oil pressure in the parking brake circuit. The voltage signal is an input of the Power Train Electronic Control Module (ECM).
If a machine service brake system failure occurs and the brake accumulator hydraulic oil pressure is lost, the machine parking brake will automatically engage.
When the engine is started, brake accumulator oil pressure increases to cut out pressure.
If the brake accumulator hydraulic oil pressure decreases to
Reference: For information on the brake accumulator oil pressure sensor for the alert indicator, refer to Systems Operation, Testing and Adjusting, "Accumulator Charging Valve (Brake) - Test and Adjust".
Brake Application
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| Illustration 11 | g03038716 |
| (1) Brake accumulator oil pressure sensor for the alert indicator and brake application | |
The brake accumulator oil pressure sensor is installed in the brake accumulator charging valve. The brake accumulator charging valve is on the left side of the rear frame.
The pressure of the parking brake oil corresponds to the voltage signal of the sensor. The changes in voltage represent changes in the parking brake oil pressure in the parking brake circuit. The voltage signal is an input of the Power Train Electronic Control Module (ECM).
If a machine service brake system failure occurs and the brake accumulator hydraulic oil pressure is lost, the machine parking brake will automatically engage.
When the engine is started, brake accumulator oil pressure increases to cut out pressure.
If the brake accumulator hydraulic oil pressure decreases to
When the engine is started, brake accumulator oil pressure increases.
The parking brake will remain engaged until the brake accumulator oil pressure increases above the actuation pressure of
Reference: For information on the brake accumulator oil pressure sensor for brake application, refer to Systems Operation, "Sensors - Brake Accumulator Oil".