Procedure to Rework the Brake Oil Cooler Hoses on AD45B Underground Articulated Trucks{1365, 5057} Caterpillar

Underground Articulated Truck:

AD45B (S/N: CXM1-UP)

Introduction

This special instruction covers the procedure to rework the brake oil cooler hoses on AD45B Underground Articulated Trucks. 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 in order 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 or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

ReferenceDisassembly and Assembly, RENR8576, "AD45B Underground Articulated Truck, Machine Systems".

Parts Required

Removal Procedure

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.

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes to prevent fluid loss and contaminants from entering the system.

1. Move the machine to a hard level surface away from operating machines and personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

5. Turn the key start switch and the battery disconnect switch to the OFF position.

6. Release the pressure in the braking system. Refer to Disassembly and Assembly, RENR8576, "System Pressure - Release".

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Illustration 1	g03451736
View of the left side of the hitch (1) 275-4831 Hose As (2) 275-4830 Hose As

7. Remove and discard 275-4831 Hose As (1) and 275-4830 Hose As (2). Retain the bolts, the washers, and the flanges for installation purposes.

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Illustration 2	g03453428
Right side view (3) 209-7517 Hose As (4) 219-1490 Hose As

8. Remove and discard 209-7517 Hose As (3) and 219-1490 Hose As (4). Retain the bolts, the washers, the flanges, and the clamps for installation purposes.

Installation Procedure

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Illustration 3	g03451756
(5) 447-0343 Hose As (6) 163-5531 Cable Tie (7) 160-2251 Abrasion Sleeve

1. Install 1285 mm (51 inch) of 160-2251 Abrasion Sleeve (7) and two 163-5531 Cable Ties (6) onto 447-0343 Hose As (5) .

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Illustration 4	g03453423
(6) 163-5531 Cable Tie (7) 160-2251 Abrasion Sleeve (8) 447-0344 Hose As

2. Install 1115 mm (44 inch) of 160-2251 Abrasion Sleeve (7) and two 163-5531 Cable Ties (6) onto 447-0344 Hose As (8) .

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Illustration 5	g03453424
View of the left side of the hitch (5) 447-0343 Hose As (8) 447-0344 Hose As (9) 4J-0524 O-Ring Seal

3. Install 447-0343 Hose As (5) and 447-0344 Hose As (8), using four 4J-0524 O-Ring Seals (9), and the bolts, the washers, and the flanges retained in Step 7 of ""Removal Procedure" ".

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Illustration 6	g03453437
Right side view (10) 4J-0527 O-Ring Seal (11) 449-1832 Hose As (12) 449-1830 Hose As

4. Install 449-1832 Hose As (11) and 449-1830 Hose As (12), using four 4J-0527 O-Ring Seals (10), and the bolts, the washers, the flanges, and the clamps retained in Step 8 of ""Removal Procedure" ".