258-4624 Wide Body Arrangement (16.8M3 SAE) Custom Support Literature for AD30 (S/N: CXR1-UP; DXR1-UP) Underground Articulated Truck{7258} Caterpillar


258-4624 Wide Body Arrangement (16.8M3 SAE) Custom Support Literature for AD30 (S/N: CXR1-UP; DXR1-UP) Underground Articulated Truck{7258}

Usage:

AD30 CXR


Underground Articulated Truck:
AD30 (S/N: CXR1-UP; DXR1-UP)

Introduction




Illustration 1g01051135

This publication contains the information for the installation of a wide body arrangement. 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.

Do not perform any procedure and do not order parts that are outlined in this publication until you understand the information that is contained in this document.

Table 1
Parts List    
Qty     Part Number     Description    
1     258-1580     Body As    
1     *258-1572     Wear Plate-Wheel Arch RH  (1)    
1     *258-1573     Wear Plate-Wheel Arch LH  (1)    
2     *258-1574     Wear Plate-Wheel Arch  (1)    
1     *258-1575     Wear Plate-Ducktail  (1)    
2     *258-1576     Wear Plate-Wheel Arch Front  (1)    
2     *258-1577     Wear Plate-Wheel Arch Rear  (1)    
1     *258-1578     Wear Plate-Floor Rear  (1)    
1     *258-1579     Wear Plate-Floor Front  (1)    
8     8T-4223     Hard Washer    
2     *211-1880     Spring    
2     *211-1881     Rod    
2     3B-4615     Pin-Cotter    
2     *229-8474     Pin-Retaining    
4     *258-2096     Spacer-Wheel    
72     *258-2097     Stud    
4     *258-2098     Axle    
8     2K-2939     O-Ring Seal    
1     *262-6927     Support LH    
1     *258-2100     Support RH    
1     *258-0096     Hose As    
1     *211-7015     Hose As    
1     *251-5436     Hose As    
1     *258-0097     Hose As    
1     *211-7016     Hose As    
1     *258-0098     Hose As    
1     *258-0099     Hose As    
1     *258-0100     Hose As    
1     *258-0101     Hose As    
1     *258-0102     Hose As    
1     *258-0103     Hose As    
1     *258-0104     Hose As    
1     *258-0105     Hose As    
1     *258-0107     Hose As    
1     *258-0109     Hose As    
1     *258-0111     Hose As    
1     *258-0113     Hose As    
1     *258-0115     Hose As    
1     *258-0118     Hose As    
1     *258-0120     Hose As    
38     *258-2101     Plate-Retainer    
13     *163-5531     Cable Tie    
1     *258-2102     Mudflap RH    
1     *258-2103     Mudflap LH    
20     8T-4196     Bolt    
40     8T-4121     Hard Washer    
20     8T-4133     Nut    
8     8T-0106     Bolt    
1     *230-4250     Film Gp-Body Dump    
1     *224-9484     Cylinder and Mtg Gp-Hoist  (2)    
1     *224-6435     Lines Gp-Hoist (LH)  (2)    
1     *233-0721     Lines Gp-Hoist (RH) (2)    
( 1 ) * Part of 258-1580 Body As. Install as required
( 2 ) Order as required.

Install the Axle Spacers

ReferenceDisassembly and Assembly, RENR6911, "AD30 Underground Articulated Truck Power Train", "Final Drive, Brake and Wheel - Remove".

ReferenceDisassembly and Assembly, RENR6911, "AD30 Underground Articulated Truck Power Train", "Final Drive, Brake and Wheel - Install".

ReferenceSpecifications, RENR6909, "AD30 Underground Articulated Truck Power Train", "Final Drive and Wheel".

  1. Remove the final drive, brake and wheel. Refer to Disassembly and Assembly, RENR6911, "AD30 Underground Articulated Truck Power Train", "Final Drive, Brake and Wheel - Remove".



    Illustration 2g01082233

    Axle assembly (typical front/rear)

    (1) 258-2098 Axle

    (2) 7X-0851 Nut

    (3) 6V-8237 Washer

    (4) 258-2097 Stud

    (5) 258-2096 Spacer-Wheel

    (6) 2K-2939 O-Ring Seal

  1. Install eighteen 258-2097 Studs (4). Tighten studs (4) to a torque of 400 ± 60 N·m (300 ± 45 lb ft).

  1. Install the final drive, brake and wheel with the additional following items: two 2K-2939 O-Ring Seals (6), 258-2096 Spacer-Wheel (5) and 258-2098 Axle (1). Refer to Disassembly and Assembly, RENR6911, "AD30 Underground Articulated Truck Power Train", "Final Drive, Brake and Wheel - Install" and Specifications, RENR6909, "AD30 Underground Articulated Truck Power Train", "Final Drive and Wheel".

  1. Repeat Steps 1 through Step 3 for the other three final drives, brakes and wheels.

Brake Lines (Front Axle)




    Illustration 3g01082241

    Front axle brake lines

    (P) Parking brake port connection

    (S) Service brake port connection

    (1) 258-0098 Hose As

    (2) 163-5531 Cable Tie

    (3) 211-7016 Hose As

    (4) 258-0099 Hose As

    (5) 258-0100 Hose As

  1. Remove the existing front axle brake lines. Discard the existing front axle brake lines.

  1. Install 258-0098 Hose As (1), 211-7016 Hose As (3), 258-0099 Hose As (4) and 258-0100 Hose As (5) .

  1. Use 163-5531 Cable Straps (2) to clamp the hose assemblies in position.

Brake Oil Cooler Lines (Front Axle)




    Illustration 4g01082250

    Front axle brake oil cooler lines

    (1) 258-0101 Hose As

    (2) 163-5531 Cable Tie

    (3) 258-0103 Hose As

    (4) 258-0102 Hose As

    (5) 258-0104 Hose As

  1. Remove the existing front axle brake oil cooler lines. Discard the existing front axle brake oil cooler lines.

  1. Install 258-0101 Hose As (1), 258-0103 Hose As (3), 258-0102 Hose As (4) and 258-0104 Hose As (5) .

  1. Use 163-5531 Cable Tie (2) to clamp the hose assemblies in position.

Brake Lines (Rear Axle)




    Illustration 5g01082627

    Rear axle brake lines

    (P) Parking brake port connection

    (S) Service brake port connection

    (1) 251-5436 Hose As

    (2) 163-5531 Cable Tie

    (3) 258-0096 Hose As

    (4) 211-7015 Hose As

    (5) 258-0097 Hose As

  1. Remove the existing rear axle brake lines. Discard the existing rear axle brake lines.

  1. Install 251-5436 Hose As (1), 258-0096 Hose As (3), 211-7015 Hose As (4) and 258-0097 Hose As (5) .

  1. Use 163-5531 Cable Tie (2) to clamp the hose assemblies in position.

Lines Gp-Brake Bleeder (Front)

ReferenceSystems Operation, Testing and Adjusting, RENR6915, "AD30 Underground Articulated Truck Braking System", "Purge the Air from the Parking Brake".

ReferenceSystems Operation, Testing and Adjusting, RENR6915, "AD30 Underground Articulated Truck Braking System", "Purge the Air from the Service Brakes and Retarder".




    Illustration 6g01111950

    Front brake bleeder lines

    (1) 258-0120 Hose As

    (2) 258-0118 Hose As

    (3) 258-0113 Hose As

    (4) 258-0115 Hose As

    (5) 163-5531 Cable Tie

  1. Remove the existing front brake bleeder lines. Discard the existing front brake bleeder lines.

  1. Install 258-0120 Hose As (1) .

  1. Install 258-0118 Hose As (2) .

  1. Install 258-0113 Hose As (3) .

  1. Install 258-0115 Hose As (4) .

  1. Install 163-5531 Cable Tie (5) .

  1. Purge the air from the parking brake. Refer to Systems Operation, Testing and Adjusting, RENR6915, "AD30 Underground Articulated Truck Braking System", "Purge the Air from the Parking Brake".

  1. Purge the air from the Service brakes and retarder. Refer to Systems Operation, Testing and Adjusting, RENR6915, "AD30 Underground Articulated Truck Braking System", "Purge the Air from the Service Brakes and Retarder".

Brake Oil Cooler Lines (Rear)




    Illustration 7g01082631

    Rear brake oil cooler lines (left side)

    (1) 258-0107 Hose As

    (2) 258-0105 Hose As

  1. Remove the existing rear brake oil cooler lines. Discard the existing rear brake oil cooler lines.

  1. Install 258-0107 Hose As (1) .

  1. Install 258-0105 Hose As (2) .



    Illustration 8g01082632

    Rear brake oil cooler lines (right side)

    (3) 258-0111 Hose As

    (4) 258-0109 Hose As

  1. Remove the existing rear brake oil cooler lines. Discard the existing rear brake oil cooler lines.

  1. Install 258-0109 Hose As (4) .

  1. Install 258-0111 Hose As (3) .

Modifications to the Fuel Tank and the Fender




    Illustration 9g01082641

    Fuel tank modification to attach the fender guard

    (1) Drill 12 mm (0.47 inch) in nine places

    (A) 467 mm (18.38 inch)

    (B) 292 mm (11.49 inch)

    (C) 137 mm (5.39 inch)

    (D) 20 mm (0.78 inch) typical




    Illustration 10g01082638

    (E) 70 mm (2.75 inch)

    (F) 175 mm (6.88 inch)

    (G) 170 mm (6.69 inch)

    (H) 180 mm (7.08 inch)

    (J) 86 mm (3.38 inch)

  1. Modify the fuel tank in order to attach the fender guard. Refer to Illustration 9 and Illustration 10.



    Illustration 11g01082642

    Front right side fender modification to attach the fender guard

    (1) Drill 12 mm (0.47 inch) in nine places

    (D) 20 mm (0.78 inch)

    (F) 175 mm (6.88 inch)

    (K) 83 mm (3.26 inch)

    (L) 150 mm (5.90 inch)

    (M) 76 mm (2.99 inch)

    (N) 90 mm (3.54 inch)




    Illustration 12g01082643

    Top section of the right side fender modification

    (1) Drill 12 mm (0.47 inch) in nine places

    (D) 20 mm (0.78 inch)

    (P) 125 mm (4.92 inch)

    (R) 135 mm (5.31 inch)

  1. Modify the right side fender in order to attach the fender guard. Refer to Illustration 11 and Illustration 12.



    Illustration 13g01082651

    View of the right side fender guard mounting arrangement

    (2) 258-2102 Guard

    (3) 258-2101 Plate-Retainer

    (4) 8T-4196 Bolt

    (5) 8T-4121 Hard Washer

    (6) 8T-4133 Nut

  1. Install 258-2102 Guard (2) to the fender using the following items: 258-2101 Plate-Retainer (3), 8T-4196 Bolts (4), 8T-4121 Hard Washers (5) and 8T-4133 Nuts (6) .



    Illustration 14g01083024

    View of the left side fender

    (4) 8T-4196 Bolt

    (5) 8T-4121 Hard Washer

    (6) 8T-4133 Nut

    (7) 203-1746 Retainer

    (8) 234-9715 Guard

    (9) 234-9713 Guard

    (10) 203-1236 Retainer

    (11) 234-9712 Guard

    (12) 8T-4185 Bolt

  1. Remove 234-9715 Guard (8), 234-9713 Guard (9) and 234-9712 Guard (11), 203-1746 Retainers (7) and 203-1236 Retainer (10), 8T-4185 Bolt (12), 8T-4196 Bolts (4), 8T-4121 Hard Washers (5) and 8T-4133 Nuts (6) .

  1. Discard 234-9715 Guard (8), 234-9713 Guard (9), 234-9712 Guard (11), 203-1746 Retainers (7) and 203-1236 Retainer (10). Retain 8T-4185 Bolt (12), 8T-4196 Bolts (4), 8T-4121 Hard Washers (5) and 8T-4133 Nuts (6) for assembly.



    Illustration 15g01083018

    View of the new left side fender guard

    (4) 8T-4196 Bolt

    (5) 8T-4121 Hard Washer

    (6) 8T-4133 Nut

    (13) 258-2103 Guard

    (14) 258-2101 Retainer

  1. Install 258-2103 Guard (13) in position with 258-2101 Retainers (14), 8T-4196 Bolts (4), 8T-4121 Hard Washers (5) and 8T-4133 Nuts (6) .

Modification to the Rear Frame




    Illustration 16g01083028

    View of the rear frame modification

    (1) 9R-2613 Boss

    (A) Reference 290 mm (11.41 inch)

    (B) Reference 50 mm (1.96 inch)

    (C) 60 mm (2.36 inch)

    Note: The mounting position for the existing lubrication lines must be moved to allow for clearance when the new dump body is installed.

  1. 9R-2613 Boss (1) 60 mm (2.36 inch) from the original position. Refer to Illustration 16.

Procedure to Remove the Former Dump Body

Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A     212-8974     Jack-Hoist     1    
236-8900 Support LH     1    
8T-4194 Bolt     4    
5P-8245 Hard Washer     4    
B     212-8974     Jack-Hoist     1    
236-8899 Support RH     1    
8T-4194 Bolt     4    
5P-8245 Hard Washer     4    
C     221-0350     Ring-Swivel Lifting     4    
6V-7977 Bolt     4    
9S-8216 Full Nut     4    
221-0351 Washer     4    



    Illustration 17g01083043

    Typical view of the hoist cylinder with Tooling (A) in position

    (1) 2U-9202 Tip Cylinder Pin Assembly

  1. Install Tooling (A) to the left side of the rear frame. Support the hoist cylinder using the jack as shown.

  1. Install Tooling (B) to the right side of the rear frame. Support the hoist cylinder using the jack as shown.

  1. Disconnect the lubrication line from the top of each hoist cylinder.

  1. Remove pin (1) to disconnect each hoist cylinder from the body assembly.

  1. Lower each hoist cylinder on to Tooling (A) and Tooling (B) .



    Illustration 18g01083495

    Lifting positions for the dump body

  1. Install Tooling (C) to the four positions shown in Illustration 18.

  1. Attach a suitable lifting device to Tooling (C). The weight of the dump body is approximately 4200 kg (9260 lb).



    Illustration 19g01083047

    View of the body mounting pins

    (2) 166-2372 Pin As

  1. Remove 166-2372 Pin As (2) from each side of the machine.

  1. Remove the dump body from the machine.

Wide Dump Body - Install

Table 3
Required Tools    
Tool     Part Number     Part Description     Qty    
C     221-0350     Ring-Swivel Lifting     4    
6V-7977 Bolt     4    
9S-8216 Full Nut     4    
221-0351 Washer     4    
D     4C-5592     Anti-Seize Compound     1    
E     212-8974     Jack-Hoist     1    
258-2100 Support RH     1    
8T-0106 Bolt     4    
8T-4223 Hard Washer     4    
F     212-8974     Jack-Hoist     1    
258-2099 Support LH     1    
8T-0106 Bolt     4    
8T-4223 Hard Washer     4    

Hoist Cylinder Stands




    Illustration 20g01083034

    Typical view of the hoist cylinder with Tooling (E) in position

  1. Use a suitable lifting device to support the hoist cylinders. Remove Tooling (A) and Tooling (B) listed in Table 2 from the rear frame. Install Tooling (E) and Tooling (F) listed in Tool Table 3 to both sides of the rear frame. Lower each hoist cylinder on to Tooling (E) and Tooling (F) .

Lifting Positions for the Wide Dump Body




    Illustration 21g01083495

    Lifting positions for the wide dump body with Tooling (C) installed

  1. Install Tooling (C) to the four positions shown in Illustration 21.

  1. Attach a suitable lifting device to Tooling (C). The weight of the wide dump body is approximately 48000 kg (105825 lb).

  1. Install the dump body in position on the rear frame.

Wide Dump Body Mounting Pins - Install




    Illustration 22g01083507

    View of the wide dump body mounting pins

    (1) 166-2372 Pin As

  1. Apply Tooling (D) to 166-2372 Pin As (1). Install 166-2372 Pin As (1) .

  1. Repeat Step 1 for the other 166-2372 Pin As .

Hoist Cylinder Mounting




    Illustration 23g01083043

    Typical view of the hoist cylinder with Tooling (A) installed

    (1) 2U-9202 Tip Cylinder Pin Assembly

  1. Apply Tooling (D) to 2U-9202 Tip Cylinder Pin Assembly (1). Install 2U-9202 Tip Cylinder Pin Assembly (1) to connect each hoist cylinder to the wide body assembly.

  1. Connect the lubrication line to the top of each hoist cylinder.

  1. Remove Tooling (E) and Tooling (F) from each side of the machine.

Wide Dump Body Arrangement (258-4624)




Illustration 24g01083029

Wide body arrangement

(1) 258-1579 Wear Plate-Floor

(2) 258-1576 Wear Plate-Wheel Arch

(3) 258-1578 Wear Plate-Floor

(4) 258-1574 Floor Plate-Wheel Arch

(5) 258-1573 Floor Plate-Wheel Arch LH

(6) 258-1577 Floor Plate-Wheel Arch

(7) 258-1575 Wear Plate-Ducktail

(8) 258-1572 Wear Plate-Wheel Arch RH

(9) 211-1881 Rod

(10) 211-1880 Spring

(11) 8T-4223 Hard Washer

(12) 3B-4615 Cotter Pin

(13) 229-8474 Pin-Retaining

Caterpillar Information System:

AD30 and AD55 Underground Articulated Trucks Power Train Electronic Control System Backup Alarm Always On
AD55 Underground Articulated Truck System Pressure - Release
AD55 Underground Articulated Truck Power Train Torque Converter and Transmission Hydraulic System Troubleshooting
631G and 637G Wheel Tractor-Scrapers Machine Systems Main Control Valve - Remove
988H Wheel Loader Machine Systems Evaporator Coil and Heater Coil - Install
631G and 637G Wheel Tractor-Scrapers Machine Systems Accumulator (Cushion-Hitch) - Install
2004/08/02 New Air Hose Routing Procedure Is Now Being Used {1808}
988H Wheel Loader Machine Systems Evaporator Coil and Heater Coil - Remove
631G and 637G Wheel Tractor-Scrapers Machine Systems Accumulator (Cushion-Hitch) - Remove
631G and 637G Wheel Tractor-Scrapers Machine Systems Piston Pump (Cushion-Hitch) - Install
D9T Track-Type Tractor Machine Systems Fan Reversing Valve - Install
826H Landfill Compactor, <BR>825H Soil Compactor and <BR>824H Wheel Dozer Engine Supplement Refrigerant Condenser - Remove and Install
824H Wheel Dozer, 825H Soil Compactor and 826H Landfill Compactor Machine Systems Front Frame from Rear Frame - Separate
2004/07/01 Engines Are Now Built with Semi-Crowned Lifter Rollers {1209}
631G and 637G Wheel Tractor-Scrapers Machine Systems Main Control Valve - Install
2004/07/05 Improved Analysis of Non-Warrantable Failures for Reman Vane Cartridges {5055}
988H Wheel Loader Power Train Engagement Pressure for the Transmission Clutch (Operator Monitor) - Calibrate
988H Wheel Loader Power Train Fill Time for the Transmission Clutch (Operator Monitor) - Calibrate
AccuGrade Laser System MID 114 - CID 0248 - FMI 09
988H Wheel Loader Power Train Reduced Rimpull Setting (Electronic Technician) - Adjust
854G and 854K Wheel Dozers and 992G, 992K and 994F Wheel Loaders VIMS<SUP>TM</SUP> MID 049 - CID 0826 - FMI 03
854G and 854K Wheel Dozers and 992G, 992K and 994F Wheel Loaders VIMS<SUP>TM</SUP> MID 049 - CID 0826 - FMI 04
988H Wheel Loader Power Train Torque Converter Impeller Clutch Pressure - Test
834H Wheel Dozer and 836H <BR>Landfill Compactor Electrohydraulic System Tilt and Tip Cylinder - Right Side
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.