- Load Haul Dump:
- R1700G (S/N: 8XZ421-UP)
Introduction
The supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for each standard machine. This supplement is used to determine the difference between the custom modifications and a standard machine.
The Service Manual and the Parts Manual that is available for the standard machine should be used if the service information is not in this supplementary product support literature.
Machine Controls and Operation
Joystick Control
Note: On machines S/N:8XZ291-UP, the joystick control functions will be disabled when the operator's station door is opened approximately 150 mm (6 inch). Ensure the operator's station door is firmly closed before operating the machine.
NOTICE |
---|
The standard joystick control lever is a pull-back-to-raise, push-forward-to-lower type. Certain mining regulations require machines to be equipped with a push-right-to-raise, pull-left-to-lower type. Before operating the machine, ensure you are familiar with the operation of the type of joystick control lever on your machine. |
Joystick Control Lever - Standard Type
Illustration 1 | g00988644 |
The joystick control lever performs the following functions:
FLOAT (1) - Push and hold the lever all the way forward for the FLOAT position. The bucket will lower to the ground and move up and down following the ground contour. The lever will return to the HOLD position when released. |
NOTICE |
---|
Never use the FLOAT position to lower a loaded bucket. Machine damage can result from a bucket that falls too fast. |
LOWER (2) - Push the lever forward to lower the bucket. The lever will return to the HOLD position when released. |
RAISE (3) - Pull the lever back to raise the bucket. The lever will return to the HOLD position when released. |
DUMP (4) - Push the lever across to the right to dump the bucket. The lever will return to the HOLD position when released. |
TILT BACK (5) - Pull the lever across to the left to tilt the bucket back. The lever will return to the HOLD position when released. |
HOLD (6) - The lever will return to the HOLD position automatically when released. The bucket will remain in the selected position when in the HOLD position. |
EJECT EJECTOR BUCKET (A4) - Depress and hold the left side of switch (A) while pushing the lever across to the DUMP position. This will cause the ejector bucket to eject the load. The lever will return to the HOLD position when released. |
RETRACT EJECTOR BUCKET (A5) - Depress and hold the left side of switch (A) while pulling the lever across to the TILT BACK position. This will cause the ejector plate to retract into the ejector bucket. The lever will return to the HOLD position when released. |
Joystick Control Lever - Optional Type
Illustration 2 | g00988645 |
The joystick control lever performs the following functions.
FLOAT (1) - Pull and hold the lever all the way across to the left for the FLOAT position. The bucket will lower to the ground and move up and down following the ground contour. The lever will return to the HOLD position when released. |
NOTICE |
---|
Never use the FLOAT position to lower a loaded bucket. Machine damage can result from a bucket that falls too fast. |
LOWER (2) - Pull the lever across to the left to lower the bucket. The lever will return to the HOLD position when released. |
RAISE (3) - Push the lever across to the right to raise the bucket. The lever will return to the HOLD position when released. |
DUMP (4) - Push the lever forward to dump the bucket. The lever will return to the HOLD position when released. |
TILT BACK (5) - Pull the lever back to tilt the bucket back. The lever will return to the HOLD position when released. |
HOLD (6) - The lever will return to the HOLD position automatically when released. The bucket will remain in the selected position when in the HOLD position. |
EJECT EJECTOR BUCKET (A4) - Depress and hold the left side of switch (A) while pushing the lever across to the DUMP position. This will cause the ejector bucket to eject the load. The lever will return to the HOLD position when released. |
RETRACT EJECTOR BUCKET (A5) - Depress and hold the left side of switch (A) while pulling the lever across to the TILT BACK position. This will cause the ejector plate to retract into the ejector bucket. The lever will return to the HOLD position when released. |
Maintenance Interval Schedule
Note: All safety information, warnings, and instructions must be read and understood before you perform any operation of any maintenance procedure.
Before each consecutive interval is performed, all of the maintenance requirements from the previous intervals must be performed.
Every 10 Service Hours or Daily     |
Ejector Cylinder Bearings - Lubricate     |
Ejector Plate Bearings - Lubricate     |
Ejector Cylinder Bearings - Lubricate
Illustration 3 | g01199454 |
NOTICE |
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Check that the lines attached to all the remote grease fittings are undamaged. If the grease lines are split, grease will not reach the components that require lubricating. Machine damage will result. |
Wipe off the fittings before any lubricant is applied.
- Apply lubricant through fitting (1) for the bearing at the head end of the ejector cylinder.
- Apply lubricant through remote mounted fitting (2) for the bearing at the rod end of the ejector cylinder.
- Repeat Steps 1 and 2 for the other ejector cylinder.
Ejector Plate Bearings - Lubricate
Illustration 4 | g01199455 |
NOTICE |
---|
Check that the lines attached to all the remote grease fittings are undamaged. If the grease lines are split, grease will not reach the components that require lubricating. Machine damage will result. |
Wipe off the fittings before any lubricant is applied.
- Apply lubricant through fitting (3) on each side of the bucket for the ejector plate bearings (2 points).
Specifications
Ejector Bucket
Illustration 5 | g00908069 |
(1) Apply 5P-3931 Anti-Seize Compound to the threads of the bolts prior to assembly.
- Torque for one bolt in each collet assembly ... 370 ± 50 N·m (275 ± 37 lb ft)
(2) Apply 5P-3931 Anti-Seize Compound to the threads of the bolts prior to assembly.
- Torque for the two bolts ... 430 ± 60 N·m (315 ± 45 lb ft)
(3) Apply 5P-3931 Anti-Seize Compound to the threads of the bolts prior to assembly.
- Torque for the two bolts ... 370 ± 50 N·m (275 ± 37 lb ft)
Ejector Cylinder
Illustration 6 | g01194213 |
(1) Lubricate the sealing lips with a small amount of the lubricant that is being sealed.
(2) Apply 7M-7456 Bearing Mount Compound to the wiper seal groove prior to assembly.
(3) Lubricate the threads and torque the nut to ... 1600 ± 160 N·m (1180 ± 118 lb ft)
(4) Torque the four bolts to ... 240 ± 40 N·m (180 ± 29 lb ft)
(5) Bore of a new cylinder tube ... 101.6 ± 0.25 mm (4.00 ± 0.010 inch)
(6) Diameter of a new rod ... 50.75 ± 0.038 mm (1.998 ± 0.0015 inch)
(7) Bore of a new cylinder head ... 51.08 ± 0.03 mm (2.011 ± 0.001 inch)
Solenoid Valve (Pilot)
Part No.: 152-8346
Illustration 7 | g00776085 |
(1) Torque for the nut ... 9.0 ± 0.5 N·m (80.00 ± 4.00 lb in)
(2) Coil
- Nominal Voltage ... 24 VDC
- Duty ... Continuous
- Resistance at 25° ± 5°C (77° ± 9°F) ... 32.6 ± 1.6 Ohms
- Duty ... Continuous
(3) Installation torque for the solenoid valve ... 115 ± 7 N·m (85 ± 5 lb ft)
Control Valve (Auxiliary)
Part No.: 9EQ7161
Illustration 8 | g01196073 |
(1) Installation torque for the valve ... 207 ± 8 N·m (153 ± 6 lb ft)
Minimum pressure to open the valve is ... 1400 kPa (203 psi)
Control Valve (Tilt)
Part No.: 9EQ7162
Illustration 9 | g01196073 |
(1) Installation torque for the valve ... 483 ± 18 N·m (356 ± 13 lb ft)
Minimum pressure to close the valve is ... 1400 kPa (203 psi)
Systems Operation Section
General Information
Illustration 10 | g01196398 |
Schematic for the hydraulic system (1) Tilt Cylinder (2) Auxiliary Cylinders (3) Auxiliary control valve for head end of auxiliary cylinders (4) Tilt control valve for rod end of tilt cylinder (5) Tilt control valve for head end of tilt cylinder (6) Auxiliary control valve for rod end of auxiliary cylinders (7) Pilot solenoid valve (8) Pressure tap for rod end of tilt cylinder (9) Pressure tap for head end of tilt cylinder (10) Ride control accumulator (11) Main control valve (12) Line relief valve for rod end of tilt cylinder (13) Line relief valve for head end of tilt cylinder (14) Lift cylinders (15) Relief valve for main implement pump (16) Lift circuit relief valve (17) Ride control diverter valve (18) Lift arm positioner valve (19) Float sequence valve (20) Pressure tap for parking brake and pilot system (21) Pilot control valve - lift and tilt (22) Implement and steering neutralizer valve (23) Check valves (24) Automatic lubrication system connection port (25) Parking brake control valve (26) Line to the steering circuit (27) Selector and pressure control valve (28) Manifold (29) Main implement pump (30) Pilot oil pressure reducing valve (31) Brake and pilot pump (32) Breaker relief valve (33) Portable hydraulic pump quick connect coupler (34) Hydraulic tank (35) Line to the service brake circuit |
Auxiliary Pilot Hydraulic System
Illustration 11 | g01201547 |
Location of the pilot solenoid valve |
Illustration 12 | g01201549 |
(7) Pilot solenoid valve |
Pilot solenoid valve (7) is an additional component in the optional auxiliary pilot hydraulic system. The pilot solenoid valve is located on the front frame.
Illustration 13 | g01201550 |
(36) Switch (37) Joystick control lever |
When the auxiliary pilot hydraulic system is activated, the DUMP position changes to the EJECT position also the TILT BACK position changes to the RETRACT position.
To activate the auxiliary pilot hydraulic system, press and hold the left side of switch (36) while joystick control lever (37) is moved to the EJECT or RETRACT positions.
Switch (36) energizes pilot solenoid valve (7) and allows pilot pressure oil to flow to tilt control valves (4) and (5) and auxiliary control valves (3) and (6) .
Auxiliary Main Hydraulic System
Illustration 14 | g01198754 |
(3) Auxiliary control valve for the head end of the auxiliary cylinders (6) Auxiliary control valve for the rod end of the auxiliary cylinders (38) Manifold (39) Manifold |
Illustration 15 | g01198761 |
(4) Tilt control valve for the rod end of the tilt cylinder (38) Manifold |
Illustration 16 | g01198758 |
(5) Tilt control valve for the head end of the tilt cylinder (39) Manifold |
Tilt control valves (4) and (5) and auxiliary control valves (3) and (6) are additional components in the optional auxiliary main hydraulic system. The tilt control valves and auxiliary control valves are located in manifolds (38) and (39). The manifolds are located on top of the front frame.
Tilt Circuit
The flow of implement oil from main control valve (11) to tilt cylinder (1) changes when the machine has an auxiliary hydraulic system. The implement oil now flows first to the tilt control valves and the auxiliary control valves. During normal operation the tilt control valves are open allowing implement oil to continue flowing to the tilt cylinder. The auxiliary control valves are closed stopping implement oil flowing to the auxiliary cylinders. This prevents the operation of the tilt circuit and the auxiliary circuit at the same time.
Auxiliary Circuit
Illustration 17 | g01203486 |
(36) Switch |
EJECT Operation
When the engine is running, press and hold the left side of switch (36) to energize pilot solenoid valve (7). Pilot oil flows through pilot solenoid valve (7) to tilt control valves (4) and (5) and auxiliary control valves (3) and (6). This causes the tilt control valves to close and the auxiliary control valves to open at the same time.
When tilt control valves (4) and (5) close, the flow of implement oil to tilt cylinder (1) is stopped. When the joystick control lever is moved to the EJECT position, implement oil from main control valve (11) now flows through auxiliary control valve (3) to the head end of auxiliary cylinders (2) and causes the cylinder rods to extend. Oil from the rod end of auxiliary cylinders (2) returns through auxiliary control valve (6) and main control valve (11) to hydraulic tank (34) .
RETRACT Operation
When the engine is running, press and hold the left side of switch (36) to energize pilot solenoid valve (7). Pilot oil flows through pilot solenoid valve (7) to tilt control valves (4) and (5) and auxiliary control valves (3) and (6). This causes the tilt control valves to close and the auxiliary control valves to open at the same time.
When tilt control valves (4) and (5) close, the flow of implement oil to tilt cylinder (1) is stopped. When the joystick control lever is moved to the RETRACT position, implement oil from main control valve (11) now flows through auxiliary control valve (6) to the rod end of auxiliary cylinders (2) and causes the cylinder rods to retract. Oil from the head end of auxiliary cylinders (2) returns through auxiliary control valve (3) and main control valve (11) to hydraulic tank (34) .
Auxiliary Control Valve
Illustration 18 | g01201866 |
(3) Auxiliary control valve for the head end of the auxiliary cylinders (4) Tilt control valve for the rod end of the tilt cylinder (5) Tilt control valve for the head end of the tilt cylinder (6) Auxiliary control valve for the rod end of the auxiliary cylinders (38) Manifold (39) Manifold |
Illustration 19 | g01196430 |
(3) Auxiliary control valve for the head end of auxiliary cylinders (6) Auxiliary control valve for the rod end of auxiliary cylinders (40) Drain port (41) Pilot port (42) Outlet port (implement oil) (43) Inlet port (implement oil) (44) Valve spring |
Auxiliary control valve (3) is connected to the head end of the auxiliary cylinders. Auxiliary control valve (6) is connected to the rod end of the auxiliary cylinders. The construction and operation of these valves are the same. In the normally closed position auxiliary control valves (3) and (6) stop the flow of implement oil to the auxiliary cylinders. When auxiliary control valves (3) and (6) open, implement oil flows to the auxiliary cylinders.
Valve spring (44) holds auxiliary control valves (3) and (6) in the normally closed position.
When pilot oil enters pilot port (41), the pilot oil pressure overcomes the spring force and the auxiliary control valve opens. This allows implement oil to flow from inlet port (43) to outlet port (42). The implement oil flows from outlet port (42) to the auxiliary cylinders.
Drain port (40) allows leakage from the spring chamber to drain to the hydraulic tank.
Tilt Control Valve
Illustration 20 | g01201866 |
(3) Auxiliary control valve for the head end of the auxiliary cylinders (4) Tilt control valve for the rod end of the tilt cylinder (5) Tilt control valve for the head end of the tilt cylinder (6) Auxiliary control valve for the rod end of the auxiliary cylinders (38) Manifold (39) Manifold |
Illustration 21 | g01196797 |
(4) Tilt control valve for the rod end of the tilt cylinder (5) Tilt control valve for the head end of the tilt cylinder (45) Drain port (46) Pilot port (47) Outlet port (implement oil) (48) Inlet port (implement oil) (49) Valve spring |
Tilt control valve (4) is connected to the rod end of the tilt cylinder. Tilt control valve (5) is connected to the head end of the tilt cylinder. The construction and operation of these valves are the same. In the normally open position tilt control valves (4) and (5) allow implement oil to flow to the tilt cylinder. When tilt control valves (4) and (5) close, implement oil stops flowing to the tilt cylinder.
Valve spring (49) holds tilt control valves (4) and (5) in the normally open position.
When pilot oil enters pilot port (46), the pilot oil pressure overcomes the spring force and the tilt control valve closes. This stops implement oil flowing from inlet port (48) to outlet port (47). Implement oil stops flowing from outlet port (47) to the tilt cylinder.
Drain port (45) allows leakage from the spring chamber to drain to the hydraulic tank.
Disassembly and Assembly
Ejector Bucket - Remove
Required Tools     | |||
Tool     | Part Number     | Part Description     | Qty     |
A     | 5P-8715     | Forcing Bolt     | 3     |
Start By:
a. Install the steering frame lock pin. Refer to Disassembly and Assembly, RENR4675, "Steering Frame Lock Pin - Remove and Install".
b. Release the pressure from the hydraulic system. Refer to Disassembly and Assembly, RENR4675, "Hydraulic System Pressure - Release".
Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help 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, all hoses and all tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
NOTICE |
---|
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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
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 work tools have been lowered to the ground, and the 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. |
- Disconnect hose assembly (1).
Illustration 22 | g01192179 |
- Repeat Step 1 for the other side of the lift arm assembly.
- Attach a suitable lifting device to tilt link (2). The weight of tilt link (2) is approximately 143 kg (315 lb).
Illustration 23 | g01187795 |
Typical example |
- Remove bolt (3), the washer and the nut.
- Remove three plugs (4) from collet (5) .
Illustration 24 | g01201891 |
Typical example |
- Install Tooling (A). Tighten Tooling (A) evenly to remove collet (5) .
Illustration 25 | g01187797 |
Typical example |
- Repeat Step 5 and Step 6 to remove the other side collet.
- Attach a suitable lifting device to pin (6). The weight of pin (6) is approximately 23 kg (50 lb).
Illustration 26 | g01188112 |
Typical example |
- Remove shims (7) .
Illustration 27 | g01193222 |
Typical example |
- Secure tilt link (2) to the tilt lever.
- Attach a suitable lifting device to ejector bucket (8). The weight of the ejector bucket is approximately 5830 kg (12850 lb).
Illustration 28 | g01192184 |
Typical example |
- Remove bolt (9), the washers and the nut from the lower bucket pin assembly.
Illustration 29 | g01187792 |
Typical example |
- Remove three plugs (10) .
- Install Tooling (A). Tighten Tooling (A) evenly to remove collet (11) .
Illustration 30 | g01187793 |
Typical example |
- Repeat Step 13 and Step 14 to remove the other side collet.
- Use two people to remove pin (13). The weight of pin (13) is approximately 23 kg (50 lb).
Illustration 31 | g01192187 |
Typical example |
- Remove shims (12) .
- Repeat Step 12 through Step 17 for the bucket pin assembly on the other side.
- Remove the ejector bucket.
Ejector Bucket - Disassemble
Required Tools     | |||
---|---|---|---|
Tool     | Part Number     | Part Description     | Qty     |
A     | 9EP1733     | Forcing Bolts     | 3     |
B     | 1U-9201     | Lever Puller Hoist     | 1     |
C     | 138-7574     | Link Brackets     | 2     |
D     | 3S-6224 8S-8033     |
Electric Hydraulic Pump Gp (115-VOLT) or Electric Hydraulic Pump Gp (230-VOLT)     |
1     |
6V-3175 | Double Acting Cylinder     | 1     | |
4C-9634 | Puller Stud     | 1     | |
9U-6832 | Nut     | 1     | |
9U-5341 | Adapter Plate     | 1     | |
9U-5266 | Sleeve     | 1     |
Start By:
a. Install the steering frame lock pin. Refer to Disassembly and Assembly, RENR4675, "Steering Frame Lock Pin - Remove and Install".
b. Release the pressure from the hydraulic system. Refer to Disassembly and Assembly, RENR4675, "Hydraulic System Pressure - Release".
Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help 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, all hoses and all tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
NOTICE |
---|
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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
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 work tools have been lowered to the ground, and the 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. |
- Use suitable wood blocks to support the ejector cylinders in the horizontal position.
- Remove cover plate (1) .
Illustration 32 | g01101757 |
Typical example |
- Remove bolt (2), and the washer from collet (3) .
- Remove the three rubber bungs from collet (3) .
- Install Tooling (A) to collet (3). Tighten Tooling (A) evenly to remove collet (3) .
Illustration 33 | g01101760 |
Typical example |
- Repeat Step 4 and Step 5 to remove the other side collet.
- Remove pin (5), and shims (4) .
Illustration 34 | g01102492 |
Typical example |
- Repeat Step 2 through Step 7 for the other ejector cylinder pin assembly.
- Install Tooling (B), Tooling (C) and a suitable lifting device to ejector plate (6). The weight of ejector plate (6) and the ejector flap is approximately 1240 kg (2735 lb).
Illustration 35 | g01193235 |
- Remove bolt (7), and the washer from pin (8) .
Illustration 36 | g01101762 |
Typical example |
- Use Tooling (D) to remove pin (8) .
- Remove shims (9) (not shown).
- Repeat Step 10 through Step 12 for the other side of the ejector bucket.
- Remove ejector plate (6) and the ejector flap.
- Attach a suitable lifting device to ejector flap (10). The weight of ejector flap (10) is approximately 140 kg (309 lb).
Illustration 37 | g01102485 |
Typical example |
- Remove two bolts (11), and the washers from the hinge pin.
- Use two people and remove the hinge pin to separate ejector flap (10) from ejector plate (6). The weight of the hinge pin is approximately 25 kg (55 lb).
- Remove lip seal (12) from the ejector plate.
Illustration 38 | g01102486 |
- Remove bearing (13) from the ejector plate.
- Repeat Step 18 and Step 19 for the bearing in other side of the ejector plate.
- Disconnect hose assemblies (16), (17) and (18) .
Illustration 39 | g01193241 |
- Remove clip (14) .
- Attach a suitable lifting device to ejector cylinder (15). The weight of the ejector cylinder is approximately 52 kg (115 lb).
- Remove bolt (19), and the washer from collet (20) .
Illustration 40 | g01193250 |
- Remove the three rubber bungs from collet (20) .
- Install Tooling (A) to collet (20). Tighten Tooling (A) evenly to remove collet (20) .
Illustration 41 | g01193254 |
Typical example |
- Repeat Step 25 and Step 26 to remove the other side collet.
- Remove the ejector cylinder head end pin, and the shims.
- Remove the ejector cylinder from the ejector bucket.
- Repeat Step 21 through Step 29 to remove the other ejector cylinder.
Ejector Bucket - Assemble
Required Tools     | |||
---|---|---|---|
Tool     | Part Number     | Part Description     | Qty     |
B     | 1U-9201     | Lever Puller Hoist     | 1     |
C     | 138-7574     | Link Bracket     | 2     |
E     | 5P-3931     | Anti-Seize Compound     | 1     |
F     | 1P-1839     | Bearing Puller Adapter     | 1     |
G     | 1P-0520     | Driver Gp     | 1     |
H     | 5P-0960     | Grease Cartridge (MOLYBDENUM)     | 1     |
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.
- Apply Tooling (H) to the bore of ejector cylinder (15) .
Illustration 42 | g01193266 |
- Attach a suitable lifting device to ejector cylinder (15). The weight of the ejector cylinder is approximately 52 kg (115 lb).
- Install ejector cylinder (15) to the ejector bucket. Align the bores of the ejector cylinder and the ejector bucket.
- Install the ejector cylinder pin and shims.
- Install three plastic plugs (21) to the collets.
Illustration 43 | g01102509 |
- Install three rubber bungs (22) to the collets.
Illustration 44 | g01102511 |
- Apply Tooling (E) to the inside diameter and the outside diameter of the collets.
- Install collet (20) .
Illustration 45 | g01102517 |
Typical example |
- Install the collet on the other side.
- Apply Tooling (E) 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.
Illustration 46 | g01193250 |
- Tighten bolt (19) 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).
- 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).
- 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.
- Position ejector cylinder (15) in the horizontal position using suitable wood blocks.
Illustration 47 | g01193241 |
- Install clip (14) .
- Connect hose assemblies (16), (17) and (18) .
- Repeat Step 1 through Step 16 to install the other ejector cylinder.
- Lower the temperature of bearing (13) to -75° ± 5°C (-103° ± 9°F). Use Tooling (F) to install bearing (13) to a depth of 9.5 ± 1 mm (0.37 ± 0.04 inch) below the surface of the bore.
Illustration 48 | g01102486 |
- Use Tooling (G) to install lip seal (12). Install lip seal (12) with the sealing lip towards the outside of the ejector plate.
- Repeat Step 18 and Step 19 for the other side of the ejector plate.
- Attach a suitable lifting device to ejector flap (10). The weight of ejector flap (10) is approximately 140 kg (309 lb).
Illustration 49 | g01102485 |
Typical example |
- Apply Tooling (E) to the bores of ejector flap (10) and ejector plate (6) .
- Align the bores of ejector flap (10) and ejector plate (6).
- Use two people to install the hinge pin. The weight of the hinge pin is approximately 25 kg (55 lb).
- Apply Tooling (E) to the threads of bolts (11) prior to assembly.
- Install two bolts (11), and the washers. Tighten bolts (11) to a torque of 430 ± 60 N·m (315 ± 45 lb ft).
- Install Tooling (B), Tooling (C) and a suitable lifting device to ejector plate (6). The weight of the ejector plate with the ejector flap attached is approximately 1240 kg (2735 lb).
Illustration 50 | g01193235 |
- Apply Tooling (H) to the bores of the ejector bucket and the bores of the ejector plate.
Illustration 51 | g01101762 |
Typical example |
- Align the bores of the ejector bucket and the ejector plate.
- Install shims (9) (not shown) as required between the ejector bucket and the ejector plate.
- Install pin (8) .
- Apply Tooling (E) to the threads of bolt (7) prior to assembly.
- Install bolt (7) and the washer.
- Repeat Step 30 through Step 33 for the other end of the ejector bucket.
- Apply Tooling (H) to the bore of the ejector cylinder.
Illustration 52 | g01102492 |
Typical example |
- Align the bores of the ejector plate and the ejector cylinder.
- Install shims (4) as required.
- Install pin (5) .
- Install three plastic plugs (23) to the collets.
Illustration 53 | g01103423 |
- Install three rubber bungs (24) to the collets.
Illustration 54 | g01103424 |
- Apply Tooling (E) to the inside diameter and the outside diameter of the collets.
Illustration 55 | g01101757 |
Typical example |
- Install collet (3). Install the collet to the other side.
- Apply Tooling (E) to the threads of bolt (2) .
- Install bolt (2) and the washer.
- Tighten bolt (2) 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).
Note: The collet on one side must not extend farther than the other when the bolt is tight.
- Tighten bolt (2) 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).
- Tighten bolt (2) 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.
- Install cover plate (1) .
- Repeat Step 35 through Step 48 to install the other ejector cylinder.
- Lubricate the ejector cylinder bearings. Refer to ""Ejector Cylinder Bearings - Lubricate" ".
- Lubricate the ejector plate bearings. Refer to ""Ejector Plate Bearings - Lubricate" ".
- Fill the hydraulic tank with oil to the correct level. Refer to Operation and Maintenance Manual, SEBU7323, "Hydraulic System Oil Level - Check".
End By:
a. Remove the steering frame lock pin. Refer to Disassembly and Assembly, RENR4675, "Steering Frame Lock Pin - Remove and Install".
Ejector Bucket - Install
Required Tools     | |||
Tool     | Part Number     | Part Description     | Qty     |
B     | 5P-0960     | Grease Cartridge (MOLYBDENUM)     | 1     |
C     | 5P-3931     | Anti-Seize Compound     | 1     |
Note: Ensure that the pin bores in the ejector bucket, lift arm assembly and tilt link are free of dirt and debris.
- Apply Tooling (B) to the bores of the lift arms and the tilt link.
- Attach a suitable lifting device to ejector bucket (8). The weight of the ejector bucket is approximately 5830 kg (12850 lb).
Illustration 56 | g01192184 |
Typical example |
- Align the pin bores of ejector bucket (8) and the lift arm assembly.
- Install shims (12) as required.
Illustration 57 | g01192187 |
Typical example |
- Use two people to install pin (13). The weight of pin (13) is approximately 23 kg (50 lb).
- Repeat Step 4 and Step 5 for the pin on the other side.
- Install three plugs (10) to collet (11) .
Illustration 58 | g01192193 |
Typical example |
- Apply Tooling (C) to the inside and the outside diameters of collet (11) .
- Install collet (11) .
- Repeat Step 7 through Step 9 for the collet on the other side.
- Apply Tooling (C) to the threads of bolt (9) .
Illustration 59 | g01201890 |
Typical example |
- Install bolt (9), the washer and the nut.
- Tighten bolt (9) and the nut to torque of 1800 ± 200 N·m (1330 ± 145 lb ft). After the bolt and nut are tight, hit the collet on each side with a heavy hammer until the torque on the bolt and the nut is less than 950 N·m (700 lb ft).
Note: The collet on one side must not extend farther than the other collet when the bolt and nut are tight.
- Tighten bolt (9) and the nut again to torque of 1800 ± 200 N·m (1330 ± 145 lb ft). Hit each collet again until the torque for bolt (9) and the nut is less than 1600 N·m (1180 lb ft).
- Tighten bolt (9) and the nut to a final torque of 1800 ± 200 N·m (1330 ± 145 lb ft).
- Repeat Step 7 through Step 15 for the pin assembly on the other side.
Note: At the end of 50 service hours, repeat Step 13 through Step 15 for both pin assemblies.
- Attach a suitable lifting device to tilt link (2). The weight of tilt link (2) is approximately 143 kg (315 lb). Align the bores of the ejector bucket and the tilt link.
Illustration 60 | g01193222 |
Typical example |
- Install shims (7) .
- Attach a suitable lifting device to pin (6). The weight of pin (6) is approximately 23 kg (50 lb).
Illustration 61 | g01188112 |
Typical example |
- Install pin (6) .
- Install three plugs (4) to collet (5) .
Illustration 62 | g01201891 |
Typical example |
- Apply Tooling (C) to the inside and the outside diameters of collet (5) .
- Install collet (5) .
- Repeat Step 21 through 23 for the collet on the other side.
- Apply Tooling (C) to the threads of bolt (3) .
Illustration 63 | g01187795 |
Typical example |
- Install bolt (3), the washer and the nut.
- Tighten bolt (3) and the nut to torque of 1800 ± 200 N·m (1330 ± 145 lb ft). After the bolt and nut are tight, hit the collet on each side with a heavy hammer until the torque on the bolt and the nut is less than 950 N·m (700 lb ft).
Note: The collet on one side must not extend farther than the other collet when the bolt and nut are tight.
- Tighten bolt (3) and the nut again to torque of 1800 ± 200 N·m (1330 ± 145 lb ft). Hit each collet again until the torque for bolt (3) and the nut is less than 1600 N·m (1180 lb ft).
- Tighten bolt (3) and the nut to a final torque of 1800 ± 200 N·m (1330 ± 145 lb ft).
Note: At the end of 50 service hours, repeat Step 27 through Step 29.
- Connect hose assembly (1). Repeat for the other side of the lift arm assembly.
Illustration 64 | g01192179 |
- Lubricate the ejector bucket pivot bearings. Refer to Operation and Maintenance Manual, SEBU7323, "Bucket Pivot Bearings - Lubricate".
- Lubricate the tilt linkage. Refer to Operation and Maintenance Manual, SEBU7323, "Tilt Linkage Bearings - Lubricate".
- Fill the hydraulic tank with oil to the correct level. Refer to Operation and Maintenance Manual, SEBU7323, "Hydraulic System Oil Level - Check".
End By:
a. Remove the steering frame lock pin. Refer to Disassembly and Assembly, RENR4675, "Steering Frame Lock Pin - Remove and Install".