9EQ8400 Ejector Bucket Supplement for the R2900G Load Haul Dump{6128} Caterpillar


9EQ8400 Ejector Bucket Supplement for the R2900G Load Haul Dump{6128}

Usage:

R2900G JLK


Load Haul Dump:
R2900G (S/N: JLK1-UP)

Introduction




Illustration 1g01051135

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: The machine's joystick control functions will be disabled when the parking brake is engaged and the engine speed is less than 1500 rpm.


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 2g01308253

The joystick control lever performs the functions as listed below.


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 right 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 right 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 3g01307362

The joystick control lever performs the functions as listed below.


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 right side of switch (A) while pushing the lever forward 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 right side of switch (A) while pulling the lever back 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.

Table 1
Every 10 Service Hours or Daily    
Ejector Cylinder Bearings - Lubricate    
Ejector Plate Bearings - Lubricate    

Ejector Cylinder Bearings - Lubricate




Illustration 4g01307766


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.

  1. Apply lubricant through fitting (1) for the bearing at the head end of the ejector cylinder.

  1. Apply lubricant through remote mounted fitting (2) for the bearing at the rod end of the ejector cylinder.

  1. Repeat Steps 1 and 2 for the other ejector cylinder.

Ejector Plate Bearings - Lubricate




Illustration 5g01307767


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.

  1. Apply lubricant through fitting (3) on each side of the bucket for the ejector plate bearings (2 points).

Specifications

Ejector Bucket

Part No: 9EQ8400




Illustration 6g00908069

(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)

Note: Apply 5P-3931 Anti-Seize Compound to the inside and to the outside diameters of all collets prior to assembly.

Ejector Cylinder

Part No: 9EQ8404




Illustration 7g01307772

(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) Install washer with the flat side toward the rod.

(5) Lubricate the threads and torque the four bolts to ... 240 ± 40 N·m (180 ± 29 lb ft)

(6) Bore of a new cylinder tube ... 114.35 ± 0.10 mm (4.502 ± 0.004 inch)

(7) Diameter of a new rod ... 50.75 ± 0.038 mm (1.998 ± 0.0015 inch)

(8) Bore of a new cylinder head ... 51.08 ± 0.03 mm (2.011 ± 0.001 inch)

Solenoid Valve (Pilot)

Part No: 152-8346




Illustration 8g00776085

(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

(3) Installation torque for the solenoid valve ... 115 ± 7 N·m (85 ± 5 lb ft)

Control Valve (Auxiliary/Tilt)




Illustration 9g01308575

Part No: 9EQ9589

(1) Installation torque for the valve ... 160 N·m (120 lb ft)

Minimum pressure to open the valve is ... 1000 kPa (145 psi)

Relief Valve (Line)




Illustration 10g00291579

Part No: 108-6428

Part No: 4T-4162

(1) Torque for the nut ... 50 ± 7 N·m (37 ± 5 lb ft)

(2) Torque for the valve body ... 65 ± 5 N·m (48 ± 4 lb ft)

(3) 4T-2741 Spring

Length under test force ... 58.7 mm (2.31 inch)
Test force ... 240 ± 20 N (55 ± 4 lb)
Free length after test ... 61 mm (2.4 inch)
Outside diameter ... 15.75 mm (0.620 inch)

(4) Lubricate the bore with the lubricant that is being sealed.

For testing purposes, use oil at 49 ± 3°C (120 ± 5°F)

Flow rate ... 38 ± 4 L/min (10 ± 1 US gpm)




Illustration 11g01405945

Table 2
Line Relief Valves (1)    
Relief Valve     Location    
Tilt cylinder (rod end)     A    
Ejector cylinder (head end)     B    
Ejector cylinder (rod end)     C    
Tilt cylinder (head end)     D    
( 1 ) For the part number and pressure setting of the line relief valves, refer to the specifications that follow.

(A) (B) 4T-4162 Relief Valve

Pressure setting ... 12775 ± 345 kPa (1850 ± 50 psi)

(C) (D) 108-6428 Relief Valve

Pressure setting ... 24305 ± 345 kPa (3525 ± 50 psi)

Systems Operation Section

Hydraulic System General Information




Illustration 12g01308576

Schematic for the hydraulic system

(1) Tilt cylinder

(2) Auxiliary cylinders

(3) Manifolds

(4) Manifold

(5) Line relief valve for rod end of auxiliary cylinders

(6) Pressure tap for rod end of auxiliary cylinders

(7) Pressure tap for head end of tilt cylinder

(8) Line relief valve for head end of tilt cylinder

(9) Pressure tap for head end of auxiliary cylinders

(10) Pressure tap for rod end of tilt cylinder

(11) Pilot solenoid valve

(12) Line relief valve for head end of auxiliary cylinders

(13) Line relief valve for rod end of tilt cylinder

(14) Check valve

(15) Auxiliary/Tilt control valve

(16) Auxiliary/Tilt control valve

(17) Manifold

(18) Lift cylinders

(19) Check valve

(20) Ride control accumulator

(21) Pressure tap for rod end of tilt cylinder

(22) Pressure tap for head end of tilt cylinder

(23) Main control valve

(24) Manifold

(25) Ride control diverter valve

(26) Ride control solenoid valve

(27) Line relief valve for rod end of tilt cylinder

(28) Line relief valve for head end of tilt cylinder

(29) Lift circuit relief valve

(30) Ride control relief valve

(31) Implement and steering solenoid valve

(32) Parking brake control valve

(33) Main relief valve

(34) Parking brake solenoid valve

(35) Parking brake oil pressure switch

(36) Pilot control valve

(37) Check valve

(38) Pressure tap for the parking brake circuit

(39) Lift arm positioner valve

(40) Float sequence valve

(41) Selector and pressure control valve

(42) Line to parking brake circuit

(43) Line from steering circuit

(44) Manifold

(45) Breaker relief valve

(46) Manifold

(47) Brake accumulator charging valve

(48) Line to brake accumulator

(49) Manifold

(50) Manifold

(51) Check valve

(52) Portable hydraulic pump quick connect coupler

(53) Pilot and braking pump

(54) Steering pump

(55) Implement pump

(56) Hydraulic oil filters

(57) Hydraulic tank

(58) Pilot oil relief valve

(59) Pressure tap for the pilot system

(60) Pilot oil filter

(61) Check valve

(62) Portable hydraulic pump quick connect coupler

Auxiliary Pilot Hydraulic System




Illustration 13g01311369



Illustration 14g01308595

Pilot solenoid valve (11) is an additional component in the optional auxiliary pilot hydraulic system. The pilot solenoid valve is located under the cover on the front frame.




Illustration 15g01308585

(63) Switch

(64) 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 right side of switch (63) while joystick control lever (64) is moved to the EJECT or RETRACT positions.

Switch (63) energizes pilot solenoid valve (11) and allows pilot pressure oil to flow to auxiliary/tilt control valves (15) and (16) .

Auxiliary Main Hydraulic System




Illustration 16g01309017

Auxiliary/Tilt control valves (15) and (16) are additional components in the optional auxiliary main hydraulic system. The auxiliary/tilt control valves are located in manifolds (17) and (24). The manifolds are located under the cover on top of the front frame.

Tilt Circuit

The flow of oil from main control valve (23) to tilt cylinder (1) changes when the machine has an auxiliary hydraulic system. The oil now flows first to auxiliary/tilt control valves (15) and (16). During normal operation auxiliary/tilt control valves (15) and (16) allow oil to continue flowing to tilt cylinder (1). Auxiliary/tilt control valves (15) and (16) stop oil flowing to auxiliary cylinders (2). This prevents the operation of the tilt circuit and the auxiliary circuit at the same time.

Auxiliary Circuit




Illustration 17g01309016

(63) Switch

Eject Operation

When the engine is running, press and hold the right side of switch (63) to energize pilot solenoid valve (11). Pilot oil flows through pilot solenoid valve (11) to auxiliary/tilt control valves (15) and (16). This causes the spools in auxiliary/tilt control valves (15) and (16) to move to the left.

When the spools in auxiliary/tilt control valves (15) and (16) move to the left, the flow of oil to tilt cylinder (1) is stopped. When the joystick control lever is moved to the EJECT position, oil from main control valve (23) now flows through auxiliary control valve (16) 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 (15) and main control valve (23) to hydraulic tank (57) .

RETRACT Operation

When the engine is running, press and hold the right side of switch (63) to energize pilot solenoid valve (11). Pilot oil flows through pilot solenoid valve (11) to auxiliary/tilt control valves (15) and (16). This causes the spools in auxiliary/tilt control valves (15) and (16) to move to the left.

When the spools in auxiliary/tilt control valves (15) and (16) move to the left, the flow of oil to tilt cylinder (1) is stopped. When the joystick control lever is moved to the RETRACT position, oil from main control valve (23) now flows through auxiliary control valve (15) 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 (16) and main control valve (23) to hydraulic tank (57) .

Control Valve (Auxiliary/Tilt)




Illustration 18g01308636

(15) Auxiliary/Tilt control valve

(16) Auxiliary/Tilt control valve

(65) Drain port

(66) Outlet port (auxiliary)

(67) Inlet port (implement oil)

(68) Outlet port (tilt cylinder)

(69) Pilot port

(70) Valve spring

Auxiliary/Tilt control valves (15) and (16) are pilot operated directional valves. The construction and operation of the valves are the same. In the normal operating position auxiliary/tilt control valves (15) and (16) allow implement oil to flow to tilt cylinder (1). Valve spring (70) holds auxiliary/tilt control valves (15) and (16) in the normal operating position.

Auxiliary/Tilt control valve (15) is connected to the head end of tilt cylinder (1) and the rod end of auxiliary cylinders (2) .

Auxiliary/Tilt control valve (16) is connected to the rod end of tilt cylinder (1) and the head end of auxiliary cylinders (2) .

When pilot oil enters pilot port (69), the pilot oil pressure overcomes valve spring (70) and the auxiliary/tilt control valve spool moves. This stops oil flowing from inlet port (67) to outlet port (68). Oil stops flowing from outlet port (68) to the tilt cylinder.

Oil can now flow to auxiliary cylinders (2). Oil flows from inlet port (67) to outlet port (66) .

Drain port (65) allows leakage from the spring chamber to drain to the hydraulic tank.

Relief Valve (Line)




Illustration 19g01405945

Auxiliary/Tilt control valve

(A) Line relief valve

(B) Line relief valve

(C) Line relief valve

(D) Line relief valve

The line relief valves are located on the auxiliary/tilt control valve. The auxiliary/tilt control valve is located in the front frame.

Line relief valve (A) is for the rod end of the tilt cylinder, line relief valve (B) is for the head end of the auxiliary cylinder, line relief valve (C) is for the rod end of the auxiliary cylinder, line relief valve (D) is for the head end of the tilt cylinder.

When the auxiliary/tilt valve spools are in the HOLD position, the line relief valves limit the maximum pressure in the auxiliary and tilt circuits.

Note: The operation of the line relief valves are similar. An explanation of a typical line relief valve is given.




Illustration 20g00910952

Line relief valve

(1) Spring

(2) Passage

(3) Plate

(4) Valve

(5) Passage

(6) Orifice

(7) Inlet

Any external force on the cylinder will increase the oil pressure in inlet (7). If the oil pressure against valve (4) exceeds the force of spring (1), valve (4) will open.

Oil then flows through passage (5) to the hydraulic tank. The pressure in inlet (7) is reduced in order to prevent damage to the components of the circuit.

Testing and Adjusting Section

------ WARNING! ------

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.

----------------------

------ WARNING! ------

Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine.

To prevent personal injury or death, perform the following:

Park the machine on a smooth, level surface.

Lower the work tool to the ground and engage the parking brake.

Stop the engine and remove the key.

Block the wheels and install the steering frame lock.

----------------------


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.





Illustration 21g01405945

Auxiliary/Tilt control valve

(A) Line relief valve for rod end of tilt cylinder

(B) Line relief valve for head end of auxiliary (ejector) cylinder

(C) Line relief valve for rod end of auxiliary (ejector) cylinder

(D) Line relief valve for head end of tilt cylinder

Table 3
Pressure Setting for the Line Relief Valves    
Cylinder     Head End     Rod End    
Tilt    
24305 ± 345 kPa (3525 ± 50 psi)    

12775 ± 345 kPa (1850 ± 50 psi)    
Auxiliary (Ejector)    
12775 ± 345 kPa (1850 ± 50 psi)    

24305 ± 345 kPa (3525 ± 50 psi)    

  1. Release the pressure from the hydraulic system.

    ReferenceRefer to Systems Operation, Testing and Adjusting, RENR8555, "System Pressure - Release"

  1. Remove relief valve (A) from the auxiliary/tilt control valve. Insert a plug into the opening in order to prevent debris from entering the auxiliary/tilt control valve.

  1. Install relief valve (A) into test bench.

  1. For the correct pressure of the relief valve, refer to Table 3.

    Note: If the pressure is not correct, the relief valve needs to be adjusted. Proceed to Step 5 for the adjustment procedure.




    Illustration 22g01407429

    Line relief valve

    (1) Adjusting screw

    (2) Locknut

  1. Loosen locknut (2). Turn adjustment screw (1) clockwise in order to increase the pressure of the relief valve. Turn adjustment screw (1) counterclockwise in order to decrease the pressure of the relief valve. Tighten locknut (2) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

  1. When the correct pressure setting is reached remove relief valve (A) from test bench and install into auxiliary/tilt control valve. Tighten relief valve to a torque of 65 ± 5 N·m (48 ± 4 lb ft).

  1. For testing relief valves (B), (C) and (D), proceed with Step 2 through Step 6.

Electrical System General Information




Illustration 23g01311365

Schematic for the auxiliary electrical circuit

The components of the auxiliary circuit are the auxiliary switch, the attachment relay and the pilot solenoid.




Illustration 24g01311745

(1) Auxiliary switch




Illustration 25g01311746

(2) Attachment relay




Illustration 26g01312234

(3) Pilot solenoid

With the battery disconnect switch in the ON position, 24 volt power is supplied from the batteries via circuit breaker 3 to attachment relay (2) and via circuit breaker 4 to auxiliary switch (1). When auxiliary switch (1) is depressed, attachment relay (2) is energized. Power is then supplied to energize pilot solenoid (3). Pilot pressure oil will flow to the auxiliary/tilt control valves.

Disassembly and Assembly

Ejector Bucket - Remove

Table 4
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, RENR8556, "Steering Frame Lock - Remove and Install".

b. Release the pressure from the hydraulic system. Refer to Disassembly and Assembly, RENR8556, "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.


------ WARNING! ------

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.

----------------------



    Illustration 27g01308647

  1. Disconnect hose assembly (1) .

  1. Repeat Step 1 for the hose assembly on the other side.



    Illustration 28g01187795

  1. Attach a suitable lifting device to tilt link (2). The weight of tilt link (2) is approximately 160 kg (350 lb).

  1. Remove bolt (3), the washer and the nut.



    Illustration 29g01201891

  1. Remove three plugs (4) from collet (5) .



    Illustration 30g01187797

  1. Install Tooling (A). Tighten Tooling (A) evenly to remove collet (5) .

  1. Repeat Step 5 and Step 6 to remove the other side collet.



    Illustration 31g01188112

  1. Attach a suitable lifting device to pin (6). The weight of pin (6) is approximately 23 kg (50 lb).

  1. Remove pin (6) .



    Illustration 32g01193222

  1. Remove shims (7) .

  1. Secure tilt link (2) to the tilt lever.



    Illustration 33g01192184

    Typical example

  1. Attach a suitable lifting device to ejector bucket (8). The weight of the ejector bucket is approximately 7660 kg (16890 lb).



    Illustration 34g01309010

  1. Remove bolt (9), the washers and the nut from the lower bucket pin assembly.

  1. Remove three plugs (10) .



    Illustration 35g01187793

    Typical example

  1. Install Tooling (A). Tighten Tooling (A) evenly to remove collet (11) .

  1. Repeat Step 14 and Step 15 to remove the other side collet.



    Illustration 36g01192187

    Typical example

  1. Use two people to remove pin (13). The weight of pin (13) is approximately 23 kg (50 lb).

  1. Remove shims (12) .

  1. Repeat Step 13 through Step 18 for the bucket pin assembly on the other side.

  1. Remove the ejector bucket.

Ejector Bucket - Disassemble

Table 5
Required Tools    
Tool     Part Number     Part Description     Qty    
A     9EQ9681     Support     2    
B     9EP1733     Forcing Bolts     3    
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, RENR8556, "Steering Frame Lock - Remove and Install".

b. Release the pressure from the hydraulic system. Refer to Disassembly and Assembly, RENR8556, "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.


------ WARNING! ------

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.

----------------------



    Illustration 37g01338208

    Rear view of the ejector bucket

  1. Use Tooling (A) to support ejector cylinder (1) in the horizontal position.

  1. Repeat Step 1 for the other side ejector cylinder.



    Illustration 38g01338648

    Typical example

  1. Remove cover plate (2) .

  1. Remove bolt (3), and the washer from collet (4) .

  1. Remove the three rubber bungs from collet (4) .



    Illustration 39g01338649

    Typical example

  1. Install Tooling (B) to collet (4). Tighten Tooling (B) evenly to remove collet (4) .

  1. Repeat Step 5 and Step 6 to remove the other side collet.



    Illustration 40g01338651

    Typical example

  1. Remove pin (6), and shims (5) .

  1. Repeat Step 3 through Step 8 for the other ejector cylinder pin assembly.



    Illustration 41g01326959

  1. Install Tooling (C) and a suitable lifting device to main ejector plate assembly (7). The weight of main ejector plate assembly (7) and the lower ejector plate assembly is approximately 1515 kg (3340 lb).



    Illustration 42g01338655

    Typical example

  1. Remove bolt (8), and the washer from pin (9) .

  1. Use Tooling (D) to remove pin (9) .

  1. Remove shims (10) (not shown).

  1. Repeat Step 11 through Step 13 for the other side of the ejector bucket.

  1. Remove main ejector plate assembly (7) and the lower ejector plate assembly.



    Illustration 43g01338656

  1. Attach a suitable lifting device to lower ejector plate assembly (11). The weight of lower ejector plate assembly (11) is approximately 180 kg (400 lb).

  1. Remove two bolts (12), and the washers from the hinge pin.

  1. Use two people and remove the hinge pin to separate lower ejector plate assembly (11) from main ejector plate assembly (7). The weight of the hinge pin is approximately 32 kg (70 lb).



    Illustration 44g01338657

  1. Remove lip seal (13) from the main ejector plate assembly.

  1. Remove bearing (14) from the main ejector plate assembly.

  1. Repeat Step 19 and Step 20 for the other side bearing in the main ejector plate assembly.



    Illustration 45g01330137

  1. Disconnect hose assemblies (16), (17) and (18) .

  1. Remove clip (15) .

  1. Attach a suitable lifting device to ejector cylinder (15). The weight of the ejector cylinder is approximately 65 kg (145 lb).

  1. Remove Tooling (A) .



    Illustration 46g01193250

  1. Remove bolt (19), and the washer from collet (20) .

  1. Remove the three rubber bungs from collet (20) .



    Illustration 47g01338663

    Typical example

  1. Install Tooling (B) to collet (20). Tighten Tooling (B) evenly to remove collet (20) .

  1. Repeat Step 27 and Step 28 to remove the other side collet.

  1. Remove the ejector cylinder head end pin, and the shims.

  1. Remove the ejector cylinder from the ejector bucket.

  1. Repeat Step 22 through Step 31 to remove the other side ejector cylinder.

Disassembly and Assembly Information

Table 6
Required Tools    
Tool     Part Number     Part Description     Qty    
E     125-0079     Hydraulic Cylinder Repair Stand Gp     1    
F     195-4609     Seal Pick     1    
G     7M-7456     Bearing Mount Compound     1    


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.





Illustration 48g01330594

(2) (5) Lubricate the sealing lips with the lubricant that is being sealed.

(1) (3) (7) Apply Tooling (G) to the seal grooves prior to installing the seals.

(4) Lubricate the threads and tighten the nut to a torque of 1600 ± 160 N·m (1180 ± 118 lb ft).

(6) Lubricate the threads and tighten the four bolts to a torque of 240 ± 40 N·m (180 ± 29 lb ft).

Ejector Bucket - Assemble

Table 7
Required Tools    
Tool     Part Number     Part Description     Qty    
A     9EQ9681     Support     2    
C     138-7574     Link Bracket     2    
H     5P-3931     Anti-Seize Compound     1    
J     1P-1839     Bearing Puller Adapter     1    
K     1P-0520     Driver Gp     1    
L     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.




    Illustration 49g01338665

  1. Apply Tooling (L) to the bore of ejector cylinder (1) .

  1. Attach a suitable lifting device to ejector cylinder (1). The weight of the ejector cylinder is approximately 65 kg (145 lb).

  1. Install ejector cylinder (1) to the ejector bucket. Align the bores of the ejector cylinder and the ejector bucket.

  1. Install the ejector cylinder pin and shims.



    Illustration 50g01102509

  1. Install three caps (21) .



    Illustration 51g01102511

  1. Install three bungs (22) .

  1. Apply Tooling (H) to the inside diameter and the outside diameter of the collets.



    Illustration 52g01102517

    Typical example

  1. Install collet (20) .

  1. Install the collet on the other side.



    Illustration 53g01193250

  1. Apply Tooling (H) 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.

  1. Tighten bolt (19) to a torque of 370 ± 50 N·m (275 ± 37 lb ft). After the bolt is tight, hit collet (20) on each side with a heavy hammer until the torque on the bolt is less than 200 N·m (150 lb ft).

  1. 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).

  1. 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.




    Illustration 54g01330137

  1. Install Tooling (A) in order to support ejector cylinder (1) in the horizontal position.

  1. Connect hose assemblies (16), (17) and (18) .

  1. Install clip (15) .

  1. Repeat Step 1 through Step 16 for the other side ejector cylinder.



    Illustration 55g01338657

    Typical example

  1. Lower the temperature of bearing (14). Use Tooling (J) to install bearing (14) .

  1. Use Tooling (K) to install lip seal (13). Install lip seal (13) with the sealing lip towards the outside of the main ejector plate assembly.

  1. Repeat Step 18 and Step 19 for the other side of the main ejector plate assembly.



    Illustration 56g01338656

  1. Attach a suitable lifting device to lower ejector plate assembly (11). The weight of lower ejector plate assembly (11) is approximately 180 kg (400 lb).

  1. Apply Tooling (H) to the bores of lower ejector plate assembly (11) and main ejector plate assembly (7) .

  1. Align the bores of lower ejector plate assembly (11) and main ejector plate assembly (7) .

  1. Use two people to install the hinge pin. The weight of the hinge pin is approximately 32 kg (70 lb).

  1. Apply Tooling (H) to the threads of bolts (12) prior to assembly.

  1. Install two bolts (12), and the washers. Tighten bolts (12) to a torque of 430 ± 60 N·m (315 ± 45 lb ft).



    Illustration 57g01326959

  1. Install Tooling (C) and a suitable lifting device to ejector plate (7). The weight of the main ejector plate assembly with the lower ejector plate assembly attached is approximately 1515 kg (3340 lb).



    Illustration 58g01338655

    Typical example

  1. Apply Tooling (L) to the bores of the ejector bucket and the bores of the main ejector plate assembly.

  1. Align the bores of the ejector bucket with the bores of the main ejector plate assembly.

  1. Install shims (10) (not shown) as required between the ejector bucket and the main ejector plate assembly.

  1. Install pin (9) .

  1. Apply Tooling (H) to the threads of bolt (8) prior to assembly.

  1. Install bolt (8), and the washer.

  1. Repeat Step 30 through Step 33 for the other side of the ejector bucket.



    Illustration 59g01338651

    Typical example

  1. Apply Tooling (L) to the bore of the ejector cylinder.

  1. Align the bores of the main ejector plate assembly with the bore of the ejector cylinder.

  1. Install shims (5) as required.

  1. Install pin (6) .



    Illustration 60g01103423

  1. Install three caps (23) to the collets.



    Illustration 61g01103424

  1. Install three bungs (24) to the collets.



    Illustration 62g01338648

  1. Apply Tooling (H) to the inside diameter and the outside diameter of the collets.

  1. Install collet (4). Install the collet to the other side.

  1. Apply Tooling (H) to the threads of bolt (3) .

  1. Install bolt (3) and the washer.

    Note: The collet on one side must not extend farther than the other when the bolt is tight.

  1. Tighten bolt (3) 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).

  1. Tighten bolt (3) 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).

  1. Tighten bolt (3) 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 47.

  1. Install cover plate (2) .



    Illustration 63g01338208

    Rear view of the ejector bucket

  1. Remove Tooling (A) from ejector cylinder (1) .

  1. Repeat Step 35 through Step 49 for the other side ejector cylinder.

  1. Lubricate the ejector cylinder bearings. Refer to ""Ejector Cylinder Bearings - Lubricate" ".

  1. Lubricate the main ejector plate assembly bearings. Refer to ""Ejector Plate Bearings - Lubricate" ".

  1. Fill the hydraulic tank with oil to the correct level. Refer to Operation and Maintenance Manual, SEBU7333, "Hydraulic System Oil Level - Check".

End By:

a. Remove the steering frame lock pin. Refer to Disassembly and Assembly, RENR8556, "Steering Frame Lock - Remove and Install".

Ejector Bucket - Install

Table 8
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.

  1. Apply Tooling (B) to the bores of the lift arms and the tilt link.



    Illustration 64g01192184

    Typical example

  1. Attach a suitable lifting device to ejector bucket (8). The weight of the ejector bucket is approximately 7660 kg (16890 lb).

  1. Align the pin bores of ejector bucket (8) and the lift arm assembly.



    Illustration 65g01192187

    Typical example

  1. Install shims (12) as required.

  1. Use two people to install pin (13). The weight of pin (13) is approximately 23 kg (50 lb).

  1. Repeat Step 4 and Step 5 for the pin on the other side.



    Illustration 66g01192193

    Typical example

  1. Install three plugs (10) to collet (11) .

  1. Apply Tooling (C) to the inside and the outside diameters of collet (11) .

  1. Install collet (11) .

  1. Repeat Step 7 through Step 9 for the collet on the other side.



    Illustration 67g01201890

    Typical example

  1. Apply Tooling (C) to the threads of bolt (9) .

  1. Install bolt (9), the washer and the nut.

    Note: The collet on one side must not extend farther than the other collet when the bolt and nut are tight.

  1. 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).

  1. 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).

  1. Tighten bolt (9) and the nut to a final torque of 1800 ± 200 N·m (1330 ± 145 lb ft).

  1. 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.




    Illustration 68g01193222

    Typical example

  1. 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.

  1. Install shims (7) .



    Illustration 69g01188112

    Typical example

  1. Attach a suitable lifting device to pin (6). The weight of pin (6) is approximately 23 kg (50 lb).

  1. Install pin (6) .



    Illustration 70g01201891

    Typical example

  1. Install three plugs (4) to collet (5) .

  1. Apply Tooling (C) to the inside and the outside diameters of collet (5) .

  1. Install collet (5) .

  1. Repeat Step 21 through Step 23 for the collet on the other side.



    Illustration 71g01187795

    Typical example

  1. Apply Tooling (C) to the threads of bolt (3) .

  1. Install bolt (3), the washer and the nut.

    Note: The collet on one side must not extend farther than the other collet when the bolt and nut are tight.

  1. 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).

  1. 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).

  1. 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.




    Illustration 72g01192179

  1. Connect hose assembly (1).

  1. Repeat Step 30 for the hose assembly on the other side.

  1. Lubricate the ejector bucket pivot bearings. Refer to Operation and Maintenance Manual, SEBU7333, "Bucket Pivot Bearings - Lubricate".

  1. Lubricate the tilt linkage. Refer to Operation and Maintenance Manual, SEBU7333, "Tilt Linkage Bearings - Lubricate".

  1. Fill the hydraulic tank with oil to the correct level. Refer to Operation and Maintenance Manual, SEBU7333, "Hydraulic System Oil Level - Check".

End By:

a. Remove the steering frame lock pin. Refer to Disassembly and Assembly, RENR8556, "Steering Frame Lock - Remove and Install".

Parts Manual




Illustration 73g01408382



Illustration 74g01408383



Illustration 75g01407871



Illustration 76g01407872



Illustration 77g01408374



Illustration 78g01408376



Illustration 79g01407878



Illustration 80g01408372



Illustration 81g01408377



Illustration 82g01408378



Illustration 83g01408379



Illustration 84g01408391



Illustration 85g01408380



Illustration 86g01408381



Illustration 87g01408397



Illustration 88g01407881



Illustration 89g01407888

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