2008/09/01 Caterpillar

Load Haul Dump:

R1300GSeries II (S/N: RSL1-UP)

R1300G (S/N: LJB1-UP)

Disassembly and Assembly, RENR8587, "R1300G Series II Load Haul Dump Machine Systems", "Ejector Bucket - Disassemble". This module is part of Service Manual, RENR8531 Volume 2.Disassembly and Assembly, RENR6942, "R1300G Load Haul Dump Machine Systems", "Ejector Bucket - Disassemble". This module is part of Service Manual, RENR6923 Volume 2.

The information in this article has changed. Replace this article with the following information.

Ejector Cylinder - Assemble

Assembly Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	304-6264	Support	2
	304-6262	Top Bracket	2
	3B-4615	Cotter Pin	2
C	138-7575	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.

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Illustration 1	g01365698

1. Apply Tooling (L) to the bore of ejector cylinder (2) .

2. Attach a suitable lifting device to ejector cylinder (2). The weight of the ejector cylinder is approximately 32 kg (70 lb.)

3. Align the bores of ejector cylinder (2) and the ejector bucket.

4. Install the ejector cylinder head end pin and shims, as required.

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Illustration 2	g01388339

5. Install three caps (22) to the collets.

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Illustration 3	g01388340

6. Install three bungs (23) to the collets.

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

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Illustration 4	g01388341

8. Install collet (21) .

9. Install the collet on the other side.

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Illustration 5	g01387959

10. Apply Tooling (H) to the threads of bolt (20) prior to assembly. Install bolt (20) and the washer.

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

11. Tighten bolt (20) 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).

12. Tighten bolt (20) 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).

13. Tighten bolt (20) 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.

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Illustration 6	g01387957

14. Connect hose assemblies (16) and (17) to the ejector cylinder.

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Illustration 7	g01346163

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Illustration 8	g01346162

15. Install Tooling (A) in order to support ejector cylinder (2) in the horizontal position.

16. Connect hose assembly (18) .

17. Install clip (19) and the bolt.

18. Repeat Step 1 through Step 17 for the other ejector cylinder.

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Illustration 9	g01387956

19. Lower the temperature of bearing (15) to −75° ± 5°C (−103° ± 9°F). Use Tooling (J) to install bearing (15) to a depth of 9.5 ± 1 mm (0.37 ± 0.04 inch) below the outside surface of the ejector plate.

20. Use Tooling (K) to install lip seal (14). Install lip seal (14) with the sealing lip towards the outside of the ejector plate.

21. Repeat Step 19 and Step 20 for the other side of the ejector plate.

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Illustration 10	g01387953

22. Attach a suitable lifting device to ejector flap (12). The weight of ejector flap (12) is approximately 90 kg (200 lb).

23. Apply Tooling (H) to the bores of ejector flap (12) and ejector plate (8) .

24. Align the bores of ejector flap (12) and ejector plate (8).

25. Install the hinge pin.

26. Apply Tooling (H) to the threads of bolts (13) prior to assembly.

27. Install two bolts (13), and the washers. Tighten bolts (13) to a torque of 430 ± 60 N·m (315 ± 45 lb ft).

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Illustration 11	g01387304

28. Attach Tooling (C) and a suitable lifting device to ejector plate (8). The weight of the ejector plate with the ejector flap attached is approximately 605 kg (1335 lb).

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Illustration 12	g01387950

29. Apply Tooling (L) to the bores of the ejector bucket and the bores of the ejector plate.

30. Align the bores of the ejector bucket with the bores of the ejector plate.

31. Install shims (11) (not shown) as required between the ejector bucket and the ejector plate.

32. Install pin (10) .

33. Apply Tooling (H) to the threads of bolt (9) prior to assembly.

34. Install bolt (9), and the washer.

35. Repeat Step 30 through Step 34 for the other side of the ejector bucket.

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Illustration 13	g01387303

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

37. Align the bore of the ejector plate with the bore of the ejector cylinder.

38. Install shims (6) as required.

39. Install pin (7) .

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Illustration 14	g01388339

40. Install three caps (22) to the collets.

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Illustration 15	g01388340

41. Install three bungs (23) to the collets.

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

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Illustration 16	g01387301

43. Install collet (5) .

44. Install the collet on the other side.

45. Apply Tooling (H) to the threads of bolt (4) prior to assembly.

46. Install bolt (4) and the washer.

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

47. Tighten bolt (4) 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).

48. Tighten bolt (4) 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).

49. Tighten bolt (4) to a final torque of 370 ± 50 N·m (275 ± 37 lb ft).

    Note: At the end of 50 service hours, repeat Step 47 through Step 49.

50. Install cover plate (3) .

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Illustration 17	g01346163

51. Remove Tooling (A) from the ejector bucket.

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Illustration 18	g01387947

52. Install cover plate (1) .

53. Repeat Step 36 through Step 52 for the other ejector cylinder.

54. Lubricate the ejector cylinder bearings. Refer to Operation and Maintenance Manual, "Ejector Cylinder Bearing - Lubricate".

55. Lubricate the ejector plate bearings. Refer to Operation and Maintenance Manual, "Ejector Plate Bearing - Lubricate".

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

End By:

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