Procedure to Install Tow Hook Release on R1300G Load Haul Dump Machines {4251, 4257, 4284} Caterpillar

Load Haul Dump

R1300G (S/N: LJB1379-UP; NJB1-UP)

Introduction

This special instruction covers the procedure to install tow hook release on R1300G S/N:LJB1379-UP Load Haul Dump Machines. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Reference: Disassembly and Assembly, RENR6942, "R1300G Load Haul Dump Machine Systems"

Reference: Systems Operation Testing and Adjusting, RENR6937, "R1300G Load Haul Dump Braking System"

Reference: Operation and Maintenance Manual, SEBU7329, "R1300G Load Haul Dump"

Reference: Service Manual, RENR8594, "Machining and Welding Information for Load Haul Dumps"

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury 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.

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

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Tools Required

Parts Required

Machine Preparation

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

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

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

3. Stop the engine.

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

5. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

6. Release system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".

Tow Hook - Install

Note: For welding repairs performed on Caterpillar Underground machines using Manual Metal Arc Welding (MMAW), use AWS E7016 electrodes for the first three passes. Use AWS E7018 electrodes for the remaining passes of the welding repair.

Note: For all welding repairs performed on Caterpillar Underground machines using Gas Metal Arc Welding (GMAW) use AWS ER70S-6 wire.

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Illustration 1	g03318621
Rear view of the machine (1) Casting section (A) 135 mm (5.30 inch) (B) 190 mm (7.50 inch)

1. Preheat the area prior to arc air gouging. Refer to Service Manual, "Preheat, Interpass, and Heat Input" and Table 4.
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   Table 4

   Preheat °C (°F)

   Minimum 75 °C (170 °F)

2. Remove casting section (1).

3. Thoroughly grind clean the area of the rear casting, remove all scale and carbon.
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   Illustration 2	g03318630
   Rear view of the machine (2) 379-9788 Fixture (3) 287-9876 Stud (C) 30 mm (1.20 inch)

4. Install 379-9788 Fixture (2).

5. Install four 287-9876 Studs (3).
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   Illustration 3	g03318636
   Rear view of the machine (4) 302-0852 Gusset (5) 302-0851 Gusset

6. Weld 302-0852 Gusset (4) and 302-0851 Gusset (5) in position. Refer to Illustration 3, Table 5, and Table 6.

   Note: Ensure 302-0852 Gusset (4) and 302-0851 Gusset (5) are positioned square.

   Note: Do not let the temperature drop below the recommended preheat temperature.

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   Table 5

   Preheat °C (°F)	Maximum Interpass Temperature
   Minimum 140 °C (280 °F)	220 °C (400 °F)

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   Table 6

   Item	Dimension
   W1	10 mm (0.40 inch) tacking weld in four places.

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   Illustration 4	g03318639
   Rear view of the machine (4) 302-0852 Gusset (5) 302-0851 Gusset (6) 302-7620 Hook (7) 302-0848 Shaft

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   Illustration 5	g03327267
   Rear view of the machine (4) 302-0852 Gusset (5) 302-0851 Gusset (6) 302-7620 Hook (7) 302-0848 Shaft

7. Install 302-0848 Shaft (7) into 302-7620 Hook (6).

8. Using a suitable lifting device, install 302-0848 Shaft (7) and 302-7620 Hook (6) in position. The weight of 302-0848 Shaft (7) and 302-7620 Hook (6) combined is approximately 50 kg (110 lb).

9. Weld 302-0848 Shaft (7) to 302-0852 Gusset (4) and 302-0851 Gusset (5). Refer to Illustration 4, Illustration 5, and Table 7.
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   Table 7

   Item	Dimension
   W2	10 mm (0.40 inch) tacking weld.

10. Remove the lifting device.
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    Illustration 6	g03319127
    Released position (6) 302-7620 Hook (7) 302-0848 Shaft (8) Piston (9) Top Plate (10) Cross Beam

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    Illustration 7	g03319128
    Applied position (6) 302-7620 Hook (7) 302-0848 Shaft (8) Piston (9) Top Plate (10) Cross Beam (G) 17 ± 0.5 mm (0.67 ± 0.02 inch)

11. Check the position of 302-7620 Hook (6). 302-7620 Hook (6) must meet the following conditions:

    Released Position

    Refer to Illustration 6.

    • 302-7620 Hook (6) must touch Cross Beam (10) at point (D)

    • 302-7620 Hook (6) must touch Piston (8) at point (F)

    • No gap should be visible between Piston (8) and Top Plate (9) at point (E)

    Applied Position

    Refer to Illustration 7.

    • A distance of 17 ± 0.5 mm (0.67 ± 0.02 inch) (G) must be visible between Piston (8) and Top Plate (9)
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    Illustration 8	g03319129
    View from top (4) 302-0852 Gusset (5) 302-0851 Gusset (6) 302-7620 Hook (7) 302-0848 Shaft (11) 302-7621 Plate (H) 134 mm (5.25 inch) (J) No weld both sides

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    Illustration 9	g03319132
    View from below (6) 302-7620 Hook (7) 302-0848 Shaft (11) 302-7621 Plate (12) 8T-9389 Bolt (13) 5P-8245 Hard Washer (J) No weld both sides

12. Using a suitable lifting device, install two 302-7621 Plates (11) in position. Secure each 302-7621 Plate (11) using two 8T-9389 Bolts (12) and two 5P-8245 Hard Washers (13).The weight of each 302-7621 Plate (11) is approximately 40 kg (90 lb).

    Note: Ensure each 302-7621 Plate (11) is positioned square.

13. Remove the lifting device.

14. Weld two 302-7621 Plates (11) to either end of 302-0848 Shaft (7). Refer to Illustration 8, Illustration 9, Table 8, and Table 9.

    Note: Ensure that no weld is applied to 302-7620 Hook (6).

    Note: Do not let the temperature drop below the recommended preheat temperature.

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    Table 8

    Preheat °C (°F)	Maximum Interpass Temperature
    Minimum 140 °C (280 °F)	220 °C (400 °F)

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    Table 9

    Item	Dimension
    W3	8 mm (0.30 inch) Fillet weld.

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    Illustration 10	g03319142
    View from below (6) 302-7620 Hook (11) 302-7621 Plate (12) 8T-9389 Bolt (13) 5P-8245 Hard Washer

15. Using a suitable lifting device, remove the hook assembly by removing four bolts (12). The weight of the hook assembly is approximately 130 kg (285 lb).

    Note: Tacking welds (W2) will require removing in order to remove the hook assembly.

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    Illustration 11	g03320011
    View from top (6) 302-7620 Hook (7) 302-0848 Shaft (11) 302-7621 Plate

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    Illustration 12	g03320020
    View from below (6) 302-7620 Hook (7) 302-0848 Shaft (11) 302-7621 Plate

16. Fully weld two 302-7621 Plates (11) to 302-0848 Shaft (7). Refer to Illustration 11, Illustration 12, Table 10, and Table 11.

    Note: Ensure that no weld is applied to 302-7620 Hook (6).

    Note: Do not let the temperature drop below the recommended preheat temperature.

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    Table 10

    Preheat °C (°F)	Maximum Interpass Temperature
    Minimum 140 °C (280 °F)	220 °C (400 °F)

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    Table 11

    Item	Dimension
    W4	Fully weld.

17. Grind flush the top welds for assembly purposes.
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    Illustration 13	g03320032
    (4) 302-0852 Gusset (5) 302-0851 Gusset

18. Weld 302-0852 Gusset (4) and 302-0851 Gusset (5) all around. Refer to Illustration 13, Table 12, and Table 13.

    Note: Do not let the temperature drop below the recommended preheat temperature.

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    Table 12

    Preheat °C (°F)	Maximum Interpass Temperature
    Minimum 140 °C (280 °F)	220 °C (400 °F)

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    Table 13

    Item	Dimension
    W5	15 mm (0.60 inch) Fillet weld all around.

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    Illustration 14	g03320035
    Lifting the hook assembly (6) 302-7620 Hook (12) 8T-9389 Bolt (13) 5P-8245 Hard Washer

19. Using a suitable lifting devise, install the hook assembly in position. The weight of the hook assembly is approximately 130 kg (285 lb).

20. Install four 8T-9389 Bolts (12) and four 5P-8245 Hard Washers (13).

    Note: Ensure that the hook assembly is positioned square.

21. Check the position of 302-7620 Hook (6). Refer to Step 11.
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    Illustration 15	g03320037
    (4) 302-0852 Gusset (5) 302-0851 Gusset (6) 302-7620 Hook (11) 302-7621 Plate

22. Weld two 302-7621 Plates (11) in position. Refer to Illustration 15, Table 14, and Table 15.

    Note: Ensure that no weld is applied to 302-7620 Hook (6).

    Note: Do not let the temperature drop below the recommended preheat temperature.

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    Table 14

    Preheat °C (°F)	Maximum Interpass Temperature
    Minimum 140 °C (280 °F)	220 °C (400 °F)

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    Table 15

    Item	Dimension
    W6	8 mm (0.30 inch) Fill weld, 15 mm (0.60 inch) Fillet weld.
    W7	15 mm (0.60 inch) Fillet weld.
    W8	15 mm (0.60 inch) Fillet weld all around.

23. Tighten four 8T-9389 Bolts (12). Refer to Illustration 14.
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    Illustration 16	g03320856
    (2) 379-9788 Fixture (14) 287-9927 Mount As (K) 36 mm (1.40 inch)

24. Weld 287-9927 Mount As (14) in position. Refer to Illustration 16 and Table 16.

    Note: Ensure that the mount assembly is positioned square.

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    Table 16

    Item	Dimension
    W9	5 mm (0.20 inch) Fillet weld.
    W10	5 mm (0.20 inch) Fillet weld.

25. Remove 379-9788 Fixture (2). Refer to Illustration 16.

26. Clean up all welds and smooth outer edges of 302-7621 Plates (11).

27. Paint the tow hook assembly.
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    Illustration 17	g03321234
    (15) 3B-8489 Grease Fitting (16) 4B-4158 Drive Screw (17) 312-3241 Notice Plate (18) 312-3243 Warning Plate (All except U.S.) (18) 312-3242 Warning Plate (U.S. Only)

28. Install two notice plates (17) and warning plate (18).

    Note: Ensure the correct warning plate (18) is installed.

29. Install 3B-8489 Grease Fitting (15), and grease the tow hook.

Brake Release Cylinder - Install

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Illustration 18	g03318142
(1) 155-9905 Brake Release Cylinder Gp (Except U.S.) (1) 361-8553 Brake Release Cylinder Gp (U.S. Only) (2) 3J-1907 O-Ring Seal (3) 8C-2948 Tee (4) 6V-3965 Fitting (5) 6V-0852 Dust Cap

1. Install Item (2) through Item (5) to brake release cylinder (1).

   Note: Ensure that the correct brake release cylinder is used.

2. Apply 5P-3931 Anti-Seize Compound to the outside diameter of brake release cylinder (1).
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   Illustration 19	g03318149
   View from the front of the machine (1) 155-9905 Brake Release Cylinder Gp (Except U.S.) (1) 361-8553 Brake Release Cylinder Gp (U.S. Only) (2) 3J-1907 O-Ring Seal (6) 9X-8882 Bolt (7) 8T-4122 Hard Washer (8) 030-7937 Port Connector

3. Install brake release cylinder (1). Tighten 9X-8882 Bolts (6) to a torque of 215 ± 40 N·m (160 ± 30 lb ft).

4. Install 030-7937 Port Connector (8) and 3J-1907 O-Ring Seal (2).

Valve and Hosing - Install

Sequence Valve - Assemble and Install

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Illustration 20	g03242458
Sequence valve (1) 186-8817 Valve As (2) 030-7955 Flared Tee (3) 3J-1907 O-Ring Seal (4) 2R-6806 O-Ring Connector (5) 186-8852 Sequence Valve

1. Assemble Item (1) through Item (5). Torque 186-8852 Sequence Valve (5) to 45 ± 5 N·m (33 ± 4 lb ft).
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   Illustration 21	g03242497
   (6) 7X-0440 Bolt (7) 8T-4224 Hard Washer

2. Install the assembled sequence valve using two 7X-0440 Bolts (6) and two 8T-4224 Hard Washers (7).

Shuttle Valve - Assemble and Install

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Illustration 22	g03242476
Shuttle valve (1) 8J-6173 Valve Assembly (2) 4S-4869 Tee (3) 3K-0360 O-Ring Seal (4) 5P-6944 Adapter (5) 118-4728 Elbow (6) 6M-6853 O-Ring Tee (7) 3J-1907 O-Ring Seal

1. Assemble Item (1) through Item (7).
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   Illustration 23	g03242517
   (8) 5P-2675 Bolt (9) 8T-4205 Hard Washer

2. Install the assembled shuttle valve using two 5P-2675 Bolts (8) and two 8T-4205 Hard Washers (9).

Hosing - Install

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Illustration 24	g03245336
(1) Brake release cylinder (2) 243-3072 Hose As (3) 304-6375 Hose As (4) 5M-3062 Bolt (5) 8T-4896 Hard Washer (6) 4D-6466 Clip

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Illustration 25	g03245337
(2) 243-3072 Hose As (3) 304-6375 Hose As (4) 5M-3062 Bolt (5) 8T-4896 Hard Washer (6) 4D-6466 Clip (7) 4L-9337 Bolt (8) 9M-4136 Spacer (9) Sequence valve

1. Install 243-3072 Hose As (2) and 304-6375 Hose As (3) using Item (4) through Item (8). Refer to Illustration 24 and Illustration 25.
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   Illustration 26	g03245356
   (10) Parking brake oil pressure reducing valve (11) Cap (12) Parking brake control valve (13) Cap

2. Remove cap (11) and cap (13). Retain cap (13).
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   Illustration 27	g03245396
   (9) Sequence valve (10) Parking brake oil pressure reducing valve (14) 243-3077 Hose As

3. Install 243-3077 Hose As (14). Secure with cable ties, as required.
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   Illustration 28	g03245436
   (9) Sequence valve (12) Parking brake control valve (15) 6D-4246 Clip (16) 243-3074 Hose As (17) 243-3075 Hose As (18) Shuttle valve

4. Install 243-3074 Hose As (16) and 243-3075 Hose As (17).

5. Install 6D-4246 Clip (15).
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   Illustration 29	g03245456
   (12) Parking brake control valve (19) Hose assembly (20) Hose assembly (21) Plug

6. Disconnect hose assembly (19) and hose assembly (20).

7. Remove and discard plug (21).
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   Illustration 30	g03245476
   (12) Parking brake control valve (13) Cap (18) Shuttle valve (22) 243-3076 Hose As (23) 243-3073 Hose As (24) 1U-0423 Check Valve (25) 3J-1907 O-Ring Seal

8. Install cap (13) that was retained in Step 2 to parking brake control valve (12).

9. Install 243-3076 Hose As (22), 243-3073 Hose As (23), 1U-0423 Check Valve (24), and 3J-1907 O-Ring Seal (25).

   Note: Install 1U-0423 Check Valve (24) with the arrow in the UP position.

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   Illustration 31	g03248317
   (15) 6D-4246 Clip (18) Shuttle valve (19) Hose assembly (20) Hose assembly

10. Connect hose assembly (19) and hose assembly (20) that were disconnected in Step 6, to shuttle valve (18).

11. Install 6D-4246 Clip (15).

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

13. Purge the air from the brake release system. Refer to Systems Operation, Testing and Adjusting, "Brake Release System Air - Purge".

14. Test the brake release system. Refer to Systems Operation, Testing and Adjusting, "Brake Release System - Test".

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