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

Underground Articulated Truck:

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

Introduction

Illustration 1	g01051135

This publication contains the information for the installation of a wide body arrangement. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

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

Install the Axle Spacers

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

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

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

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

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Illustration 2	g01082233
Axle assembly (typical front/rear) (1) 258-2098 Axle (2) 7X-0851 Nut (3) 6V-8237 Washer (4) 258-2097 Stud (5) 258-2096 Spacer-Wheel (6) 2K-2939 O-Ring Seal

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

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

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

Brake Lines (Front Axle)

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Illustration 3	g01082241
Front axle brake lines (P) Parking brake port connection (S) Service brake port connection (1) 258-0098 Hose As (2) 163-5531 Cable Tie (3) 211-7016 Hose As (4) 258-0099 Hose As (5) 258-0100 Hose As

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

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

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

Brake Oil Cooler Lines (Front Axle)

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Illustration 4	g01082250
Front axle brake oil cooler lines (1) 258-0101 Hose As (2) 163-5531 Cable Tie (3) 258-0103 Hose As (4) 258-0102 Hose As (5) 258-0104 Hose As

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

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

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

Brake Lines (Rear Axle)

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Illustration 5	g01082627
Rear axle brake lines (P) Parking brake port connection (S) Service brake port connection (1) 251-5436 Hose As (2) 163-5531 Cable Tie (3) 258-0096 Hose As (4) 211-7015 Hose As (5) 258-0097 Hose As

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

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

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

Lines Gp-Brake Bleeder (Front)

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

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

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Illustration 6	g01111950
Front brake bleeder lines (1) 258-0120 Hose As (2) 258-0118 Hose As (3) 258-0113 Hose As (4) 258-0115 Hose As (5) 163-5531 Cable Tie

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

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

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

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

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

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

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

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

Brake Oil Cooler Lines (Rear)

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Illustration 7	g01082631
Rear brake oil cooler lines (left side) (1) 258-0107 Hose As (2) 258-0105 Hose As

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

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

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

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Illustration 8	g01082632
Rear brake oil cooler lines (right side) (3) 258-0111 Hose As (4) 258-0109 Hose As

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

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

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

Modifications to the Fuel Tank and the Fender

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Illustration 9	g01082641
Fuel tank modification to attach the fender guard (1) Drill 12 mm (0.47 inch) in nine places (A) 467 mm (18.38 inch) (B) 292 mm (11.49 inch) (C) 137 mm (5.39 inch) (D) 20 mm (0.78 inch) typical

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Illustration 10	g01082638
(E) 70 mm (2.75 inch) (F) 175 mm (6.88 inch) (G) 170 mm (6.69 inch) (H) 180 mm (7.08 inch) (J) 86 mm (3.38 inch)

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

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Illustration 11	g01082642
Front right side fender modification to attach the fender guard (1) Drill 12 mm (0.47 inch) in nine places (D) 20 mm (0.78 inch) (F) 175 mm (6.88 inch) (K) 83 mm (3.26 inch) (L) 150 mm (5.90 inch) (M) 76 mm (2.99 inch) (N) 90 mm (3.54 inch)

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Illustration 12	g01082643
Top section of the right side fender modification (1) Drill 12 mm (0.47 inch) in nine places (D) 20 mm (0.78 inch) (P) 125 mm (4.92 inch) (R) 135 mm (5.31 inch)

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

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Illustration 13	g01082651
View of the right side fender guard mounting arrangement (2) 258-2102 Guard (3) 258-2101 Plate-Retainer (4) 8T-4196 Bolt (5) 8T-4121 Hard Washer (6) 8T-4133 Nut

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

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Illustration 14	g01083024
View of the left side fender (4) 8T-4196 Bolt (5) 8T-4121 Hard Washer (6) 8T-4133 Nut (7) 203-1746 Retainer (8) 234-9715 Guard (9) 234-9713 Guard (10) 203-1236 Retainer (11) 234-9712 Guard (12) 8T-4185 Bolt

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

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

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Illustration 15	g01083018
View of the new left side fender guard (4) 8T-4196 Bolt (5) 8T-4121 Hard Washer (6) 8T-4133 Nut (13) 258-2103 Guard (14) 258-2101 Retainer

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

Modification to the Rear Frame

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Illustration 16	g01083028
View of the rear frame modification (1) 9R-2613 Boss (A) Reference 290 mm (11.41 inch) (B) Reference 50 mm (1.96 inch) (C) 60 mm (2.36 inch)

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

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

Procedure to Remove the Former Dump Body

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Illustration 17	g01083043
Typical view of the hoist cylinder with Tooling (A) in position (1) 2U-9202 Tip Cylinder Pin Assembly

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

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

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

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

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

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Illustration 18	g01083495
Lifting positions for the dump body

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

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

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Illustration 19	g01083047
View of the body mounting pins (2) 166-2372 Pin As

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

9. Remove the dump body from the machine.

Wide Dump Body - Install

Hoist Cylinder Stands

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Illustration 20	g01083034
Typical view of the hoist cylinder with Tooling (E) in position

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

Lifting Positions for the Wide Dump Body

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Illustration 21	g01083495
Lifting positions for the wide dump body with Tooling (C) installed

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

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

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

Wide Dump Body Mounting Pins - Install

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Illustration 22	g01083507
View of the wide dump body mounting pins (1) 166-2372 Pin As

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

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

Hoist Cylinder Mounting

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Illustration 23	g01083043
Typical view of the hoist cylinder with Tooling (A) installed (1) 2U-9202 Tip Cylinder Pin Assembly

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

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

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

Wide Dump Body Arrangement (258-4624)

Illustration 24	g01083029
Wide body arrangement (1) 258-1579 Wear Plate-Floor (2) 258-1576 Wear Plate-Wheel Arch (3) 258-1578 Wear Plate-Floor (4) 258-1574 Floor Plate-Wheel Arch (5) 258-1573 Floor Plate-Wheel Arch LH (6) 258-1577 Floor Plate-Wheel Arch (7) 258-1575 Wear Plate-Ducktail (8) 258-1572 Wear Plate-Wheel Arch RH (9) 211-1881 Rod (10) 211-1880 Spring (11) 8T-4223 Hard Washer (12) 3B-4615 Cotter Pin (13) 229-8474 Pin-Retaining