R1600G Load Haul Dump Machine Systems Ejector Bucket - Disassemble Caterpillar


Ejector Bucket - Disassemble
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1.1. Disassembly Procedure
2.1. Disassembly and Assembly Information for the Ejector Cylinder

Disassembly Procedure

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     304-6261     Support Bracket     2    
B     199-5815     Forcing Bolts     3    
C     1U-9201     Lever Puller Hoist     1    
D     138-7574     Link Brackets     2    
E     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:

  1. Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".
  2. Release the hydraulic system pressure. Refer to Disassembly and Assembly, "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, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare 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 1g01413705

    Rear view of the ejector bucket

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



    Illustration 2g01413709

  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 3g01413696

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

  1. Use Tooling (B) to remove the collet on the other side.



    Illustration 4g01413698

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

  1. Repeat Step 1 through Step 7 for the other ejector cylinder pin assembly.



    Illustration 5g01413708

  1. Install Tooling (C), Tooling (D) 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 1180 kg (2600 lb).



    Illustration 6g01413704

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

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

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

  1. Repeat Step 10 through Step 12 for the other side of the ejector bucket.

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



    Illustration 7g01413706

  1. Attach a suitable lifting device to lower ejector plate assembly (11). The weight of lower ejector plate assembly (11) is approximately 170 kg (375 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 25 kg (55 lb).



    Illustration 8g01413710

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

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

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



    Illustration 9g01413694

  1. Disconnect hose assemblies (15), (16) and (18) .

  1. Remove clip (17) .

  1. Attach a suitable lifting device to ejector cylinder (1). The weight of the ejector cylinder is approximately 40 kg (88 lb).

  1. Remove Tooling (A) .



    Illustration 10g01193250

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



    Illustration 11g01413703

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

  1. Use Tooling (B) to remove the collet on the other side.

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

  1. Remove the ejector cylinder from the ejector bucket.

  1. Repeat Step 21 through Step 29 for the other ejector cylinder.

Disassembly and Assembly Information for the Ejector Cylinder

Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
F     125-0079     Hydraulic Cylinder Repair Stand Gp     1    
G     195-4609     Seal Pick     1    
H     7M-7456     Bearing Mount Compound     1    
J     9S-3263     Thread Lock Compound     1    
K     169-5464     Quick Cure Primer     1    
L     155-0695     Thread Lock 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, "AVSpare Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on AVSpare products.

Dispose of all fluids according to local regulations and mandates.





Illustration 12g01413701

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

(1) (3) (8) Apply Tooling (H) to the seal grooves prior to installing the seals.

(4) Apply Tooling (K) then apply Tooling (J) to the threads of the nut prior to assembly. Tighten the nut to a torque of 1600 ± 160 N·m (1180 ± 118 lb ft).

(6) Install flat side of washer towards the rod assembly.

(7) Apply Tooling (K) then apply Tooling (L) to the threads of the four bolts prior to assembly. Tighten the four bolts to a torque of 240 ± 40 N·m (180 ± 29 lb ft).

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