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2002/11/25 A Front Mounted Liquid Level Gauge for the Hydraulic Oil Tank is Available {7479} Caterpillar


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A Front Mounted Liquid Level Gauge for the Hydraulic Oil Tank is Available {7479}
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2002/11/25 [SEPD0657]
2002/11/25 A New Alternator Guard is Used {1405}
2002/11/25 An Improved Hose Assembly for Machines with Dual Fuel Tanks is now Used {1710}
HYDRAULIC SYSTEM
TANK GP
2002/11/25 A Front Mounted Liquid Level Gauge for the Hydraulic Oil Tank is Available {7479}
Load Haul Dump:
R1300 (S/N: 6QW)
R1600 (S/N: 9EW)
R1700 (S/N: 4LZ)
R1700G (S/N: 8XZ)
R2900 (S/N: BAR; 5TW)

Reference: Service Magazine, SEPD0025, 02 July 1990, "Welding on Fuel and Hydraulic Tanks".

Reference: Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures", "Safety".

Reference: Disassembly and Assembly, RENR4612 (9EL9611), "R1300 LHD Vehicle Systems", "Remove Hydraulic Oil Tank". This module is part of Service Manual, RENR4600 Volume 2.

Reference: Disassembly and Assembly, RENR4631 (9EP0571), "R1600 LHD Vehicle Systems", "Remove Hydraulic Oil Tank". This module is part of Service Manual, RENR4646 (9EP3159) Part B.

Reference: Disassembly and Assembly, RENR4562 (9EL2026), "R1700 LHD Vehicle Systems", "Remove Hydraulic Oil Tank". This module is part of Service Manual, RENR44586 (9EL4182) Part B.

Reference: Disassembly and Assembly, RENR4675 (9EP5405), "R1700G LHD Vehicle Systems", "Hydraulic Tank - Remove". This module is part of Service Manual, RENR4656 (9EP5386) Volume 2.

Reference: Disassembly and Assembly, RENR4582 (9EL3678), "R2900 LHD Vehicle Systems", "Remove Hydraulic Tank". This module is part of Service Manual, RENR4747 Part B.

Reference: Disassembly and Assembly, RENR4612 (9EL9611), "R1300 LHD Vehicle Systems", "Disassemble Hydraulic Oil Tank". This module is part of Service Manual, RENR4600 Volume 2.

Reference: Disassembly and Assembly, RENR4631 (9EP0571), "R1600 LHD Vehicle Systems", "Disassemble Hydraulic Oil Tank". This module is part of Service Manual, RENR4646 (9EP3159) Part B.

Reference: Disassembly and Assembly, RENR4562 (9EL2026), "R1700 LHD Vehicle Systems", "Disassemble Hydraulic Oil Tank". This module is part of Service Manual, RENR44586 (9EL4182) Part B.

Reference: Disassembly and Assembly, RENR4675 (9EP5405), "R1700G LHD Vehicle Systems", "Hydraulic Tank - Disassemble". This module is part of Service Manual, RENR4656 (9EP5386) Volume 2.

Reference: Disassembly and Assembly, RENR4582 (9EL3678), "R2900 LHD Vehicle Systems", "Disassemble Hydraulic Tank". This module is part of Service Manual, RENR4747 Part B.

Reference: Disassembly and Assembly, RENR4612 (9EL9611), "R1300 LHD Vehicle Systems", "Assemble Hydraulic Oil Tank". This module is part of Service Manual, RENR4600 Volume 2.

Reference: Disassembly and Assembly, RENR4631 (9EP0571), "R1600 LHD Vehicle Systems", "Assemble Hydraulic Oil Tank". This module is part of Service Manual, RENR4646 (9EP3159) Part B.

Reference: Disassembly and Assembly, RENR4562 (9EL2026), "R1700 LHD Vehicle Systems", "Assemble Hydraulic Oil Tank". This module is part of Service Manual, RENR44586 (9EL4182) Part B.

Reference: Disassembly and Assembly, RENR4675 (9EP5405), "R1700G LHD Vehicle Systems", "Hydraulic Tank - Assemble". This module is part of Service Manual, RENR4656 (9EP5386) Volume 2.

Reference: Disassembly and Assembly, RENR4582 (9EL3678), "R2900 LHD Vehicle Systems", "Assemble Hydraulic Tank". This module is part of Service Manual, RENR4747 Part B.

Reference: Disassembly and Assembly, RENR4612 (9EL9611), "R1300 LHD Vehicle Systems", "Install Hydraulic Oil Tank". This module is part of Service Manual, RENR4600 Volume 2.

Reference: Disassembly and Assembly, RENR4631 (9EP0571), "R1600 LHD Vehicle Systems", "Install Hydraulic Oil Tank". This module is part of Service Manual, RENR4646 (9EP3159) Part B.

Reference: Disassembly and Assembly, RENR4562 (9EL2026), "R1700 LHD Vehicle Systems", "Install Hydraulic Oil Tank". This module is part of Service Manual, RENR44586 (9EL4182) Part B.

Reference: Disassembly and Assembly, RENR4675 (9EP5405), "R1700G LHD Vehicle Systems", "Hydraulic Tank - Install". This module is part of Service Manual, RENR4656 (9EP5386) Volume 2.

Reference: Disassembly and Assembly, RENR4582 (9EL3678), "R2900 LHD Vehicle Systems", "Install Hydraulic Tank". This module is part of Service Manual, RENR4747 Part B.

A front mounted liquid level gauge for the hydraulic oil tank is available. The front mounted liquid level gauge has marked levels for different situations providing a more accurate method of checking the hydraulic tank oil level. The 132-6277 Liquid Level Gauge is adaptable to the following machines: R1300 (S/N: 6QW1-UP), R1600 (S/N: 9EW1-UP), R1700-127 and Up, R1700G (S/N: 8XZ1-UP), R2900-101 to 170 and R2900 (S/N: 5TW1-UP). Refer to the following Tables and the Illustrations for the machine that is being serviced.

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

Personal injury or death can result from an explosion.

Applying heat to a tank which has held flammable liquids, even when empty, can result in residual flammable liquid or vapor igniting with explosive force.

Do Not weld or flame cut on any tank that has held flammable liquid without taking the proper precautions. Such as; filling the tank with either carbon dioxide or water.

Read the article in the Service Magazine, July 2, 1990, "Welding On Fuel And Hydraulic Tanks".

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R1300 Load Haul Dump Front Mounted Liquid Level Gauge Installation

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Table 1
Parts Needed    
Item     Qty     Part Number     Description    
4     2     9EP8879     Boss    
8     2     8F-3469     O-Ring Seal    
9     1     9EP9830     Bracket As    
10     2     9B-7237     Bolt    
11     2     6V-8801     Nut    
12     2     8T-4896     Hard Washer    
13     1     132-6277     Liquid Level Gauge    

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Table 2
Tools Needed    
Part Number     Description     Quantity    
9EP9821     Jig     1    
9EP9822     Jig     1    
0S-1579     Bolt     2    
5P-8245     Hard Washer     2    

  1. Remove the hydraulic oil tank. Disassembly and Assembly, RENR4612 (9EL9611), "R1300 LHD Vehicle Systems", "Remove Hydraulic Oil Tank".

  1. Disassemble the hydraulic oil tank. Refer to Disassembly and Assembly, RENR4612 (9EL9611), "R1300 LHD Vehicle Systems", "Disassemble Hydraulic Oil Tank".
    Show/hide table

    Illustration 1g00917131

    View of the hydraulic oil tank modifications

    (1) 9EP9821 Jig

    (2) Drill two holes 7.5 mm (0.29 inch)

    (A) 50 mm (1.96 inch)

    (B) 100 mm (3.93 inch)

    (C) 330.20 mm (13.00 inch)

  1. Install 9EP9821 Jig (1) to the hydraulic oil tank.

  1. Using 9EP9821 Jig ( 1) as a guide drill two holes (2). Refer to Illustration 1.

  1. Remove 9EP9821 Jig (1) .
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    Illustration 2g00917672

    View of the hydraulic oil tank modification

    (W1) Fillet weld all around 6 mm (0.24 inch) in two places

    (3) 9EP9822 Jig

    (4) 9EP8879 Boss

    (5) 5P-8245 Hard Washer

    (6) 0S-1579 Bolt

  1. Install two 9EP8879 Bosses (4) to 9EP9822 Jig (3) using the following parts: Two 5P-8245 Hard Washers (5) and two 0S-1579 Bolts (6) .

  1. Install the 9EP9822 Jig, complete, as an assembly to the hydraulic oil tank.

    Note: Before attempting Step 8 refer to Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures", "Safety" and Service Magazine, SEPD0025, 02 July 1990, "Welding on Fuel and Hydraulic Tanks".

  1. Weld 9EP8879 Bosses (4) to the hydraulic oil tank. Refer to Illustration 2.

  1. Remove 9EP9822 Jig (3) .
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    Illustration 3g00917683

    View of the new liquid level gauge installation

    (7) 121-7958 Bolt

    (8) 8F-3469 O-Ring Seal

    (9) 9EP9830 Bracket As

    (10) 9B-7237 Bolt

    (11) 6V-8801 Nut

    (12) 8T-4896 Hard Washer

    (13) 132-6277 Liquid Level Gauge

    (14) Hydraulic oil tank

  1. Assemble the hydraulic oil tank. Refer to Disassembly and Assembly, RENR4612 (9EL9611), "R1300 LHD Vehicle Systems", "Assemble Hydraulic Oil Tank".

  1. Install hydraulic oil tank (14). Refer to Disassembly and Assembly, RENR4612 (9EL9611), "R1300 LHD Vehicle Systems", "Install Hydraulic Oil Tank".

  1. Install 9EP9830 Bracket (9) using the following parts: Two 9B-7237 Bolts (10), two 8T-4896 Hard Washers (12) and two 6V-8801 Nuts (11) .

  1. Install 132-6277 Liquid Level Gauge (13). Refer to Illustration 3.

R1600 Load Haul Dump Front Mounted Liquid Level Gauge Installation

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Table 3
Parts Needed    
Item     Qty     Part Number     Description    
4     2     9EP8879     Boss    
8     2     8F-3469     O-Ring Seal    
9     1     9EP9843     Bracket    
10     2     9B-7237     Bolt    
11     2     6V-8801     Nut    
12     2     8T-4896     Hard Washer    
13     1     132-6277     Liquid Level Gauge    

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Table 4
Tools Needed    
Part Number     Description     Quantity    
9EP9840     Jig     1    
9EP9841     Jig     1    
5P-8245     Hard Washer     2    
0S-1579     Bolt     2    

  1. Remove the hydraulic oil tank. Refer to Disassembly and Assembly, RENR4631 (9EP0571), "R1600 LHD Vehicle Systems", "Remove Hydraulic Oil Tank".

  1. Disassemble the hydraulic oil tank. Refer to Disassembly and Assembly, RENR4631 (9EP0571), "R1600 LHD Vehicle Systems", "Disassemble Hydraulic Oil Tank".
    Show/hide table

    Illustration 4g00918529

    View of the hydraulic oil tank modification

    (1) 9EP9841 Jig

    (2) Drill two holes 7.5 mm (0.29 inch)

    (A) 55 mm (2.16 inch)

    (B) 200 mm (7.87 inch)

    (C) 330.2 mm (13.00 inch)

  1. Install 9EP9841 Jig (1) to the hydraulic oil tank.

  1. Using 9EP9841 Jig (1) as a guide drill two holes (2). Refer to Illustration 4.

  1. Remove 9EP9841 Jig (1) .
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    Illustration 5g00918531

    View of the hydraulic oil tank modification

    (W1) Fillet weld all around 6 mm (0.24 inch) in two places

    (3) 9EP9840 Jig

    (4) 9EP8879 Boss

    (5) 5P-8245 Hard Washer

    (6) 0S-1579 Bolt

  1. Install 9EP8879 Bosses (4) to 9EP9840 Jig (3) using the following parts: Two 5P-8245 Hard Washers (5) and two 0S-1579 Bolts (6) .

  1. Install the 9EP9840 Jig, complete, as an assembly to the hydraulic oil tank.

    Note: Before attempting Step 8 refer to Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures", "Safety" and Service Magazine, SEPD0025, 02 July 1990, "Welding on Fuel and Hydraulic Tanks".

  1. Weld 9EP8879 Bosses (4) to the hydraulic oil tank. Refer to Illustration 5.

  1. Remove 9EP9840 Jig (3) .
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    Illustration 6g00918532

    View of the new liquid level gauge installation

    (7) 121-7958 Bolt

    (8) 8F-3469 O-Ring Seal

    (9) 9EP9843 Bracket As

    (10) 9B-7237 Bolt

    (11) 6V-8801 Nut

    (12) 8T-4896 Hard Washer

    (13) 132-6277 Liquid Level Gauge

    (14) Hydraulic oil tank

  1. Assemble the hydraulic oil tank. Refer to Disassembly and Assembly, RENR4631 (9EP0571), "R1600 LHD Vehicle Systems", "Assemble Hydraulic Oil Tank".

  1. Install hydraulic oil tank (14). Refer to Disassembly and Assembly, RENR4631 (9EP0571), "R1600 LHD Vehicle Systems", "Install Hydraulic Oil Tank".

  1. Install 9EP9843 Bracket (12) using the following parts: Two 9B-7237 Bolts (10), two 8T-4896 Hard Washers (12) and two 6V-8801 Nuts (11) .

  1. Install 132-6277 Liquid Level Gauge (13) to hydraulic oil tank (14). Refer to Illustration 6.

R1700 and R1700G Load Haul Dump Front Mounted Liquid Level Gauge Installation

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Table 5
Parts Needed    
Item     Qty     Part Number     Description    
4     2     9EP8879     Boss    
8     2     8F-3469     O-Ring Seal    
9     1     9EQ2347     Bracket    
10     2     9B-7237     Bolt    
11     2     6V-8801     Nut    
12     2     8T-4896     Hard Washer    
13     1     132-6277     Liquid Level Gauge    

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Table 6
Tools Needed    
Part Number     Description     Quantity    
9EP9840     Jig     1    
9EP9841     Jig     1    
5P-8245     Hard Washer     2    
0S-1579     Bolt     2    

  1. Remove the hydraulic oil tank. For R1700 Load Haul Dump refer to Disassembly and Assembly, RENR4562 (9EL2026), "R1700 LHD Vehicle Systems", "Remove Hydraulic Oil Tank". For R1700G Load Haul Dump refer to Disassembly and Assembly, RENR4675 (9EP5405), "R1700G LHD Vehicle Systems", "Hydraulic Tank - Remove".

  1. Disassemble the hydraulic oil tank. For R1700 Load Haul Dump refer to Disassembly and Assembly, RENR4562 (9EL2026), "R1700 LHD Vehicle Systems", "Disassemble Hydraulic Oil Tank". For R1700G Load Haul Dump refer to Disassembly and Assembly, RENR4675 (9EP5405), "R1700G LHD Vehicle Systems", "Hydraulic Tank - Disassemble".
    Show/hide table

    Illustration 7g00918534

    View of the hydraulic oil tank modification for R1700 and R1700G

    (1) 9EP9841 Jig

    (2) Drill two holes 7.5 mm (0.29 inch)

    (A) 55 mm (2.16 inch)

    (B) 200 mm (7.87 inch)

    (C) 330.2 mm (13.00 inch)

  1. Install 9EP9841 Jig (1) to the hydraulic oil tank.

  1. Using 9EP9841 Jig (1) as a guide drill two holes (2). Refer to Illustration 7.

  1. Remove 9EP9841 Jig (1) .
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    Illustration 8g00918864

    View of the hydraulic oil tank modification for R1700 and R1700G

    (W1) Fillet weld all around 6 mm (0.24 inch) in two places

    (3) 9EP9840 Jig

    (4) 9EP8879 Boss

    (5) 5P-8245 Hard Washer

    (6) 0S-1579 Bolt

  1. Install 9EP8879 Bosses (4) to 9EP9840 Jig (3) using the following parts: Two 5P-8245 Hard Washers (5) and two 0S-1579 Bolts (6) .

  1. Install the 9EP9840 Jig, complete, as an assembly to the hydraulic oil tank.

    Note: Before attempting Step 8 refer to Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures", "Safety" and Service Magazine, SEPD0025, 02 July 1990, "Welding on Fuel and Hydraulic Tanks".

  1. Weld 9EP8879 Bosses (4) to the hydraulic oil tank. Refer to Illustration 8.

  1. Remove 9EP9840 Jig (3) .
    Show/hide table

    Illustration 9g00918860

    View of the new liquid level gauge installation

    (7) 121-7958 Bolt

    (8) 8F-3469 O-Ring Seal

    (9) 9EQ2347 Bracket As

    (10) 9B-7237 Bolt

    (11) 6V-8801 Nut

    (12) 8T-4896 Hard Washer

    (13) 132-6277 Liquid Level Gauge

    (14) Hydraulic oil tank

  1. Assemble the hydraulic oil tank. For R1700 Load Haul Dump refer to Disassembly and Assembly, RENR4562 (9EL2026), "R1700 LHD Vehicle Systems", "Assemble Hydraulic Oil Tank". For R1700G Load Haul Dump refer to Disassembly and Assembly, RENR4675 (9EP5405), "R1700G LHD Vehicle Systems", "Hydraulic Tank - Assemble".

  1. Install the hydraulic oil tank. For R1700 Load Haul Dump refer to Disassembly and Assembly, RENR4562 (9EL2026), "R1700 LHD Vehicle Systems", "Install Hydraulic Oil Tank". For R1700G Load Haul Dump refer to Disassembly and Assembly, RENR4675 (9EP5405), "R1700G LHD Vehicle Systems", "Hydraulic Tank - Install".

  1. Install 9EQ2347 Bracket (9) using the following parts: Two 9B-7237 Bolts (10), two 8T-4896 Hard Washers (12) and two 6V-8801 Nuts (11) .

  1. Install 132-6277 Liquid Level Gauge (13) to hydraulic oil tank (14). Refer to Illustration 9.

R2900 Load Haul Dump Front Mounted Liquid Level Gauge Installation

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Table 7
Parts Needed    
Item     Qty     Part Number     Description    
4     2     9EP8871     Boss    
8     2     8F-3469     O-Ring Seal    
9     2     9B-7237     Bolt    
10     2     6V-8801     Nut    
11     2     8T-4896     Hard Washer    
12     1     9EP8870     Bracket    
13     1     132-6277     Liquid Level Gauge    

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Table 8
Tools Needed    
Part Number     Description     Quantity    
9EP8875     Jig     1    
9EP8876     Jig     1    
5P-8245     Hard Washer     2    
0S-1579     Bolt     2    

  1. Remove the hydraulic oil tank. Refer to Disassembly and Assembly, RENR4582 (9EL3678), "R2900 LHD Vehicle Systems", "Remove Hydraulic Tank".

  1. Disassemble the hydraulic tank. Refer to Disassembly and Assembly, RENR4582 (9EL3678), "R2900 LHD Vehicle Systems", "Disassemble Hydraulic Tank".
    Show/hide table

    Illustration 10g00920387

    View of the hydraulic oil tank modifications

    (1) 9EP8875 Jig

    (2) Drill two holes 7.5 mm (0.29 inch)

    (A) 50 mm (1.96 inch)

    (B) 251.2 mm (9.88 inch)

    (C) 330.2 mm (13.00 inch)

  1. Install 9EP8875 Jig (1) to the hydraulic oil tank.

  1. Using 9EP8875 Jig (1) as a guide drill two holes (2). Refer to Illustration 10.

  1. Remove 9EP8875 Jig (1) .
    Show/hide table

    Illustration 11g00920389

    View of the hydraulic oil tank modification

    (W1) Fillet weld all around 6 mm (0.24 inch) in two places

    (3) 9EP8876 Jig

    (4) 9EP8871 Boss

    (5) 5P-8245 Hard Washer

    (6) 0S-1579 Bolt

  1. Install two 9EP8871 Bosses (4) to 9EP8876 Jig (3) using the following parts: Two 5P-8245 Hard Washers (5) and two 0S-1579 Bolts (6) .

  1. Install the 9EP8876 Jig, complete, as an assembly to the hydraulic oil tank.

    Note: Before attempting Step 8 refer to Maintenance Manual, RENR4700 (1DE0603), "Machine Repairs and Welding Procedures", "Safety" and Service Magazine, SEPD0025, 02 July 1990, "Welding on Fuel and Hydraulic Tanks".

  1. Weld 9EP8871 Bosses (4) to the hydraulic oil tank. Refer to Illustration 11.

  1. Remove 9EP8876 Jig (3) .
    Show/hide table

    Illustration 12g00920391

    View of the liquid level gauge installation

    (7) 121-7958 Bolt

    (8) 8F-3469 O-Ring Seal

    (9) 9B-7237 Bolt

    (10) 6V-8801 Nut

    (11) 8T-4896 Hard Washer

    (12) 9EP8870 Bracket

    (13) 132-6277 Liquid Level Gauge

    (14) Hydraulic oil tank

  1. Assemble the hydraulic oil tank. Refer to Disassembly and Assembly, RENR4582 (9EL3678), "R2900 LHD Vehicle Systems", "Assemble Hydraulic Tank".

  1. Install the hydraulic oil tank. Refer to Disassembly and Assembly, RENR4582 (9EL3678), "R2900 LHD Vehicle Systems", "Install Hydraulic Tank".

  1. Install 9EP8870 Bracket (12) using the following parts: Two 9B-7237 Bolts (9), two 8T-4896 Hard Washers (11) and two 6V-8801 Nuts (10) .

  1. Install 132-6277 Liquid Level Gauge (13). Refer to Illustration 12.

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