Custom Product Option "3Z-5911" 735 Extended Long Wheel Base Machine{7000} Caterpillar

Articulated Truck:

735 (S/N: B1N236,252)

Introduction

This Special Instruction is for the 735 Extended Long Wheel Base machine.

This Special Instruction identifies the differences in components that are used on the 735 Extended Long Wheel Base machine to the standard machine. The Special Instruction identifies the changes in the hydraulic system and the electrical system of the machine. The Special Instruction also supplies information for testing and adjusting the 735 Extended Long Wheel Base machine.

References

Reference: Systems Operation, Testing and Adjusting, RENR5129, "735, 740 and 740 EJECTOR Articulated Trucks Braking System"

Reference: Schematic, RENR6734, "735, 740 and 740 EJECTOR Articulated Truck Electrical System"

Reference: Systems Operation, Testing and Adjusting, RENR5126, "735 and 740 Articulated Trucks Hoist, Steering, Suspension, and Fan Drive Systems"

Reference: Disassembly and Assembly, RENR5140, "735, 740 and 740 EJECTOR Articulated Truck Machine System"

Graphic Color Codes

Illustration 1	g00771291

(A) Red ... Pump discharge pressure

(B) Red Stripes and White Stripes ... First pressure reduction

(C) Red Dots ... Second pressure reduction

(D) Orange ... Pilot system pressure

(E) Orange Stripes and White Stripes ... Reduced pilot system pressure

(F) Blue ... Blocked oil

(G) Green ... Suction oil, return oil, and case drain oil

(H) Yellow ... Moving parts and activated valve sections

(I) Purple ... Pressurized gas

(J) Gray ... Cutaway sections, and non-activated valve sections

Note: The hydraulic system that is covered in this Special Instruction may not require all of the colors in Illustration 1.

General Information

Specifications

Illustration 2	g01177680

Illustration 3	g01177681

Table 1

		Metric Units	English Units
A	Length (Overall)	13.03 m	(42.75 ft)
B	Length (Over Frame)	(12.903 m)	(42.35 ft)
C	Width (Mirror to Mirror)	(4.119 m)	(13.52 ft)
D	Width (Across the Tires)	(3.370 m)	(11.06 ft)
E	Height (Top of Muffler)	(4.006 m)	(13.15 ft)
F	Height (Top of Cap)	(3.703 m)	(12.15 ft)
	Weight	(26470 kg)	(58360 lb)

Parts

Comparison of Components

Table 2

Differences in Components with Standard 735 Machine
Standard 735 Machine	735 Extended Long Wheel Base
226-8617 General Arrangement	3Z-5911 General Arrangement
153-0444 Machine Installation	Equipment is not installed.
164-9856 Hoist Cylinder and Mounting	Equipment is not installed.
246-0909 Front Wiring	270-7441 Front Wiring
153-1118 Hoist Pump and Mounting	270-3075 Pump and Mounting
188-7300 Cover part of 162-5242 Hydraulic Tank	274-4233 Cover
166-5846 Pump Lines	270-3077 Pump Lines
152-7101 Hoist Oil Lines	270-4890 Hoist Oil Lines
153-1139 Hoist Oil Lines	271-0169 Manifold Lines
166-3938 Return Lines	270-3078 Return Lines
251-3503 Pressure Test Lines	270-3079 Pressure Test Lines
153-0438 Axle and Frame Arrangement	270-3072 Axle and Frame Arrangement

Table 3

Comparison of the Axle and Frame Arrangement on the Extended Long Wheel Base Machine with Standard 735 Machine
Standard 735 Machine 153-0438 Axle and Frame Arrangement	735 Extended Long Wheel Base 270-3072 Axle and Frame Arrangement
141-6857 Oscillating Hitch
152-7027 Hitch Drive Shaft
153-0483 Center Axle Arrangement
153-0484 Rear Axle Arrangement
187-2675 Rear Drive Shaft Group	270-3081 Rear Drive Shaft Group
152-7029 Parking Brake Control	270-3082 Parking Brake Control
152-7030 Grease Lines	270-3083 Grease Lines
241-6069 Rear Wiring	270-3085 Rear Wiring
152-7033 Service Brake Lines	270-3086 Service Brake Lines
152-7034 Differential Lock Lines	270-3087 Differential Lock Lines
166-3946 Axle Oil Cooler Lines	270-3088 Axle Oil Cooler Lines
152-7035 Rear Frame	270-3089 Rear Frame

Table 4

Differences in the Rear Frame Arrangement with Standard 735 Machine
Standard 735 Machine 152-7035 Rear Frame	735 Extended Long Wheel Base 270-3089 Rear Frame
138-7962 Suspension	138-7962 Suspension
141-6855 Rear Frame	270-3091 Rear Frame

270-7441 Front Wiring

Table 5

Parts List 270-7441 Front Wiring
1	1	2V-2043	Flared Locknut
2	1	3E-6449	Temperature Switch
3	1	3E-6450	Pressure Switch
4	1	3E-6451	Temperature Switch Gp
5	3	3J-1907	O-Ring Seal
6	84	3S-2093	Cable Strap
7	2	3S-8665	Clip
8	3	4L-6454	Bolt
9	2	4P-7429	Clip
10	2	4P-7429	Clip
11	17	4P-7581	Clip
12	6	4P-8134	Clip
13	6	5C-2890	Nut
14	2	5K-3294	Clip
15	1	5M-3062	Bolt
16	2	5P-2566	Bolt
17	1	5P-4115	Hard Washer
18	2	5P-9085	Clip
19	6	6D-3479	Clip
20	2	6D-4244	Clip
21	3	6D-4246	Clip
22	2	6U-0455	Strap
23	2	6U-0456	Strap
24	2	6U-2703	Angle Bracket
25	1	6V-2383	Clip
26	3	7C-4354	Clip
27	2	7U-9542	Clamping Plate
28	1	7X-0292	Bolt
29	2	8C-3121	Bolt
30	7	8M-2770	Clip
31	5	8M-2773	Clip
32	2	8T-2501	Bolt
33	39	8T-4121	Hard Washer
34	2	8T-4123	Plated Washer
35	13	8T-4133	Nut
36	23	8T-4136	Bolt
37	1	8T-4137	Bolt
38	6	8T-4138	Bolt
39	1	8T-4185	Bolt
40	4	8T-4196	Bolt
41	2	8T-4223	Hard Washer
42	2	8T-4224	Hard Washer
43	2	8T-4780	Bolt
44	5	8T-4896	Hard Washer
45	8	9M-4972	Clip
46	1	9X-7378	O-Ring Seal
47	11	9X-8256	Washer
48	2	106-8704	Arc Suppressor As
49	1	114-5333	Pressure Switch
50	1	118-3534	Magnetic Switch Gp
51	1	122-7052	Spacer
52	1	134-2252	Temperature Sensor Gp
53	1	149-2612	Relay
54	1	165-6365	Fitting As
55	1	194-6722	Pressure Sensor Gp
56	1	204-5396	Plate As
57	1	204-7884	Bracket
58	1	205-5594	Plate As
59	1	205-5595	Plate
60	1	206-6810	Mounting Bracket
61	1	207-4757	Bracket As
62	2	211-8021	Bracket
63	1	213-6947	Pressure Switch Gp
64	1	241-6065	Fuel Tank Harness As
65	1	247-8168	Front Chassis Harness As
66	1	265-0764	Plate As
67	1	270-7449	Harness As
68	1	270-7456	Harness As

270-3075 Pump and Mounting

Table 6

Parts List 270-3075 Pump and Mounting Refer to Illustration 4.
1	1	255-3539	Pump Gp
2	1	5F-3106	O-Ring Seal
3	2	7X-2553	Bolt
4	2	9X-8257	Washer

Illustration 4	g01176512
270-3075 Pump and Mounting

270-3077 Pump Lines

Table 7

Parts List 270-3077 Pump Lines Refer to Illustration 5.
1	2	6U-0456	Strap
2	1	145-5181	Spacer
3	1	190-6258	Hose As
4	1	209-7530	Spacer
5	1	214-4734	Hose As
6	1	274-1393	Hose As
7	1	274-1395	Hose As
8	2	117-1266	O-Ring Seal
9	1	148-8362	Elbow Gp
10	1	157-6199	Grommet
11	6	1P-4579	Half Flange
12	2	1P-4582	Half Flange
13	4	1P-4585	Half Flange
14	3	4J-0524	O-Ring Seal
15	1	4J-0527	O-Ring Seal
16	1	5P-7468	Clip
17	1	5P-7469	Clip
18	1	5P-7470	Clip
19	1	5P-7471	Clip
20	1	5P-7703	Grommet
21	1	5P-8444	Grommet
22	1	6V-6782	Clip
23	1	6V-6783	Clip
24	1	8T-4183	Bolt
25	16	8T-4184	Bolt
26	8	8T-4193	Bolt
27	19	8T-4223	Hard Washer
28	1	8T-4244	Nut
29	1	8T-4910	Bolt
30	1	8T-6868	Bolt
31	8	9X-8257	Washer

Illustration 5	g01176845
270-3077 Pump Lines

270-4890 Oil Lines

Table 8

Parts List 270-4890 Oil Lines Refer to Illustration 6.
1	1	194-1556	Tube As
2	1	194-1559	Tube As
3	2	194-7711	Hose As
4	1	197-6651	Shield As
5	1	207-8892	Tube As
6	1	271-6285	Mounting and Valve Gp
7	1	274-1396	Tube As
8	1	1P-3704	Rectangular Seal
9	2	1P-5761	Half Flange
10	4	4J-0520	O-Ring Seal
11	3	5K-9090	O-Ring Seal
12	8	5P-1076	Hard Washer
13	8	8C-3206	Half Flange
14	8	8T-1889	Clip
15	8	8T-1890	Clip
16	30	8T-4121	Hard Washer
17	5	8T-4133	Nut
18	4	8T-4182	Bolt
19	4	8T-4192	Bolt
20	2	8T-4195	Bolt
21	15	8T-4196	Bolt
22	4	8T-4223	Hard Washer
23	4	8T-4244	Nut
24	4	8T-4956	Bolt
25	4	8T-6685	Bolt

Illustration 6	g01176844
270-4890 Oil Lines

270-3078 Return Lines

Table 9

Parts List 270-3078 Return Lines Refer to Illustration 7.
1	2	6U-0455	Strap
2	3	6U-0456	Strap
3	1	148-8336	Connector As
4	1	156-1778	Hose As
5	1	193-1516	Hose As
6	1	148-8383	Elbow As
7	1	148-8407	Plug As
8	2	1P-4579	Half Flange
9	2	1P-4582	Half Flange
10	1	4J-0524	O-Ring Seal
11	1	4J-0527	O-Ring Seal
12	8	8T-4184	Bolt
13	8	8T-4223	Hard Washer

Illustration 7	g01176846
270-3078 Return Lines

270-3079 Test Lines

Table 10

Parts List 270-3079 Test Lines Refer to Illustration 8.
1	11	6U-0455	Strap
2	8	121-0530	Hydraulic Fitting Gp
3	1	185-2620	Plate
4	1	204-6012	Bracket As
5	2	257-8083	Hose As
6	3	257-8092	Hose As
7	2	257-8093	Hose As
8	1	257-8095	Hose As
9	1	148-8378	Elbow As
10	2	148-8415	Reducer As
11	8	6V-0852	Dust Cap
12	8	6V-9168	Nut
13	3	8T-4121	Hard Washer
14	3	8T-4195	Bolt

Illustration 8	g01176847
270-3079 Test Lines

271-0169 Manifold Lines

Table 11

Parts List 271-0169 Manifold Lines Refer to Illustration 9.
1	2	6U-0456	Strap  (1)
2	1	153-3528	Manifold
3	1	189-9940	Hose As  (1)
4	1	189-9941	Hose As  (1)
5	1	148-8313	Adapter As
6	1	148-8411	Plug
7	1	153-6262	Union As  (1)
8	1	164-5567	Coupling Fitting Gp
9	4	4J-0520	O-Ring Seal
10	2	5H-4019	Cover
11	1	6V-0852	Dust Cap
12	8	8C-3206	Half Flange
13	17	8T-4121	Hard Washer
14	16	8T-4196	Bolt
15	1	8T-4198	Bolt

( 1 )

This part is used for shipping only.

Illustration 9	g01176848
271-0169 Manifold Lines The Illustration shows the hydraulic link that is installed for shipping.

270-3081 Rear Drive Shaft Group

Table 12

Parts List 270-3081 Rear Drive Shaft Group Refer to Illustration 10.
1	1	187-2676	Universal Joint Group
2	1	187-2677	Universal Joint Group
3	1	213-9787	Drive Shaft
4	1	266-3836	Joint
5	24	0S-0484	Bolt
6	4	8T-4132	Nut
7	4	8T-4175	Bolt
8	8	9X-8257	Washer

Illustration 10	g01171909
270-3081 Rear Drive Shaft Group

270-3082 Brake Control Group

Table 13

Parts List 270-3082 Brake Control Group Refer to Illustration 11.
1	1	128-4197	Hose As
2	1	163-5632	Brake Accumulator
3	1	164-5567	Coupling Fitting Gp
4	1	190-6278	Hose As
5	1	190-6282	Tube As
6	1	190-6290	Brake Control Valve Gp
7	1	202-3063	Bracket
8	1	221-5281	Hose As
9	1	222-5608	Elbow As
10	1	222-6869	Connector As
11	1	271-4299	Tube
12	1	273-0031	Tube
13	1	148-8336	Connector As
14	1	148-8340	Connector As
15	1	148-8361	Elbow As
16	1	148-8365	Elbow As
17	1	148-8375	Elbow Gp
18	1	148-8377	Elbow Gp
19	2	5P-4116	Hard Washer
20	2	5P-7462	Clip
21	2	5P-7463	Clip
22	2	6V-0683	Grommet
23	1	6V-0852	Dust Cap
24	1	6V-8398	O-Ring Seal
25	1	6V-9168	Nut
26	1	6V-9169	Bulkhead Nut
27	2	7X-7729	Washer
28	4	8T-1885	Clip
29	4	8T-1886	Clip
30	4	8T-4121	Hard Washer
31	2	8T-4133	Nut
32	2	8T-4137	Bolt
33	2	8T-4196	Bolt
34	2	8T-6870	Bolt

Illustration 11	g01171950
270-3082 Brake Control Group

270-3083 Grease Lines

Table 14

Parts List 270-3083 Grease Lines Refer to Illustration 12.
1	5	3B-8485	Grease Fitting
2	5	4U-1697	Bulkhead Adapter
3	5	5B-3254	Jam Nut
4	5	5U-7151	Cap
5	1	148-0168	Hose As
6	1	153-8341	Cover Plate
7	1	159-7192	Bracket
8	1	214-3067	Tube As
9	3	214-3068	Hose As
10	1	271-5326	Hose As
11	1	271-5327	Hose As
12	4	124-0174	Clip
13	4	2N-1287	Flared Elbow
14	2	5P-5008	Reducer
15	3	7S-8920	Clip
16	3	7S-8921	Clip
17	1	8L-6557	Connector
18	6	8T-1887	Clip
19	6	8T-1888	Clip
20	20	8T-4121	Hard Washer
21	7	8T-4133	Nut
22	13	8T-4195	Bolt
23	6	8W-8909	Sleeve

Illustration 12	g01171949
270-3083 Grease Lines

270-3085 Rear Wiring

Table 15

Parts List 270-3085 Rear Wiring
1	2V-2043	Flared Locknut
1	3E-6451	Temperature Switch Gp
1	3J-1907	O-Ring Seal
1	3K-0360	O-Ring Seal
27	3S-2093	Cable Strap
4	8T-4223	Hard Washer
4	8T-4956	Bolt
2	8W-8528	Sleeve
1	213-6947	Pressure Switch Gp
1	274-4246	Harness
1	274-4248	Light and Warning Gp

270-3086 Service Brake Lines

Table 16

Parts List 270-3086 Service Brake Lines Refer to Illustration 13.
1	1	177-0105	Hose As
2	1	190-9821	Elbow As
3	1	271-5488	Tube
4	1	273-0032	Tube
5	1	148-8341	Connector As
6	1	169-7404	Elbow As
7	1	5P-7464	Clip
8	1	5P-7465	Clip
9	1	6V-7359	Grommet
10	2	6V-9170	Bulkhead Nut
11	1	7J-9108	O-Ring Seal
12	4	8T-4121	Hard Washer
13	2	8T-4133	Nut
14	1	8T-4139	Bolt
15	2	8T-4186	Bolt
16	1	8T-4223	Hard Washer
17	2	9R-1004	Clip
18	2	9R-1005	Clip

Illustration 13	g01171948
270-3086 Service Brake Lines

270-3087 Differential Lock Lines

Table 17

Parts List 270-3087 Differential Lock Lines Refer to Illustration 14.
1	1	115-7817	Hose As
2	1	163-8452	Hose As
3	1	190-6291	Bracket
4	1	206-9434	Bracket
5	1	214-5027	Tube As
6	1	271-6279	Tube As
7	1	273-0033	Tube As
8	2	148-8318	Connector As
9	2	148-8377	Elbow Gp
10	1	153-6246	Tee Gp
11	4	5P-4116	Hard Washer
12	1	5P-7462	Clip
13	1	5P-7463	Clip
14	1	6V-0683	Grommet
15	1	6V-8397	O-Ring Seal
16	3	6V-9168	Nut
17	2	7X-0507	Hard Washer
18	3	8T-1887	Clip
19	3	8T-1888	Clip
20	1	8T-4186	Bolt
21	4	8T-4189	Bolt
22	3	8W-8909	Sleeve

Illustration 14	g01172379
270-3087 Differential Lock Lines

270-3088 Axle Oil Cooler Lines

Table 18

Parts List 270-3088 Axle Oil Cooler Lines Refer to Illustration 15.
1	4	6U-0456	Strap
2	16	118-9573	Bolt
3	1	153-2942	Tube As
4	1	153-2943	Tube As
5	1	153-2944	Tube As
6	1	153-2945	Tube As
7	1	159-2880	Manifold
8	2	195-3763	Hose As
9	2	197-4926	Hose As
10	1	271-7055	Tube As
11	1	271-7056	Tube As
12	1	273-0034	Tube As
13	1	273-0035	Tube As
14	2	1P-3705	Rectangular Seal
15	12	4J-0520	O-Ring Seal
16	7	7S-8920	Clip
17	7	7S-8921	Clip
18	2	7X-0823	Union
19	24	8C-3206	Half Flange
20	4	8T-0315	O-Ring Seal
21	1	8T-1887	Clip
22	1	8T-1888	Clip
23	4	8T-1889	Clip
24	4	8T-1890	Clip
25	56	8T-4121	Hard Washer
26	11	8T-4133	Nut
27	2	8T-4178	Bolt
28	1	8T-4186	Bolt
29	42	8T-4196	Bolt
30	8	8T-4223	Hard Washer
31	16	8T-4896	Hard Washer
32	8	8T-6868	Bolt
33	1	8W-8909	Sleeve
34	2	9R-1004	Clip
35	2	9R-1005	Clip

Illustration 15	g01172380
270-3088 Axle Oil Cooler Lines

270-3091 Rear Frame

Table 19

Parts List 270-3091 Rear Frame
6	6V-8237	Washer
6	8T-0365	Bolt
4	8T-4139	Bolt
8	8T-4183	Bolt
16	8T-4223	Hard Washer
4	8T-4244	Nut
2	142-0050	Bushing
1	144-4083	Bracket
2	162-5516	Bushing
2	162-5517	Seal
2	162-5518	Retainer Ring
1	174-6769	Guard Frame Assembly
1	189-2908	Clamp
1	194-5012	Deflector
1	270-3080	Frame
1	274-9141	Plate

Hydraulic Schematic

Illustration 16	g01163626
(1) Trailer high pressure system. This component is not shipped. For the purpose of shipping, the output port and the input port of manifold (3) are hydraulically connected. (2) Test point (Trailer high pressure system pressure) (3) Manifold Rear frame (4) Cold oil manifold (5) Relief valve (Service brake cooling) (6) Gear pump (A) Service brake cooling system (B) Hydraulic tank

The Schematic shows the hydraulic system for the trailer high pressure system and the supply side of cooling oil for the service brake cooling system. The trailer high pressure system replaces the hoist system on the 735 Extended Long Wheel Base machine. For more information on the service brake cooling system, refer to Systems Operation, RENR5129, "735, 740 and 740 EJECTOR Articulated Trucks Braking System".

Note: For the purpose of shipping, the output port and the input port of manifold (3) are hydraulically connected. The hydraulic connection allows hydraulic oil that is pumped by the trailer high pressure system side of pump (6) to return directly to hydraulic tank (B). In the shipped state, a relief valve is not installed in the trailer high pressure system side of the pump.

Electrical Schematic

Reference: Schematic, RENR6734, "735, 740 and 740 EJECTOR Articulated Truck Electrical System".

The Schematic for the Extended Long Wheel Base machine is identical to the standard machine with the exception of three additional wires in the hitch harness that connect to the transmission harness. The three additional wires are used to provide a facility for a magnetic switch that will inhibit higher gear selections. Use Schematic, RENR6734, "735, 740 and 740 EJECTOR Articulated Truck Electrical System" for troubleshooting and include sections (A) and (B) that are identified in the following illustrations.

Illustration 17	g01164444
The transmission harness and hitch harness Section A and Section B highlight the differences in the harnesses on the 735 Extended Long Wheel Base. The remaining sections of the schematic are identical to the standard 735.

Illustration 18	g01165156
Section A that shows the hitch harness and part of the transmission harness

Illustration 19	g01165157
Section B shows part of the transmission harness.

For information about all of the electrical system on the machine with the exception of the transmission harness and the hitch harness, refer to Schematic, RENR6734, "735, 740 and 740 EJECTOR Articulated Truck Electrical System". For information about the transmission harness and the hitch harness on the 735 Extended Long Wheel Base machine, refer to Illustration 17, Illustration 18 and Illustration 19.

For the additional wiring in the transmission harness, refer to Table 20.

Table 20

Additional Wiring in the Transmission Harness
799-CF53	WH-18
P795-CF54	PK-18
201-CF55	BK-18

For the additional wiring in the hitch harness, refer to Table 21.

Table 21

Additional Wiring in the Hitch Harness
799-J15	WH-18
P795-J16	PK-18
201-J17	BK-18

For the part numbers of the new harnesses on the 735 Extended Long Wheel Base machine, refer to Table 22.

Table 22

Harnesses
Part Number	Description
240-7456	Transmission Harness
240-7449	Hitch Harness
274-4247 (1)	Harness (Rear Lamps)
274-4246 (1)	Harness (Rear Chassis)

( 1 )

This harness is revised because the harness has been rerouted. The circuit for this harness is identical to the standard machine.

Illustration 20	g01176511

In order to wire a 229-5527 Position Sensor , make a harness as detailed in Illustration 20. Use the 229-5527 Position Sensor with a 5G-7820 Magnet .

System Operation

Illustration 21	g01163626
(1) Trailer high pressure system. This component is not shipped. For the purpose of shipping, the output port and the input port of manifold (3) is hydraulically connected. (2) Test point ( Trailer high pressure system pressure) (3) Manifold (Rear frame) (4) Cold oil manifold (5) Relief valve (Service brake cooling) (6) Gear pump (A) Service brake cooling system (B) Hydraulic tank

Note: For the purpose of shipping, the output port and the input port of manifold (3) are hydraulically connected. The hydraulic connection allows hydraulic oil that is pumped by the trailer high pressure system side of pump (6) to return directly to hydraulic tank (B). In the shipped state, a relief valve is not installed in the trailer high pressure system side of the pump.

Hydraulic oil for the Trailer high pressure system is drawn from hydraulic tank (B) that also supplies hydraulic oil for the brake system.

Hydraulic oil is drawn from hydraulic tank (B) by gear pump (6). The gear pump is driven by the engine. The gear pump draws hydraulic oil for both the Trailer high pressure system and the service brake cooling system. For information on the service brake cooling system, refer to Systems Operation, RENR5129, "735, 740 and 740 EJECTOR Articulated Trucks Braking System".

Hydraulic oil for Trailer high pressure system (1) is supplied directly to manifold (3) on the rear frame by gear pump (6). Return hydraulic oil from the trailer high pressure system is routed through the manifold on the rear frame to hydraulic tank (A) via cold oil manifold (4) that is on the front frame.

Hydraulic oil for service brake cooling system (A) is supplied directly to cold oil manifold (4) on the front frame by gear pump (6). If the system pressure for the service brake cooling system is exceeded, relief valve (Service brake cooling) (5) in the cold oil manifold relieves excess oil to the return line from trailer high pressure system (1) .

Component Locations

Illustration 22	g01163762
Typical example Test point (trailer high pressure system pressure) (2) on manifold (3) on the rear frame.

Illustration 23	g01163763
Relief valve (Service brake cooling) (5) in cold oil manifold (4) on the front frame.

Illustration 24	g01163764
Gear pump (6) on the engine.

Testing and Adjusting

Troubleshooting

The service brakes are overheating

Possible Causes

1. The relief valve for the oil cooler core for the service brake cooling system is stuck open. The relief valve is in the cold oil manifold on the front frame.
   • Refer to Systems Operation for the location of the relief valve.

2. The oil cooler core is blocked or damaged or the flow of coolant through the oil cooler core is too low.

3. The service brakes have been misused.
   • Refer to Operation and Maintenance Manual, "Service Brake Control".

   • Refer to Operation and Maintenance Manual, "Engine Compression Brake Control".

The trailer high pressure system operates slowly.

Possible Causes

1. The oil is not at operating temperature.
   • Refer to Systems Operation, Testing and Adjusting, RENR5126, "General Information" for information on warming the oil.

2. The gear pump for the trailer high pressure system is worn or faulty.

Testing and Adjusting

Trailer High Pressure System Pressure - Test

Note: For the purpose of shipping, the output port and the input port of manifold (3) are hydraulically connected. The hydraulic connection allows hydraulic oil that is pumped by the trailer high pressure system side of pump (6) to return directly to hydraulic tank (B). In the shipped state, a relief valve is not installed in the trailer high pressure system side of the pump. This test is only of use once a trailer high pressure system has been connected.

Ensure that the oil is at operating temperature. Refer to Systems Operation, Testing and Adjusting, RENR5126, "General Information" for information on warming the oil.

Park the machine on a level surface. Move the parking brake control to the ENGAGED position. Move the hoist control to the HOLD position and shut off the engine. Install the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".

Show/hide table



Illustration 25	g01164497
Typical example Manifold on the rear frame

1. Remove the dust cap and install a 6890 kPa (1000 psi) pressure gauge onto the test fitting on the manifold.

2. Start the engine.

3. Run the engine at low idle. Record the pressure that is displayed on the pressure gauge.

4. Run the engine at high idle. Record the pressure that is displayed on the pressure gauge.

5. Run the engine at high idle and operate the trailer high pressure system. Record the pressure that is displayed on the pressure gauge.

6. Shut off the engine.

7. Remove the steering frame lock.

All the recorded pressures should be in the range that is specified by the manufacturer of the trailer high pressure system.

Gear Pump (Trailer High Pressure System and Cooling Oil) - Test

Ensure that the oil is at operating temperature. Refer to Testing and Adjusting, "General Information" for information on warming the oil.

Park the machine on a level surface. Move the parking brake control to the ENGAGED position and move the hoist control to the HOLD position. Shut off the engine.

If there is a problem with the gear pump, the operating times for the trailer high pressure system might be incorrect. If there is a problem with the gear pump, the system pressure may be incorrect.

Illustration 26	g01164763
The gear pump is located beneath the cab.

1. Test the pressure for the hoist system. Refer to Systems Operation, Testing and Adjusting, "Trailer High Pressure System Pressure - Test". If the system pressure is incorrect and the system pressure cannot be corrected by adjustment, there may be a problem with the gear pump.

2. If the gear pump is malfunctioning due to damage, the gear pump must be replaced.

   Refer to Disassembly and Assembly, RENR5140, "Gear Pump (Hoist) - Remove" and Disassembly and Assembly, RENR5140, "Gear Pump (Hoist) - Install", as an example of removing and installing the gear pump.

Specifications

255-3539 Gear Pump

Illustration 27	g01163618

Gear pump (1) is made of two gear pumps built in tandem. Gear pump (1a) supplies hydraulic oil to the service brake cooling system. Gear pump (1b) supplies hydraulic oil to the trailer high pressure system.

Gear Pump (1a) (Service Brake Cooling System)

Maximum pressure ... 20700 kPa (3000 psi)

Flow rate per revolution at 6900 kPa (1000 psi) and 65 °C (150 °F) ... 181 cc (11 in³)

Flow per minute at 700 RPM ... 126700 cc (7730 in³)

Flow per minute at 2105 RPM ... 381000 cc (23250 in³)

Gear Pump (1b) (Trailer High Pressure System)

Maximum pressure ... 31000 kPa (4500 psi)

Flow rate per revolution at 6900 kPa (1000 psi) and 65 °C (150 °F) ... 45 cc (2.75 in³)

Flow per minute at 700 RPM ... 31500 cc (1920 in³)

Flow per minute at 2105 RPM ... 94725 cc (5780 in³)

271-5451 Cold Oil Manifold

Illustration 28	g01163619

(1) 126-6099 Relief Valve

126-6099 Relief Valve (Service Brake Cooling)

Illustration 29	g01163620

The setting for the cold oil relief valve at an oil flow of 38 ± 4 L/min (10 ± 1 US gpm) ... 790 ± 30 kPa (115 ± 5 psi)

(1) Torque for plug 105 ± 20 N·m (80 ± 15 lb ft)

(2) Torque for testing 160 ± 30 N·m (120 ± 20 lb ft)

(3) 8B-4624 Shims

Do not adjust the number of shims at this location. Number of shims ... 7

(4) 8B-4624 Shims

In order to change the pressure, adjust the number of shims at this location. Number of shims ... 8

162-5242 Hydraulic Tank (Trailer High Pressure System and Brake)

The 162-5242 Hydraulic Tank (Trailer High Pressure System and Brake) is identical to the 162-5242 Hydraulic Tank (Hoist and Brake) on the standard machine. The exception is the replacement of the 188-7300 Cover with the 274-4233 Cover on the 735 Extended Long Wheel Base machine. The 274-4233 Cover incorporates an addition 207-9829 Tube for the suction side of the 255-3539 Gear Pump .

Illustration 30	g00876640

(1) 192-7620 Oil Level Gauge

Torque for the retaining screws ... 7 N·m (62 lb in)

(2) 157-7911 Breather

Relief pressure ... 50 kPa (7.25 psi)

Vacuum relief ... 0.1 kPa (0.015 psi)

Filtration ... 10 Microns

(3) Torque for the retaining bolt ... 115 ± 5 N·m (85 ± 3.5 lb ft)

(4) 6P-3860 Spring

Test force ... 467 ± 37 N (105 ± 8 lb)

Test length ... 41.9 mm (1.6 inch)

Free length after test ... 91.7 mm (3.6 inch)

Outside diameter ... 71.5 mm (2.8 inch)

(5) Bypass valve (crack) ... 150 kPa (22 psi)

(6) 5J-2926 Spring

Test force ... 60.6 ± 4.3 N (13.62 ± 1 lb)

Test length ... 75.7 mm (3 inch)

Free length after test ... 137.2 mm (5.4 inch)

Outside diameter ... 58.3 mm (2.3 inch)

(7) 132-8876 Oil Filter Element As

Filtration ... 6 Microns

(8) 7B-3039 Spring

Test force ... 16 ± 1.3 N (3.50 ± 0.3 lb)

Test length ... 26.2 mm (1.03 inch)

Free length after test ... 36.5 mm (1.44 inch)

Outside diameter ... 19.8 mm (0.78 inch)