Installation of the 323-4207 Valve and Lines for 725,730 and 730 Ejector Articulated Trucks{5057, 5067} Caterpillar

Articulated Truck:

725 (S/N: AFX1-UP; B1L1-UP)

730 (S/N: AGF1-UP; B1M1-UP)

730 EJECTOR (S/N: B1W1-UP)

Introduction

ReferenceDisassembly and Assembly, RENR3447, "725 and 730 Articulated Trucks Machine Systems"

This Special Instruction explains the installation of the check valve arrangement for articulated trucks. Do not begin the installation until you have read the information that is contained in this instruction.

A check valve arrangement can be added to the control system for the pilot oil for the fan and to the hydraulic circuits for charging the brake system. The arrangement for the check valve will prevent incorrect events of low brake pressure on machines that are operating in high ambient conditions.

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.

Required Parts

The required parts for the installation of the new lines group for articulated trucks are listed in Table 1.

Preparing the Machine

1. Move the machine to a smooth, horizontal location. Move the machine away from other operating machines and away from personnel.

2. Engage the parking brake.

3. Release hydraulic system pressure.

   Note: Refer to "Hydraulic System Pressure - Release" in the Disassembly and Assembly manual for your machine.

4. Raise the machine cab. Refer to Operation and Maintenance Manual.

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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.

Subassembly of the Check Valve

Illustration 1	g01592113
(A) Port (B) Port (C) Port (D) Port (2) Check Valve Gp (3) Body (5) Elbow (7) Connector (8) O-Ring Seal (9) O-Ring Seal (13) Elbow

1. Assemble the 3J-7354 O-Ring Seal (9) to the 030-7946 Elbow (5). Install the assembly into port (C) of the 322-1453 Body (3) and torque to 17 ± 2 N·m (12.5 ± 1.5 lb ft). Orient the elbow so that the open end is directed toward port (D) .

2. Assemble a 3J-1907 O-Ring Seal (8) to the 7J-4026 Elbow (13). Install the assembly into port (A) of the 322-1453 Body (3) and torque to 34 ± 3 N·m (25.1 ± 2.2 lb ft). Orient the elbow so that the open end is directed toward port (D) .

3. Assemble a 3J-1907 O-Ring Seal (8) to the 2P-1314 Connector (7). Install the connector assembly into port (D) of the 322-1453 Body (3) and torque to 34 ± 3 N·m (25.1 ± 2.2 lb ft).

4. Install the 322-0596 Check Valve Gp (2) into port (B) of the 322-1453 Body (3) .

Check Valve Installation

Illustration 2	g01592233

1. Remove the 2 existing upper bolts and washers from the clamps that retain the discharge hose to the left hand hydraulic pump.

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Illustration 3	g01592235

2. Install the 323-4814 Bracket As (4) to the left hand hydraulic pump with the 8T-4186 Bolts (17) and 8T-4121 Hard Washers (16) in place of the original hardware. Orient the bracket over the hydraulic pump.

3. Use the 7X-2534 Bolts (15) and 9X-8256 Washers (18) to assemble the check valve and body assembly to the 323-4814 Bracket As (4) . Install the valve assembly so the hydraulic connectors are directed toward the rear of the machine. Port (A) of the body should be directed toward the left hand side of the machine.

4. Locate the 240-0678 Main Control Valve Gp at the left hand side of the machine.

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Illustration 4	g01592236

5. Remove the plug from port (E). Discard the plug.

   Note: The port that is shown in illustration 4 is oriented toward the transmission. Access to the port may be difficult. Some hoses may need to be removed in order to remove the plug. The manifold is shown before installation on the machine.

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Illustration 5	g01592238

6. Some hoses may need to be removed in order to install the connector. Install a 6V-0394 Port Connector (12) with 4J-7533 O-Ring Seal (11) and torque to 9 ± 1 N·m (6.6 ± 0.7 lb ft). This port will provide load sensing pressure for the brake system.

   Note: The thread size into the manifold is 5/16 inch. The connector could be easily snapped. Be careful not to overtighten the connector.

7. Connect the 90 degree end of one of the 223-1353 Hose As (1) to the 6V-0394 Port Connector (12) at the manifold and connect the straight end of the hose to the elbow at port (C) of the check valve and body assembly.

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Illustration 6	g01592240

8. Remove the plug from port (F). Discard the plug.

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Illustration 7	g01592243

9. Install a 030-8193 Connector (6) with a 3K-0360 O-Ring Seal (10) and torque to 60 ± 6 N·m (44.3 ± 4.4 lb ft). Port (F) will provide load sensing pressure for the fan system.

10. Connect the 90 degree end of one of the 223-1353 Hose As (1) to the 030-8193 Connector (6) at the manifold and connect the straight end of the hose to the connector at port (D) of the check valve and body assembly. Refer to illustration 1.

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Illustration 8	g01592244

11. Remove the plug from port (G) at the upper corner of the manifold next to the fan control solenoid valve. Discard the plug.

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Illustration 9	g01592245

12. Install a 6V-0394 Port Connector (12) with a 4J-7533 O-Ring Seal (11) and torque to 9 ± 1 N·m (6.6 ± 0.7 lb ft). Port (G) provides the drain passage for the return oil from the check valve and body assembly.

    Note: The thread size from the connector into the manifold is 5/16 inch. This could be easily snapped. Hold the connector in place with a wrench during installation of the hose. Do not apply excessive torque during installation of the hose.

13. Connect the 90 degree end of one of the 223-1353 Hose As (1) to the 6V-0394 Port Connector (12) at the manifold and connect the straight end of the hose to the elbow at port (A) of the check valve and body assembly. Refer to illustration 1.

    .

    Note: The thread size from the connector into the manifold is 5/16 inch. This could be easily snapped. Hold the connector in place with a wrench during installation of the hose. Do not apply excessive torque during installation of the hose.

14. Secure the 223-1354 Hose As (1) to the existing hoses with the 7K-1181 Cable Straps . Make sure that the hoses cannot be damaged during operation of the machine by rubbing against other components.

15. Ensure that all fittings, hoses and hardware are fully tightened.

16. Start the machine and check for oil leaks.

17. Lower the machine cab. Refer to Operation and Maintenance Manual.

System Test

1. It will be necessary to run the engine at low idle in order to carry out the system test.

2. Run the engine at low idle and allow the brake system to fully charge the brake accumulators.

3. Connect the Caterpillar Electronic Technician (ET) to the machine and select the engine ECM.

4. By using the Override for the Diagnostic Tests, set the Bypass for the Cooling Fan to 0%. The cooling fan will speed up to the maximum. This will be clearly audible.

5. Depress the service brake pedal and release the service brake pedal several times. This action will recharge the service brake accumulators. As the brake accumulators are recharging, the cooling fan speed will decrease. When the brake accumulators have fully charged, the fan speed will return to the maximum.

6. When testing has been completed, turn off the override for the Cooling Fan in Electronic Technician or cycle the keyswitch. Either option will reset the Cooling Fan to the programmed parameters.