Replacement Of 6U-1416 Brake Valve Gp And 7U-4769 Brake Valve Gp {5481} Caterpillar

Articulated Truck:

D250B (S/N: 5WD1-UP)

D25C (S/N: 9YC1-UP)

D25D (S/N: 1HK1-UP)

D300B (S/N: 4SD1-UP)

D30C (S/N: 7ZC1-UP)

D30D (S/N: 3AJ1-UP; 1PK1-UP)

D35-HP (S/N: 3FD1-UP)

D350C (S/N: 8XC1-UP)

D350D (S/N: 9RF1-UP)

D35C (S/N: 2GD1-UP)

D400D (S/N: 8TF1-UP; 4EJ1-UP)

D40D (S/N: 2JJ1-UP)

D44 (S/N: 2LD1-UP)

D44B (S/N: 8SD1-UP)

D550B (S/N: 5ND1-UP)

Introduction

The 6U-1416 Brake Valve Gp , 7U-4769 Brake Valve Gp , and 2U-4366 Repair Kit are no longer available for the listed machines.

The 370-9046 Parking Brake Valve Gp and the 375-0710 Parking Brake Valve Gp are available as replacements for the listed machines.

The choice of using a 370-9046 Parking Brake Valve Gp or a 375-0710 Parking Brake Valve Gp is dependent on available space. Determine the available space at the location of the original parking brake control valve. Review this Special Instruction before purchasing a replacement kit and adapt the procedure that is best suited to the machine being repaired.

As a guideline, the 370-9046 Parking Brake Valve Gp suits all the machines listed except the D250B and D300B. For the D250B and D300B, with the dash mounted parking brake control, the 375-0710 Parking Brake Valve Gp is appropriate.

Ensure the information listed in this Special Instruction is understood before starting work.

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.

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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

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Crush Hazard! Before tilting the cab, remove all loose articles from the cab, secure all windows, and then close the cab doors. Improper tilting of the cab can cause the cab to fall, resulting in serious injury or death. Do not tilt the cab when occupied. Refer to the Operation and Maintenance Manual for the correct cab tilting procedure. Improper securing of a tilted cab can cause the cab to fall resulting in serious injury or death. Install the cab tilt brace to prevent the cab from falling before working under a tilted cab.

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Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.

Operation

The original 6U-1416 Brake Valve Gp and 7U-4769 Brake Valve Gp were installed in two different orientations, horizontal and vertical. In the horizontal position the brake valve handle moves forward and back. In the vertical position the brake valve handle moves up and down. In both orientations each brake valve has three positions:

1. First position (Forward/Top), parking/secondary brake disengaged (normal Traveling position).

2. Second mid position, secondary brake engaged (lever moved to stop). This position applies the service brakes (Pressure applied) and vents the parking brake chamber engaging parking brake (Spring applied).

3. Third position (Back/Bottom), parking brake engaged. This position involves releasing the detent and moving the lever to the latched position to park the vehicle. The parking brake lever remains in this latched position venting the parking brake chamber and engaging, only, the parking brake.

Air System Connector Identification

The connectors used in the air system on the listed Articulated Trucks are JIC-type. For this Special Instruction, the different sides of the JIC connectors will be identified as Port Side or Hose Side. Use Illustration 1 below as a guide to determining which side of the connector is being referred to in the procedure.

Illustration 1	g02448157
(A) Port Side (B) Hose Side

Typical Example Of Air System Before And After Installation Schematics

Air System Schematic Before Installation

Illustration 2	g02712749
(1) Port number 1 air supply (2) Air tank (3) Port number 3 vent port (4) Parking/secondary brake control (5) Service brake shuttle valve (6) Parking brake shuttle valve (7) Parking brake actuator (21) Port number 21 supply to engage service brake (22) Port number 22 supply to release parking brake and IAD air supply (A) Vent line from port number 3 (B) Air supply from service brake pedal (C) Air supply to service brake actuator

Air System Schematic After Installation

Illustration 3	g02712750
(1) Port 1 (original supply hose from tank connected to tee at port 1) (2) Air Tank (3) Port number 3 vent port (4) New hose 370-9052 Hose As (5) Tee (6) Original air supply hose to parking brake (7) 370-9047 Parking Brake Valve Gp (8) Inversion Valve (9) New hose 370-9052 Hose As connected to port (Z) (10) Air supply from service brake pedal (11) To service brake actuator (12) Service brake shuttle valve (13) Parking brake shuttle valve (14) Parking brake actuator (15) Original air supply hose to service brakes (21) Port number 21 supply to release parking brake (22) Port number 22 Pilot supply to inversion valve (A) Port A (P) Port P (R) Port R vent port (Z) Port Z

Overview Of 370-9046 Parking Brake Valve Gp And 375-0710 Parking Brake Valve Gp

The working parts of the 370-9046 Parking Brake Valve Gp and 375-0710 Parking Brake Valve Gp are identical. However, the mounting of the parking brake valves are different. Before replacement of the existing valve, inspect the available space in the area of the parking brake valve. Note the location of the new components and additional hoses.

Combined Mounted Brake Valve And Inverter Valve 370-9046 Parking Brake Valve Gp

Illustration 4	g02845367
(A) Brake Control Valve (B) Inverter Valve (C) Mounting Plate

This arrangement locates all the components for the new parking brake valve under the location of the original parking brake valve. The new arrangement requires space around the base of the new parking brake valve. Also, the new parking brake valve will extend further below the panel the parking brake valve mounts in. This arrangement keeps all the components together.

Separately Mounted Brake Valve And Inverter Valve 375-0710 Parking Brake Valve Gp

Illustration 5	g02845602
(A) Brake Control Valve (B) Inverter Valve (C) Mounting Plate

This arrangement locates the control for the new parking brake in the position of the original parking brake valve. The inverter valve is located remotely from the main components. Separate mounting reduces the space requirements for the new parking brake valve in the original parking brake valve location. However, the separate mounting requires additional space for placement of the inverter valve.

Parts Identification

370-9046 Parking Brake Valve Gp

375-0710 Parking Brake Valve Gp

Difference Between 370-9046 Parking Brake Valve Gp And 375-0710 Parking Brake Valve Gp

Pre-Installation

Inverter Valve Sub-Assembly

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Illustration 6	g02868517

1. Apply pipe sealant to the threads of connector (2) and install the connector into port "Z" on 370-9048 Valve As (1) .

   Note: Do not install an O-ring seal to 287-7272 Connector (2) .

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Illustration 7	g02868776

2. Apply pipe sealant to the threads on 8T-7861 Connectors (3). Install the connectors into port "A" and port "P" on 370-9048 Valve As (1). Fit 3J-1907 O-Ring Seals (4) on to 2P-1314 Connectors (5) and install the straight adapters into the connectors.

   Note: Do not install O-ring seals on 8T-7861 Connectors (3) .

Brake Valve Sub-Assembly

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Illustration 8	g02868861

1. Ensure that the control lever of 370-9047 Parking Brake Valve Gp (Brake Control) is locked into the detented position. Apply pipe sealant to the external threads of 139-3344 Adapters (7). Install the adapters into the three ports on the bottom of 370-9047 Parking Brake Valve Gp (6) .

   Note: Do not install any O-ring seals to Straight Adapters (7) .

Installation Of 370-9046 Parking Brake Valve Gp

This procedure is best suited for all the listed machines except D250B and D300B machines.

Parts Required For Procedure

Note: The 370-9052 Hose As (16) can be manufactured using the parts listed in table 9

Installation

1. Ensure that the machine is on a flat surface and use suitable chocks to prevent movement of the machine. Ensure that any air pressure in the air system has been released. For some machines, tilting the cab may be necessary for better access. If tilting the cab is required, tilt the cab safely. Refer to the Operation and Maintenance Manual for the proper procedure for tilting the cab.

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Illustration 9	g02417036

2. Before disconnecting the air hoses from the existing brake valve, mark hoses to ensure proper installation. Mark the supply hose "H1" which is fitted to Port "1" as marked on the body of the original brake valve. Mark the service brake hose "H21" which is fitted to Port "21". Mark the parking brake hose"H22" which is fitted to Port "22". A fourth hose with a 6.4 mm (0.25 inch) fitting is for exhaust air and is not needed. Trace the fourth hose and remove the hose from the machine. Disconnect marked air lines.

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Illustration 10	g02417037

3. Remove nuts and bolts holding the original brake valve to the mounting plate.

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Illustration 11	g02417038

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Illustration 12	g02417039

4. Fit the 370-9051 Plate As (8) into position with the angle plate to the Right Hand Side of the machine. Notice two slots are needed in the cab panel shown in Illustrations 11 and 12 to accommodate the new plate and valve assembly.

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Illustration 13	g02418659

5. Position Brake Valve Sub Assembly (6) into Plate (8). Secure brake valve onto mounting plate with 5C-9553 Bolts (9) and 9X-8256 Washers (10). Tighten the bolts to a torque of 6 ± 1 N·m (4.4 ± 0.74 lb ft). Ensure that the brake valve is orientated to the mounting plate as shown in Illustration 13.

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Illustration 14	g02418556

6. Fit 8C-8451 Bolts (11), 5C-2890 Nuts (12), and 9X-8256 Washers (10) to 370-9051 Plate As (8). Do not tighten the nuts and bolts. The bolts, nuts, and washers will be needed later for the installation of the Inverter Valve Sub Assembly (1) (Not Shown).

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Illustration 15	g02418676

7. Fit 3J-1907 O-Ring Seal (4) to 7J-4026 Elbow (13). Install elbow into port "22" on Brake Valve Sub Assembly (6). Orientate the elbow adapter as shown in Illustration 15.

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Illustration 16	g02418717

8. Fit 3J-1907 O-Ring Seal (4) to 2P-1314 Connector (5). Install the connector into port "1" on Brake Valve Sub Assembly (6) .

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Illustration 17	g02418777

9. Install 052-0572 Swivel Tee (14) to 2P-1314 Connector (5) at Port "1" on Brake Valve Sub Assembly (6). Orientate the swivel tee as shown in Illustration 17.

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Illustration 18	g02418818

10. Install 7K-9197 Elbow (15) to the bottom end of 052-0572 Swivel Tee (14) and orientate the swivel elbow as shown in Illustration 19. Do not tighten the swivel elbow at this step.

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Illustration 19	g02418798

11. Fit 3J-1907 O-Ring Seal (4) to 2P-1314 Connector (5). Install connector at Port "21" on Brake Valve Sub Assembly (6) .

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Illustration 20	g02418837

12. Install 7K-9197 Elbow (15) to 2P-1314 Connector (5) at Port "21" on Brake Valve Sub Assembly (6). Orientate the swivel elbow as shown in Illustration 20. Do not tighten the swivel elbow at this step.

13. Position Plate (8) with Brake Valve Sub Assembly (6) into the hole in the cab panel. Secure the mounting plate with 5C-9553 Bolts (9) and 9X-8256 Washers (10). Torque bolts to 6 ± 1 N·m (4.4 ± 0.7 lb ft).

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Illustration 21	g02418921
Parking brake valve assembly shown removed from cab for clarity.

14. Secure Inverter Valve Sub Assembly (1) onto Plate (8) with 8C-8451 Bolts (11), 5C-2890 Nuts (12), and 9X-8256 Washers (10) that were installed in Step 6. Torque the bolts to 6 ± 1 N·m (4.4 ± 0.7 lb ft). Use a suitable saw to trim the length of the bolts so the bolts are flush with the nuts.

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Illustration 22	g02418942
Parking brake valve assembly shown removed from cab for clarity.

15. Connect one end of 370-9052 Hose As (16) to 052-0572 Swivel Tee (14) which is connected to Port "1" on Brake Valve Sub Assembly (6). Connect the other end of the hose to 2P-1314 Connector (5) that is connected to Port "P" on Inverter Valve Sub Assembly (1) .

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Illustration 23	g02419003
Parking brake valve assembly shown removed from cab for clarity.

16. Connect one end of 370-9052 Hose As (16) to 7J-4026 Elbow (13) that is connected to Port "22" on Brake Valve Sub Assembly (6). Connect the other end of the hose to 287-7272 Connector (2) that is connected to Port "Z" on Inverter Valve Sub Assembly (1) .

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Illustration 24	g02419013

17. Connect the existing service brake hose labeled "H21" to the free 2P-1314 Connector (5) on Inverter Valve Sub Assembly (1). Connect existing air supply hose labeled "H1" to 7K-9197 Elbow (15) on the end of 052-0572 Swivel Tee (14) on Brake Valve Sub Assembly (6). Connect the existing parking brake hose labeled "H22" to the free 7K-9197 Elbow (15) on Brake Valve Sub Assembly (6). Adjust the orientation of the swivel elbows to suit the best routing of the hose before tightening the swivel elbows.

18. Turn the battery disconnect switch to the ON Position. Start the engine and allow the air system pressure to build up. Check for air leaks. Check for correct function of the Parking and Secondary Braking System.

Installation Of 375-0710 Parking Brake Valve Gp

This procedure is best suited for D250B and D300B machines.

Parts Required For Procedure

Note: The 370-9052 Hose As "16" can be manufactured using the parts listed in table 11.

Installation

Ensure that the machine is on a flat surface and use suitable chocks to prevent movement of the machine. Ensure that any air pressure in the air system has been released.

1. Using information in the Disassembly and Assembly Manual, SENR8188, "Articulated Dump Truck Operator Station & Electrical System". Loosen the right-hand instrument panel. Pull right-hand panel forward from the main dashboard in order to gain access to the rear of the parking and secondary brake control valve.

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Illustration 25	g02448397

2. Illustration 25 shows the rear of the parking and secondary brake control valve as viewed from above. The hoses are identified as follows:

   "H1" Air supply to the control valve from the machine air system. Hose is connected to Port "1" on the control valve.

   "H3" Air exhaust from the valve. The hose is connected to Port "3" on the control valve. This hose routes through an aperture in the underside of the main dashboard panel to a bulkhead fitting on the floor of the operator cab.

   "H21" Supply from the control valve to the service brake system. Connected to Port "21" on the control valve.

   "H22" Supply from the control valve to the parking brake system. Connected to Port "22" on the control valve.

   Before disconnecting the hoses, add suitable identification marks to hoses "H1", "H21", and "H22". These marks will be used for reference during the installation of the hoses onto the new 375-0710 Parking Brake Valve Gp .

   Hose "H3" is not required with the new 375-0710 Parking Brake Valve Gp . If Hose "H3" can be removed without damaging any of the wiring or other components in the dashboard, remove the hose. Add a suitable blanking cap to the bulkhead fitting on the cab floor. If damage may occur while attempting to remove Hose "H3", then secure the hose in the dashboard. Ensure that the hose will not restrict the installation of the 375-0710 Parking Brake Valve Gp .

3. Disconnect the four hoses from the brake valve then remove the valve from the instrument panel by removing the nuts and bolts.

   Note: Clean and inspect the nuts and bolts. If the hardware is worn or damaged, use new parts as required. Otherwise, retain the nuts and bolts for mounting the new parking brake valve.

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Illustration 26	g02448718
(A) Upper right-hand corner of Dash Panel

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Illustration 27	g02448719
View of the top of the dash. The bottom edge is toward the operator and the top edge is toward the window. (A) Right-hand Side (B) 113 mm (4.45 inch) (C) 75 mm (2.95 inch) (D) 80 mm (3.35 inch)

4. Use the upper right-hand corner of the dash panel, see Illustration 26, as a reference point. Drill two 6 mm (0.2 inch) clearance holes through the top of the dash panel using the dimensions shown in Illustration 27.

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Illustration 28	g02448937
Inverter Valve (3)

5. Bolt the Inverter Valve Sub Assembly (1) to the top plate of dash panel using the 193-7720 Screws (11), 129-3178 Locknuts (12) and 2 of the 9X-8256 Washers (10). Orientate the inverter valve so that the air fittings are directed towards the left-hand side of the dash panel. Port "Z" is now positioned towards the rear face of the dash panel. Illustration 28 can be used for reference.

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Illustration 29	g02449036

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Illustration 30	g02449076

6. Fit 3J-1907 O-Ring Seals (4) onto 7J-4026 Elbows (13). Install the adapters into Ports "1" and "21" on Brake Valve Sub Assembly (6). Orientate the elbows as shown in Illustration 30.

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Illustration 31	g02449117

7. Fit 3J-1907 O-Ring Seal (4) onto 2P-1314 Connector (5) and install adapter at Port "22" on Brake Valve Sub Assembly (6) .

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Illustration 32	g02449156

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Illustration 33	g02449159

8. Install 7K-9197 Elbow (15) to the straight adapter (5). Orientate the elbow to Brake Valve Sub Assembly (6) as shown in Illustration 33.

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Illustration 34	g02449163

9. Slide 370-9049 Plate (8) onto the Brake Valve Sub Assembly (6). Secure the plate to the valve using 5C-9553 Bolts (10) and 9X-8256 Washers (9) .

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Illustration 35	g02449937

10. Install 052-0572 Swivel Tee (14) and 7K-9197 Elbow (15) to the elbow (13) at Port "1" on the Brake Valve Sub Assembly (6). Orientate the swivel tee and the elbow as shown in Illustration 35.

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Illustration 36	g02450018

11. Fit Brake Valve Sub Assembly (6) and Plate (8) to the instrument panel using the original hardware. Slots in the instrument panel may be required to provide clearance for the Brake Valve mounting bolts. Orientate the valve so that the air fittings are directed towards the left-hand side of the dash.

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Illustration 37	g02450056

12. Connect the hose labeled "H1" that was connected to Port "1" on the original brake valve to Swivel Tee (14). Swivel Tee (14) is connected to Port "1" on Brake Valve Sub Assembly (6) .

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Illustration 38	g02450138

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Illustration 39	g02450149

13. Connect one end of one of 370-9052 Hose As (16) to Elbow (15) that is connected to Port "1" on Brake Valve Sub Assembly (6). Connect the other end of hose (16) to Port "P" on Inverter Valve Sub Assembly (1). Refer to Illustrations 38 and 39.

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Illustration 40	g02450217
(H22) Supply hose to parking brake system. (13) Elbow at Port "21".

14. Find the hose labeled "H22" which provides air to the parking brake system, and was connected to Port "22" on the original parking brake valve. Connect the hose to Elbow (13) at Port "21 " on the Brake Valve Sub Assembly (6) .

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Illustration 41	g02450258

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Illustration 42	g02450259

15. Connect one end of one of the remaining 370-9052 Hose As (16) to elbow (15) adapter at Port "22" on Brake Valve Sub Assembly (6). Connect the other end of the hose to Port "Z" on the Inverter Valve Sub Assembly (1). Refer to Illustrations 41 and 42.

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Illustration 43	g02450696

16. Find the hose labeled "H21" which provides air to the service brake system, and was connected to Port "21" on the original parking brake valve. Connect the hose to Port "A" on the Inverter Valve Sub Assembly (1) .

17. Ensure that all hoses are routed so that contact with other dash panel components is minimized to prevent damage during machine operation. Reinstall the right-hand instrument panel into the dash panel.

18. Turn the battery disconnect switch "ON". Start the engine and allow the air system pressure to build up. Check for air leaks. Check for correct function of the Parking and Secondary Braking System.