Alternator Connections, and Rerouting of Electrical Harnesses and Hydraulic/Coolant Lines for Certain Series B Articulated Trucks{1380, 1408, 5057} Caterpillar

Articulated Truck:

735B (S/N: L4D1-UP; T4P1-UP)

740B (S/N: L4E1-UP; T4R1-UP)

740B EJECTOR (S/N: L4F1-UP; T4S1-UP)

Introduction

Do not perform any procedure in the Special Instruction until you read and understand the information that is contained in this document.

This Special Instruction details coolant and hydraulic line, and electrical wiring harness routing issues and the corrective action required to correct each situation.

Alternator Positive Cable Retaining Nut May Be Assembled Incorrectly

Procedures

Machines with Serial Number Prefixes S/N:T4P, ; S/N:T4R, and ; S/N:T4S

• Check these machines for loose hardware and tighten if necessary.

Illustration 1	g02723612
Check terminal nut (D) and tighten if necessary.

Machines with Serial Number Prefixes S/N:L4D, ; S/N:L4E, and ; S/N:L4F

• For these machines, complete the following actions.

Table 1

Part Required
Item	Qty	Part Number	Description
1	1	5P-4115	Hard Washer

Illustration 2	g02724079

• Remove the nut (D), spring washer (C), hard washer (A), and positive battery cable (B) from the alternator

Illustration 3	g02723607
Install original hard washer (A), battery cable (B), an additional 5P-4115 Hard Washer (1), original spring washer (C), nut (D), and tighten.

• Install the original hard washer (A) onto the terminal post.

• Reinstall the battery cable (B) onto the terminal post followed by one additional 5P-4115 Hard Washer (1), the original spring washer (A), and nut (D)

• Tighten nut.

Engine Coolant Tube May Contact Pump Lines for Output Transfer Gear

Issue

Unwanted contact can occur between the 334-1484 Tube As for the 291-8922 Coolant Lines Gp and the 353-4441 Tube As and clips for that tube which are part of the 351-8200 Pump Lines Gp for the Output Transfer Gear .

Solution

For all machines, attempt to reposition the 291-8922 Coolant Lines Gp that fit to the bottom of the radiator package. Refer to ""Repositioning the 291-8922 Coolant Lines Gp " " section in this publication.

For those machines where repositioning the 291-8922 Coolant Lines Gp is not successful, proceed to the ""Installation of a 3U-2754 Clip " " section in this publication.

Parts

Table 2

Item	Qty	Part Number	Description
1	1 (as needed)	3U-2754	Clip

Repositioning the 291-8922 Coolant Lines Gp

Illustration 4	g02718998
Contact can best be checked from the left side of the radiator group, looking at the area above the Output Transfer Gear.

Illustration 5	g02719056
Located under engine on inside of right beam of front frame. View is looking forward.

1. Loosen clamp (see arrow) to give slight horizontal adjustment to tube.

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Illustration 6	g02719065
Located under the transmission, on the inside of the right beam of the front frame looking forward.

2. Loosen clamp (see arrow) to give slight vertical adjustment to tube.

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Illustration 7	g02719070
Located under the transmission, on the inside of the right beam looking rearward.

3. Loosen clamp (see arrow) to give slight vertical adjustment to tube.

4. Using all available movement of the cooling lines, lift tube as far as the clamps will allow.

5. While maintaining new position of tube, tighten all of the clamps loosened in steps 1 through 3.

6. Inspect machine for coolant leaks.

7. Recheck clearances. If adequate clearance has been obtained, no further action is required. If adequate clearance has not been obtained, proceed with ""Installation of the 3U-2754 Clip " " below.

Installation of the 3U-2754 Clip

1. Remove the front drive shaft mounted between the OTG and the front axle.

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Illustration 8	g02719101
Located under the front frame in the space between the front axle gp and the OTG, looking at the top of the OTG.

2. Remove the 8T-1887 Clip and 8T-1888 Clip from the upper location. Retain fastener.

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Illustration 9	g02719156
Located at the top front cover of the OTG.

3. Install a 3U-2754 Clip (1) in the upper location.

4. Reuse the original fastener, the 8T-1887 Clip , and the 8T-1888 Clip for the lower location. Install the clip for the lower tube over the new clip for the upper tube.

5. Reinstall the front drive shaft removed in Step 1

Brake Pump Inlet Suction Characteristics Can Be Sensitive to Minor Contamination

Solution

Testing has identified that improving brake pump suction characteristics can make the system less sensitive to minor contamination. Removing the two-component delivery arrangement and installing a single component arrangement can achieve the desired improvements.

Parts

Table 3

Parts Required
Item	Qty	Part Number	Description
1	1	337-9294	Hose As
2	2	8C-3206	Half Flange
3	2	4J-0520	O-Ring Seal
4	8	8T-4196	Bolt
5	8	8T-4121	Hard Washer
6	2	6U-0456	Strap

Repair

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Illustration 10	g02724503

1. Remove the 353-3511 Tube As (A) and set aside.

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Illustration 11	g02724505

2. Remove the 353-3509 Hose As (B) and set aside

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Illustration 12	g02724531

3. Install the 337-9294 Hose As (1) to the Brake Pump Inlet Port using two 8C-3206 Half Flanges (2), one 4J-0520 O-Ring Seal (not shown), and four 8T-4196 Bolts (4) and four 8T-4121 Hard Washers (5). Final torque is 55 N·m (41 lb ft).

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Illustration 13	g02724533

4. Attach the other end of the 337-9294 Hose As (1) to the outlet port of the hydraulic tank. Use two 8C-3206 Half Flanges (2) removed with the 353-3509 Hose As (B, Illustration 11), one 4J-0520 O-Ring Seal (now shown), and four 8T-4196 Bolts (4) and four 8T-4121 Hard Washers (5). Final torque is 55 N·m (41 lb ft).

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Illustration 14	g02724535

5. Reinstall the 5P-7468 Clip , 5P-7469 Clip , and 5P-8444 Grommet (C) removed with the 353-3509 Hose As (B) onto the new 337-9294 Hose As (1) .

6. Install two 6U-0456 Straps (6). Refer to Illustration 14 for locating the straps.

7. Check the oil level in the hydraulic tank. Refer to Operation and Maintenance Manual, "Hoist System and Brake System Oil Level - Check" for the machine that is being serviced.

Brake Hose for Front Axle Can Come Into Contact with Engine Coolant Lines

Issue

Illustration 15	g02720624
Location of contact between 291-8922 Coolant Lines Gp and 291-8777 Service Brake Lines Gp .

Contact can occur between the 207-9519 Hose As for the 291-8777 Service Brake Lines Gp and the 342-6298 Hose for the 291-8922 Coolant Lines Gp . The hose connects the 334-1478 Tube and the 334-1484 Tube As that are part of the Coolant Lines Gp.

The 209-4579 Clamp that secures the 342-6298 Hose can also contact the 207-9515 Hose As .

Illustration 16	g02720625
The best angle to examine the coolant lines is looking up from the right side of the input yoke for the front axle

Solution

Reposition the 207-9519 Hose As (C) by adjusting the angle of the 148-8382 Elbow As (B). The Elbow As connects the 207-9519 Hose As (C) to the manifold (A) on top of the front axle.

Illustration 17	g02720628
Top of Front Axle

To adjust the angle of the elbow adapter (B), loosen the hose fitting (D) at the elbow adapter. Rotate the hose in order to release any twist in the hose. Loosen the jam nut (B) for the elbow. Rotate the elbow adapter down in order to increase the radius of bend near the 342-6298 Hose (not shown). Tighten the jam nut (B) for the elbow. Check the routing of the hose before tightening the hose fitting (D). (See Illustration 18)

Illustration 18	g02720627
Adjustment of angle of elbow at manifold to increase clearance between 207-9519 Hose As for the service brakes and the coolant line.

Note: Ensure that any twisting of the hose is kept to a minimum.

Illustration 19	g02720629
Correct orientation of 209-4579 Clamps .

Check the orientation of the 209-4579 Clamps (E) which secure the 342-6298 Hose (F). Illustration 19 shows the clamps correctly orientated towards the back of the machine. If the clamps require reorientation, work on one clamp at a time in order to reduce the chance of coolant loss.

In order to change the orientation of a clamp, loosen the clamp slightly until the clamp can be rotated. Rotate the clamp to the required orientation. Tighten the clamp. Check cooling system for leaks.

Steering Gp Hose Clamp Inverted to Improve Access to the ROPS Pin

Issue

Illustration 20	g02723092

The 194-3460 Hose As , a part of the 291-8842 Pump Lines Gp can obstruct the removal of the 149-4616 Pin for the 139-4593 Rollover Protective Structure (ROPS) Mounting Gp .

Solution

Illustration 21	g02734237

Repostion the 5P-7468 Clip and 5P-7469 Clip for the 194-3460 Hose As by rotating the clip downward. A downward orientation will lower the position of the hose and clear the access for the 149-4616 Pin

Illustration 22	g02723067

Illustration 23	g02723072

Protective Boot for Alternator Positive Terminal May Not Stay In Place

Issue

Illustration 24	g02723247

During machine operation, the 8N-0869 Terminal Cover (1) may move out of position. The terminal cover may slide down the positive battery cable leaving the alternator battery terminal (A) exposed.

Solution

Illustration 25	g02723249

Secure the 8N-0869 Terminal Cover (1) in place over the alternator positive terminal (A) with one 3S-2093 Cable Strap (2). Position the 3S-2093 Cable Strap (2) as close as possible to the terminal cover, and secure as tight as possible around the battery cable. Refer to Illustration 25.

Reposition Over Hitch Wiring Harness to Correct Possible Interference with 7X-2470 Adapter and 352-3965 Clip

Issue

Illustration 26	g02724109
Area of Contact

Illustration 27	g02724115
(A) 7X-2470 Adapter (B) Outboard nut holding the 291-8849 Connecting Lines Gp (1) 3S-2093 Cable Strap (3) 336-2817 Chassis Harness As (Arrows) Areas of inappropriate contact

Inappropriate contact may occur between the 336-2817 Chassis Harness As and the 7X-2470 Adapter as well as the 352-3965 Clip for certain Articulated Trucks.

Solution

Table 4

Parts
Item	Qty	Part Number	Description
1	1	3S-2093	Cable Strap

To inspect the machine, look from the right side of the rear chassis where the over hitch lines connect to the rear chassis. The area is located between the hitch and the center axle.

Illustration 28	g02724120
View from the right side of the rear chassis where the over hitch lines connect to the rear chassis.

To correct the inappropriate contact, start by removing the 3S-2093 Cable Strap (1) from the 336-2817 Chassis Harness As (3). Remove the 352-3965 Clip (2) from the original location. Relocate the 352-3965 Clip (2) to the mounting location which is outboard from the original location.

Inspect the 336-2817 Chassis Harness As (3) for any signs of damage. The Chassis Harness As can be pulled down to inspect the section of harness that runs through the 7X-2470 Adapter (A) .

Repair the 336-2817 Chassis Harness As (3) as needed. Refer to Special Instruction, REHS7215-00, "Repair Procedure for Damaged Harness Wiring".

Route the 336-2817 Chassis Harness As (3) so that the harness runs vertically through the 7X-2470 Adapter (A) .

Route the harness under the 352-3965 Clip (2) and secure with a new 3S-2093 Cable Strap . Ensure that the harness has free play between the 3S-2093 Cable Strap and the 7X-2470 Adapter (A) .

Corrections for Interference Between the Positive Battery Cable and the Alternator Cable

Issue

A routing issue exists for the battery cables in the area between the battery box and the left side of the engine.

Illustration 29	g02725396
Area of routing problems. View is the left side of the machine with hood lifted. This area is below and rearward of the primary fuel filter and water separator.

The 336-9305 Cable As (1) may contact the 336-2808 Front Chassis Harness As (5) and/or the 336-9301 Cable As (2). The 336-9306 Cable As (3) has also been observed in the field as being too close to a two-piece metal clamp for the fuel lines.

Illustration 30	g02725397
(Arrows ) Close-up look at areas of possible contact, left side of engine. (1) 336-9305 Cable As (starter positive battery cable) (2) 336-9301 Cable As (alternator ground cable) (3) 336-9306 Cable As (alternator positive battery cable) (4) 263-6342 Clip (starter positive battery cable retainer) (5) 336-2808 Front Chassis Harness As (chassis wiring harness, left side of engine)

Solution

Illustration 31	g02723843

Remove the 263-6342 Clip (4) from location (A) and reinstall the clip at location (B) using existing hardware.

Illustration 32	g02723851

• Ensure the tape marker (C) on 336-9305 Cable As (1) is positioned fully into the cable clamp (D). Check that the 336-9305 Cable As (1) does not contact the 336-2808 Front Chassis Harness As (5). (See arrow)

• Reroute the 336-9306 Cable As (3) attached to the alternator positive terminal ensuring adequate clearance with the two-piece metal clamp holding the fuel lines. (See arrow, Illustration 30)

Illustration 33	g02723851

• Reroute the 336-9301 Cable As (2) attached to the alternator ground connection under the 336-9305 Cable As (1).

• Ensure that there is adequate clearance between cables, 1, 2, and 5.