Procedure to Replace Noncurrent Gear Pumps on Certain Articulated Trucks {5073} Caterpillar

Articulated Truck

735 (S/N: B1N1-UP; AWR1-UP)

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

740 (S/N: AXM1-UP; B1P1-UP)

740 EJECTOR (S/N: B1R1-UP; AZZ1-UP)

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

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

D350E Series II (S/N: 2XW1-UP)

D400E Series II (S/N: APF1-UP; 8PS1-UP)

Introduction

This Special Instruction provides the information required to replace the discontinued 140-0087 Pump Gp and 188-4455 Pump Gp with a 433-7514 Pump Gp on the above listed articulated trucks.

The 433-7514 Pump Gp is not a direct replacement for the 140-0087 Pump Gp and 188-4455 Pump Gp. The main differences are:

• Overall length of the pump is 12 mm (0.5 inch) larger than the discontinued pump

• Inlet (suction) port has moved rearward by 17 mm (0.67 inch)

• Outlet (discharge) port has moved rearward by 38 mm (1.5 inch)

Additional parts are required to support the installation of the 433-7514 Pump Gp. The new parts are in addition to the normal seals and gaskets (which are unchanged) and the new parts are different depending on the particular model of articulated truck that the pump is being installed on.

Do not begin the installation until you have read and understand the information that is contained in this instruction.

References

Reference: Disassembly and Assembly, SENR9145, "Disassembly and Assembly D350E Series II Articulated Truck"

Reference: Disassembly and Assembly, RENR3402, "Disassembly and Assembly D400E Series II Articulated Truck"

Reference: Special Instruction, REHS1127, "Converting the Automatic Ejector Body Articulated Truck to the Semiautomatic Ejector Body Articulated Truck"

Reference: Disassembly and Assembly, RENR5140, "Disassembly and Assembly 735, 740 and 740 EJECTOR Articulated Trucks Machine Systems"

Reference: Disassembly and Assembly, UENR0211, "Disassembly and Assembly 735B, 740B, and 740B EJECTOR Articulated Trucks Machine Systems"

Preparing the Machine

1. Park the machine in an area away from other operating machines and away from personnel.

2. Engage the parking brake.

3. Install steering frame locks.

4. Shut down the engine and turn the battery disconnect switch to the OFF position.

5. Block the wheels.

6. When working under the machine, install suitable stands under the front frame to prevent the machine lowering.

Installation of the 433-7514 Pump Gp on D350E Series II, D400E Series II and D400E Series II Ejector Articulated Trucks

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Illustration 1	g03862249
View of pump (1) 140-0087 Gear Pump Gp

1. Referring to the appropriate Caterpillar media for the machine you are working on remove the original gear pump (1) from the machine.

   Note: The illustration above shows the 140-0087 Pump Gp formerly used on D350E Series II, D400E Series II, and D400E, Series II Ejector Articulated Trucks.

   Note: When the D350E Series II, D400E Series II, and D400E, Series II Ejector Articulated Trucks were discontinued, the 140-0087 Pump Gp was also discontinued and service replaced with the 188-4455 Pump Gp, plus a 158-8522 Adapter, a 1P-3705 Seal, and four 6V-8200 Bolts.

   Note: The adaptor plate, seal, and hardware are required to allow the service technician to connect the original hydraulic lines to the 188-4455 Pump Gp, which has a different discharge port hardware arrangement.

   Note: If a 140-0087 Pump Gp is now ordered, the order will be fulfilled with a 433-7514 Pump Gp plus the adaptor plate, seal, and hardware.

   Note: If the machine being serviced has already had a pump replacement, the pump being removed may already have the adaptor plate arrangement installed.

2. Attach the 158-8522 Adapter to the discharge port of the new 433-7514 Pump Gp using the 1P-3705 Seal and 6V-8200 Bolts.

3. Install the new 433-7514 Pump Gp using the original mounting hardware and a new o-ring seal.

4. Refer to the appropriate Caterpillar media for the machine you are working on and complete the installation of the new pump.

   Note: Due to the repositioning of the discharge port, it will be necessary to loosen the support clamps for the discharge hose to allow it to be repositioned to suit the new pump.

Installation of the 433-7514 Pump Gp on 735 Articulated Trucks (S/N:AWR1-UP and ; S/N:B1N1-879)

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Illustration 2	g03862263
View of pump removal (A) existing pump

1. Referring to the appropriate Caterpillar media for the machine you are working on remove the original gear pump (A) from the machine.

2. Install the new 433-7514 Pump Gp using the original hardware and a new o-ring seal.
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   Illustration 3	g03862265
   View of pump install (1) 433-7514 Pump Gp

3. Refer to the appropriate Caterpillar media for the machine you are working on and complete the installation of the new pump.

Installation of the 433-7514 Pump Gp on 735, 740 and 740 Ejector Articulated Trucks without Sound Suppression Attachment (S/N:B1N880-UP, ; S/N:AXM1-UP, ; S/N:B1P1-UP, ; S/N:AZZ1-UP, and ; S/N:B1R1-UP)

Note: The sound suppression attachment is only used on machines with serial number prefix S/N:B1N880-UP, ; S/N:B1P1-UP and ; S/N:B1R1-UP.

Additional Parts

Installation Procedure

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Illustration 4	g03862321
View of pump and existing hose removal (A) Existing pump (B) Hose

1. Refer to the appropriate Caterpillar media for the machine you are working on and remove the original gear pump from the machine. Also remove the hose between the pump discharge port and the hoist valve, from the machine. Discard the hose.

2. Install the new 433-7514 Pump Gp using the original hardware and a new o-ring seal.

3. Connect the suction hose to the new pump using the original hardware and a new o-ring seal.

4. Install the new 467-4920 Hose As between the pump discharge port and the hoist valve using new seals and original hardware.

5. Refer to the appropriate Caterpillar media for the machine you are working on and complete the installation of the new pump.

Installation of the 433-7514 Pump Gp on 735, 740, and 740 Ejector Articulated Trucks Equipped with Sound Suppression Attachment (S/N:B1N880-UP, ; S/N:AXM1-UP, ; S/N:B1P1-UP, ; S/N:AZZ1-UP, and ; S/N:B1R1-UP)

Additional Parts

Installation Procedure

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Illustration 5	g03862521
View of pump and resonator removal (A) Existing pump (B) Resonator (C) Existing hose

1. Refer to the appropriate Caterpillar media for the machine you are working on and remove the original gear pump (A) from the machine.

   Note: It will be necessary to remove the resonator assembly (B) to allow pump removal. Retain the resonator assembly (B) and all associated hardware for reuse.

2. Remove hose (C) between the resonator assembly (B) and the hoist valve from the machine. Discard hose (C).

3. Install the new 433-7514 Pump using the original hardware and a new o-ring seal.

4. Connect the suction hose to the new pump using the original hardware and a new o-ring seal.

5. Reinstall the resonator assembly using a new seal.

6. Reattach the support clamps between the resonator assembly and the tube from the oil cooler, using the original hardware plus 7U-9542 Plate, 8T-4183 Bolt, 8T-4223 Washers and 8T-4244 Nut.

7. Install the new 467-4987 Hose As between the resonator assembly and the hoist valve using new seals and original hardware.

8. Refer to the appropriate Caterpillar media for the machine you are working on and complete the installation of the new pump.

Installation of the 433-7514 Pump Gp on 735B, 740B, and 740B Ejector Articulated Trucks Without the Sound Suppression Attachment

Additional Parts

Installation Procedure

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Illustration 6	g03862340
View of existing bracket removal (A) 359-6078 Bracket As (B) Existing pump (C) Existing clamp (D) Existing grommet (E) Existing washer

1. Referring to the Operation and Maintenance Manual for the machine you are working on, raise the operator cab, then remove and discard existing bracket (A) at the connection between the hose and tube between the hoist control valve and the brake oil cooler. Retain the hardware for reuse.

2. Referring to the appropriate Caterpillar media for the machine you are working on remove the original gear pump (B) from the machine. Also remove the hose between the pump discharge port and the hoist valve, from the machine. Discard the hose.

   Note: When removing the support clamp for the steering pump case drain hose, retain the split clamps (C), rubber grommet (D), and washer (E) for reuse. The bolt and spacer can be discarded.

3. Install the new 433-7514 Pump Gp using the original hardware and a new o-ring seal.

4. Reconnect the suction hose to the pump using the original hardware and a new o-ring seal.

5. Connect one end of the new 467-4920 Hose As to the hoist valve using the original hardware and a new o-ring seal.

   Note: Do not fully tighten the bolts at this time.

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   Illustration 7	g03862341
   View of bracket installation (1) 467-4946 Bracket As

6. Attach bracket assembly (1) at the hose and tube connection between the hoist valve and brake oil cooler using original hardware.

   Note: Do not fully tighten the bolts at this time.

7. Connect the 467-4920 Hose As to the pump using a new o-ring seal with the original split flanges. Complete the installation as follows:
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   Illustration 8	g03862343
   View of bracket installation (B) existing hardware (1) 467-4946 Bracket As

   1. Use the existing hardware (B) between bracket assembly (1) and the split flanges.
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      Illustration 9	g03862344
      View of bracket installation (C) Existing washer (D) Existing bolt (2) 7U-9542 Bracket As (3) 8T-4194 Bolt

   2. Use the new bolt (3) with existing washer (C) to retain bracket (2) in place of the original bolt and spacer and washer. Orientate the bracket as shown in the illustration.

   3. Use the original bolt (D) and washer (C) in the final location.

8. Tighten the bolts that secure the hose and tube assembly to bracket (1).

9. Tighten the bolts that secure the hose to the hoist valve.
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   Illustration 10	g03862350
   View of hose installation (4) 7U-9542 Clamping Plate (5) 8T-4956 Bolt (6) 8T-4223 Hard Washer (7) 8T-4244 Nut

10. Secure the steering pump case drain hose to clamping plate (4) as shown using the original clamps and grommet with bolt (5), two washers (6) and nut (7). Ensure that there will be sufficient clearance between the hose and the cab anchor pin when the cab is lowered.

11. Referring to the appropriate Caterpillar media for the machine you are working on complete the installation of the new pump.

Installation of the 433-7514 Pump Gp on 735B, 740B, and 740B Ejector Articulated Trucks Equipped with Sound Suppression Attachment

Additional Parts Required

Installation Procedure

The installation procedure is similar to the method that is used on machines that are not equipped with the sound suppression attachment, with the following differences:

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Illustration 11	g03862364
View of existing resonator removal (A) existing resonator

1. During removal of the original pump, remove and retain the resonator assembly (A).

2. Retain the hardware, clamps, and rubber grommet that are attached to the resonator. Discard the clips which are attached to the steel tube to the oil cooler.

3. Remove the hose between the resonator assembly (A) and the hoist valve from the machine. Discard the hose.

4. Install the new pump using original hardware and new seals.

5. Connect the suction hose to the new pump using original hardware and new seal.
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   Illustration 12	g03862363
   View of bracket installation (1) 467-4946 Bracket As

6. Reinstall the resonator using a new seal, attaching the new bracket (1) in place of the original support bracket.
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   Illustration 13	g03862362
   View of clip installation (2) 5P-7468 Clip (3) 5P-7469 Clip (4) 5P-8444 Grommet

7. Reinstall the original support clamps around the resonator and steel tube to the oil cooler, using the new clip (2) and clip (3) and grommet (4) around the cooler tube.

8. Install the 467-4987 Hose As between the resonator assembly and the hoist valve.

9. Refer to the appropriate Caterpillar media for the machine you are working on, and the installation procedure for machines without the sound suppression attachment, and complete the installation of the pump.