- Articulated Truck
- 735C (S/N: LFJ1-254; TFJ1-261)
- 740C EJECTOR (S/N: LFN1-276; TFN1-189)
- 745C (S/N: JE81-90118; JE91-102; LFK1-982; TFK1-1548)
- 740C EJECTOR (S/N: LFN1-276; TFN1-189)
Introduction
This Special Instruction will provide the information required to install updated steering lines and service brake plate - accumulator on the machines listed above.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Safety
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 must also have the necessary training, skills, and tools 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. Caterpillar cannot anticipate every possible circumstance of a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.
Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.
Operation of the machine and the maintenance of the machine must not occur unless the instructions and warnings in the machines Operation and Maintenance Manual have been read and the instructions and the warnings are understood.
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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. |
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Never enter an articulation area while the machine is running. Completely shut down the machine and install the articulation blocking device (if so equipped) before entering the articulation area. Failure to observe this precaution may result in injury or death |
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Do not operate any control lever until certain that all personnel are clear of any machine movement, even if the pump motor is not running. Personnel may be seriously injured or killed if struck by a moving machine or machine component. |
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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed. |
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Hot hydraulic oil under high pressure can remain in the components of the hydraulic system or the power train system after the engine has been stopped. The uncontrolled release of the hydraulic oil can cause sudden machine movement and can also result in the following conditions:
If hydraulic oil penetrates body tissue, the injury must be treated immediately by a doctor who is familiar with this type of injury. Use a board or a piece of cardboard to check for a hydraulic oil leak. Make sure that all of the attachments have been lowered to the ground and that all trapped pressure has been released from the hydraulic system and the power train system. Also, make sure that the hydraulic oil is cool before the removal of any components or lines. Remove the hydraulic oil filler cap only when the engine is stopped and the filler cap is cool enough to touch with your bare hand. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
Required Parts
| Parts List | ||
| Item | Qty | Part |
| 1 | 1 | 8T-4191 Bolt |
| 2 | 1 | 8T-4121 Hard Washer |
| 3 | 1 | 521-0628 Bracket Assembly |
| 4 | 2 | 7K-1181 Cable Strap(1) |
| 5 | 1 | 521-1323 Bracket Assembly(2) |
| 6 | 3 | 6U-0455 Strap(3) |
| 7 | 1 | 521-5035 Hose Assembly |
| 8 | 1 | 521-5036 Hose Assembly |
| 9 | 1 | 7G-3834 Clip |
| 10 | 1 | 7G-3833 Clip |
| 11 | 1 | 7G-3832 Grommet |
| 12 | 2 | 8T-4956 Bolt |
| 13 | 2 | 8T-4223 Hard Washer |
| 14 | 1 | 6U-0456 Strap |
| 15 | 1 | 290-5562 Mount |
| 16 | 1 | 6V-8398 O-Ring Seal |
| 17 | 1 | 6V-8942 O-Ring Reducer |
| 18 | 1 | 9X-6580 Nut |
| 19 | 1 | 217-8454 Hose Assembly |
| 20 | 1 | 502-2067 Plate |
| 21 | 1 | 3S-2093 Cable Strap |
| (1) | Only one required for LRC machines |
| (2) | Not required for LRC machines |
| (3) | Only two are required for LRC machines |
Prepare the Machine
- Move the machine to a smooth horizontal location. Move away from any machines that are working and any personnel.
- Move the transmission control to the NEUTRAL position and engage the parking brake.
- Stop the engine.
- Place blocks in front of the wheels and behind the wheels.
- Raise the engine hood. Refer to the proper machine Operation and Maintenance Manual, "Hood Control" for instructions.
- Repeatedly engage and disengage the service brakes until all the stored pressure in the accumulator is used.
- Repeatedly engage and disengage the parking brake until all the stored pressure in the accumulators is used.
- Turn the battery disconnect switch to the OFF and remove the key.
- Install the steering frame locks. Refer to the proper machine Operation and Maintenance Manual for instructions.
- Loosen the cap on the hydraulic tank to relieve pressure in the tank.
Installation Procedure
- Remove cover panels (A) from the right-hand side of the operator cab.
- Verify that the front service brake accumulator has the correct pre-charge pressure. Refer to Testing and Adjusting, "Brake Accumulator (Service) – Test and Charge" for the correct specification and procedure.
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Illustration 2 g06147358 (B) Bracket Show/hide table
Illustration 3 g06147368 (B) Bracket - Remove and discard bracket (B) and all associated hardware securing the steering and heater lines in place.
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Illustration 4 g06147662 (1) 8T-4191 Bolt
(2)8T-4121 Hard Washer - Blank off the empty hole on the bottom side of the HVAC using one bolt (1) and one hard washer (2).
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Illustration 5 g06147685 (C) Dual Mounting Strap - Working in the same area as Step 4, remove dual mounting straps (C) which secure the signal line to the steering hose. Retain the hardware for later use.
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Illustration 6 g06147693 (D) Plate
(E) Bolt
(F) Washer - Remove plate (D), bolt (E), washer (F), and the cable strap securing the steering lines to the top of the powertrain cooler.
Note: Retain bolt (E) and washer (F) for later use.
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Illustration 7 g06147732 (G) Bracket
(H) P-Clip
(J) Bolt
(K) Washer - Remove bracket (G), p-clips (H), two bolts (J), and two washers (K) used to secure the fender harness to the top of the powertrain cooler.
Note: Retain p-clips (H), one bolt (J), and one washer (K) for later use.
Note: Bracket (G) may not be equipped on all machines.
Note: The additional harness pointed out in Illustration 7 is for HRC machines only.
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Illustration 8 g06147748 (L) Hose Assembly
(M) Hose Assembly - Remove and discard hose assembly (L) and hose assembly (M).
Note: Ensure that all exposed connections on the machine are capped to prevent hydraulic contamination.
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Illustration 9 g06147804 (E) Bolt
(F) Washer
(H) P-Clip
(J) Bolt
(K) Washer
(3)521-0628 Bracket Assembly - Install bracket assembly (3) in place starting on top using one bolt (E) and one washer (F).
- Reinstall p-clips (H) to hold the harness assemblies in place using one bolt (J) and one washer (K). Installing p-clips (H) will also secure the lower section of bracket assembly (3) in place.
Note: The additional harness shown in Illustration 9 will only be equipped on HRC machines.
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Illustration 10 g06147810 (4) 7K-1181 Cable Strap - Secure the fender harness in place using cable strap (4).
Note: The harness on the right-hand side will only be equipped on HRC machines.
Note: Step 12 through Step 18 only apply to HRC machines. All other machines may proceed to Step 19.
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Illustration 11 g06147843 (N) Straps - Remove and retain two straps (N) that secure the heater lines in place.
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Illustration 12 g06147850 (P) P-Clip - Remove and retain two p-clips (P) and associated hardware.
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Illustration 13 g06147855 (Q) Bolt
(R) Washer
(S) Bracket - Remove and retain bolt (Q) and washer (R) securing bracket (S) in place.
Note: Discard bracket (S).
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Illustration 14 g06147863 (Q) Bolt
(R) Washer
(5)521-1323 Bracket Assembly - Install bracket assembly (5) in place as shown in Illustration 14 using one bolt (Q) and one washer (R).
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Illustration 15 g06147865 (5) 521-1323 Bracket Assembly - Ensure that bracket assembly (5) is clear from the HVAC system.
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Illustration 16 g06147871 (P) P-Clip - Reinstall two p-clips (P) and associated hardware.
Note: P-clips (P) were removed in Step 13.
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Illustration 17 g06147906 (N) Straps
(6)6U-0455 Strap - Reinstall two straps (N) and one strap (6) to secure the heater lines in place.
Note: Straps (N) were removed in Step 12.
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Illustration 18 g06147912 (C) Dual Mounting Strap - Secure the signal line to the heater hoses under the HVAC using dual mounting straps (C) removed in Step 5.
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Illustration 19 g06147918 (7) 521-5035 Hose Assembly - Install hose assembly (7) to the inner steering connections as shown in Illustration 19.
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Illustration 20 g06147924 (8) 521-5036 Hose Assembly - Install hose assembly (8) to the outer steering connections as shown in Illustration 20.
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Illustration 21 g06147944 (9) 7G-3834 Clip
(10)7G-3833 Clip
(11)7G-3832 Grommet
(12)8T-4956 Bolt
(13)8T-4223 Hard Washer - Secure the steering hoses in place as shown above using one clip (9), one clip (10), one grommet (11), two bolts (12), and two hard washers (13).
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Illustration 22 g06147948 - Ensure that there is adequate clearance between the hose assemblies and powertrain cooler.
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Illustration 23 g06147959 (7) 521-5035 Hose Assembly
(8)521-5036 Hose Assembly
(14)6U-0456 Strap - Secure hose assembly (7) and hose assembly (8) in place using one strap (14).
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Illustration 24 g06154553 Top view of brake hose routing
(6)6U-0455 Strap
(15)290-5562 MountShow/hide table
Illustration 25 g06147965 Bottom view of brake hose routing
(6)6U-0455 Strap
(15)290-5562 Mount - Continue the brake hose routing from the underside of the HVAC. Group the hoses together in two bundles routed side by side. Secure the hoses together using two straps (6) and mount (15). This is required to prevent the brake lines from hitting the steering lines when the cab is tilted.
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Illustration 26 g06147980 (T) Tube Assembly
(U) Clamp
(V) Accumulator - Remove brake accumulator tube assembly (T), on the right-hand side of the operator cab and loosen clamp (U) securing accumulator (V) in place.
Note: Ensure that all stored hydraulic pressure is relieved from the brake circuit. Verify that pressure is relieved by measuring the front brake actuation pressure at the test point shown in Illustration 26, or check the service brake accumulator pressure at the CMPD.
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Illustration 27 g06147993 (U) Clamp
(V) Accumulator
(W)151.9 ± 3 mm (5.98 ± 0.12 inch) - Raise accumulator (V) so the top of the accumulator bottle is
151.9 ± 3 mm (5.98 ± 0.12 inch) from the top of clamp (U). Refer to Illustration 27 for details. - Once accumulator (V) is at the proper height, tighten clamp (U) to secure it in place.
Note: Accumulator (V) is raised to allow for service access to the underside of the bottle.
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Illustration 28 g06147999 (V) Accumulator
(16)6V-8398 O-Ring Seal
(17)6V-8942 O-Ring Reducer
(18)9X-6580 Nut - Install O-Ring (16) to O-Ring reducer (17) and secure the assembly to the T-piece on accumulator (V) using one nut (18).
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Illustration 29 g06148000 (19) 217-8454 Hose Assembly - Install hose assembly (19) as shown in Illustration 29.
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Illustration 30 g06194752 (20) 502-2067 PlateShow/hide table
Illustration 31 g06194748 (20) 502-2067 Plate
(21)3S-2093 Cable Strap - Remove the existing front service brake accumulator plate and install new plate (20) using one cable strap (21) as shown in Illustration 31.
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Illustration 32 g06154571 - Validate there is sufficient clearance between the positioning of the accumulator and the cab.
- Tilt the cab and ensure that there is no interference with the installed components. Refer to the proper machine Operation and Maintenance Manual, "Cab - Tilt" for instructions.
- Lower the cab and start the machine. Purge any air from the brake system and perform lock-to-lock steering to purge any air from the steering system. Refer to the proper machine Operation and Maintenance Manual for instructions.
- Check the area for leaks prior to reinstalling the covers.
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| Illustration 1 | g06147343 |
| (A) Panels | |
