740 Articulated Truck B1P00001-UP (MACHINE) POWERED BY C1...

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Product: ARTICULATED TRUCK

Model: 740 ARTICULATED TRUCK B1P
Configuration: 740 Articulated Truck B1P00001-UP (MACHINE) POWERED BY C15 Engine

Testing and Adjusting

735 and 740 Articulated Trucks Steering, Suspension, and Body Hoist
Hydraulic Systems
Media Number -RENR5126-06Publication Date -01/01/2009Date Updated -12/01/2009

i02555266

Suspension Cylinder (Front) - Purge and Charge

SMCS - 7201-045; 7201-542

Part Number -
S/N - B1P1-UP

Part Number -
S/N - AXM1183-UP

Part Number -
S/N - AWR589-UP

Part Number -
S/N - B1N1-UP

Perform Testing and Adjusting, "Visual Inspection" before you service the suspension
cylinders.

The machine must be on level ground when you inspect the suspension cylinder
charge. The truck body must be empty. Coast the machine to a gentle stop without
using the brakes. Apply the parking brake. Check the dimensions of the front
suspension from the top of the wheel rim to the top of the fender on both sides of the
machine. Compare these dimensions to the dimensions that were recorded previously.
The suspension height will be different for each machine.

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Note: Both suspension cylinders must be charged at the same time. If only one
suspension cylinder needs servicing, perform the procedure on both suspension
cylinders.

Oil Requirements (Suspension Cylinder)

When you rebuild a suspension cylinder or when you assemble a suspension cylinder,
use TDTO 10 W oil in the quantity that is specific to the machine. Refer to Table 1.

Table 1
Oil Quantities For Suspension Cylinders
Model Qty

725
4 L (1.0567 US gal)
730
730 Ejector 4 L (1.0567 US gal)

735
3.92 L (1.0355 US gal)
740
740 Ejector 3.92 L (1.0355 US gal)

Note: When you are charging the suspension cylinder with oil, use TDTO 10 W oil
and add 1U-9891 Hydraulic Oil Additive. The ratio of additive to oil is 12.5 ml per 1 L
(0.2642 US gal).

After the suspension cylinder contains the required amount of oil, install the
suspension cylinder. After this has been done, normal charging procedures can be
performed.

Charging Valves (Type 1 and Type 2)

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Illustration 1 g01142833

Suspension cylinder with Type 1 charging valve

If the machine is installed with Type 1 charging valves, use 7S-5106 Chucks on the
charging valves in the following procedures.

Illustration 2 g01142834

Suspension cylinder with Type 2 charging valve

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If the machine is installed with Type 2 charging valves, use 1S-8938 Chucks on the
charging valves in the following procedures.

Type 2 chucks incorporate an additional valve which must be opened and closed by
rotating nut (A). To open the charging valve, perform the following procedure:

1. Ensure that all charging equipment is fully closed.

2. Install the chuck onto the charging valve.

3. Rotate nut (A) counterclockwise in order to open the additional valve.

4. Turn the check valve on the chuck clockwise in order to open the charging valve.

To close the charging valve, perform the following procedure:

1. Turn the check valve on the chuck counterclockwise in order to close the
charging valve.

2. Rotate nut (A) clockwise in order to close the additional valve. Tighten the nut to
7 ± 1 N·m (5 ± 0.7 lb ft).

3. Remove the chuck from the charging valve.

Charging Tools

Illustration 3 g00295778

9U-5617 Oil Refill Pump

(1) Shutoff valve for the regulator

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(2) 7S-5106 Chuck

(3) Shutoff valve

(4) Charging hoses

Note: Replace chucks (2) with 1S-8938 Chucks if the machine is installed with Type 2
charging valves.

Illustration 4 g00831850

175-5507 Nitrogen Charging Group

(5) 162-4147 Hose As

(6) 8S-4600 Fitting

(7) 8S-1506 Coupling

(8) 162-4146 Regulator

(9) 1S-8938 Chuck

(10) 7S-5106 Chuck

(11) 8T-0859 Pressure Gauge

(12) 8S-4599 Coupling

(13) 2S-5244 Fitting

(14) 1S-8937 Needle Valve

(15) 2D-7325 Pipe Tee

(16) 1S-8941 Hose As

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Note: Chuck (10) is required for Type 1 charging valves. Chuck (9) is required for
Type 2 charging valves.

Illustration 5 g00833037

175-7410 Nitrogen Charging Fitting Gp

(17) 8S-7169 Coupling

(18) 1S-8941 Hose As

(19) 7S-5106 Chuck

(20) 175-6857 Hose As

(21) 2D-7325 Pipe Tee

(22) 1S-8937 Needle Valve

(23) 5P-8998 Fitting

(24) 3D-8884 Elbow

Note: Replace chuck (19) with a 1S-8938 Chuck if the machine is installed with Type
2 charging valves.

Lowering the Suspension

Table 2
Required Tools

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Tool Part Number Part Description Qty

1S-8937 Needle Valve 1
175-6857 Hose As 1
A 8S-7169 Coupling 1
1S-8941 Hose As 1
(1)
7S-5106 Chuck 1
B 1S-8938 (2) Chuck 1
(1)
Type 1 charging valves
(2)
Type 2 charging valves

Note: Tooling (A) in Table 2 is part of the 175-7410 Nitrogen Charging Fitting Gp.
Refer to Charging Tools.

Personal injury or death can result from sudden suspension

cylinder movement.

Sudden movement, up or down, can cause the clearance

above your head to change rapidly.

Read all warning labels on the suspension cylinders before

servicing. Do not check the oil in the suspension cylinder until
all the nitrogen pressure has been released.

Do not, under any condition, remove valves, cover or plugs

from the cylinder unless the rod is fully retracted and all the
nitrogen pressure is released.

Do not stand under the machine when testing or adjusting the

suspension cylinders.

When the suspension is lowered clearances between the

machine frames and suspension components are reduced.

Persons on or near the machine could be injured by crushing.

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Keep all personnel clear of the machine until the suspension

has been lowered.

NOTICE

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, "Caterpillar

Dealer Service Tool Catalog" for tools and supplies suitable
to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and

mandates.

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Illustration 6 g00995672

Typical example

(1) Port (O)

(2) Port (N)

(3) Side Port

1. Remove the cover which protects the charging valves at port (1) and port (2).
Remove the valve cap from the charging valve in port (2) that is located on top
side of the suspension cylinders. Before installing Tooling (A), turn the check
valve on the chuck counterclockwise in order to ensure that the charging valve
will not open during installation. Make sure that the needle valve on the opposite
end is fully closed. Install Tooling (A) with the chuck on the charging valve and
the needle valve into a suitable approved container.

2. Turn the check valve on the chuck clockwise. This opens up the charging valve.
Move away from the machine before moving to the next step.

3. Open the needle valve and allow the nitrogen to flow through the charging valve
into the suitable container. When the suspension cylinder has bottomed
completely, leave the check valve and the needle valve in position for five
minutes in order to allow the pressure in the suspension cylinder to equalize.

Purge and Charging the Suspension Cylinder

Table 3
Required Tools
Tool Part Number Part Description Qty
1S-8937 Needle Valve 1
175-6857 Hose As 1
A 8S-7169 Coupling 1
1S-8941 Hose As 1
7S-5106 (1) Chuck 1
B 9U-5617 Oil Refill Pump 1
C 175-5507 Nitrogen Charging Group 1
D 1S-8938 (2) Chuck 1
(1)
Type 1 charging valves
(2)
Type 2 charging valves

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Note: Tooling (A) in Table 3 is part of the 175-7410 Nitrogen Charging Fitting Gp.
Refer to Charging Tools.

Personal injury or death can result from sudden suspension

cylinder movement.

Sudden movement, up or down, can cause the clearance

above your head to change rapidly.

Read all warning labels on the suspension cylinders before

servicing. Do not check the oil in the suspension cylinder until
all the nitrogen pressure has been released.

Do not, under any condition, remove valves, cover or plugs

from the cylinder unless the rod is fully retracted and all the
nitrogen pressure is released.

Do not stand under the machine when testing or adjusting the

suspension cylinders.

When the suspension is lowered clearances between the

machine frames and suspension components are reduced.

Persons on or near the machine could be injured by crushing.

Keep all personnel clear of the machine until the suspension

has been lowered.

NOTICE

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.

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Refer to Special Publication, NENG2500, "Caterpillar

Dealer Service Tool Catalog" for tools and supplies suitable
to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and

mandates.

Illustration 7 g00995672

Typical example

(1) Port (O)

(2) Port (N)

(3) Side Port

1. Remove the valve cap from the charging valve in port (3) that is located on the
suspension cylinder toward the rear of the machine. Before installing Tool (A),
turn the check valve on the chuck counterclockwise in order to ensure that the
charging valve will not open during installation. Make sure that the needle valve
on the opposite end is fully closed. Install Tooling (A) with the chuck on the
charging valve and insert the needle valve into a suitable approved container.

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2. Turn the check valve on the chuck clockwise. This opens up the charging valve.
Move away from the machine before moving to the next step.

3. Open the needle valve and allow oil and nitrogen to flow through the charging
valves into the suitable container. When the suspension cylinder has bottomed
completely, leave the check valve and the needle valve in position for five
minutes in order to allow the pressure in the suspension cylinder to equalize.

4. Remove the cover which protects the charging valves at port (1) and port (2) (not
shown). Remove the valve cap from the charging valve in port (1) and attach
Tooling (B) .

5. Use Tooling (B) in order to inject oil into the suspension cylinder. The oil will
flow through the suspension cylinder then out of the charging valve in port (3)
and Tooling (A) into a suitable container. When the oil that is flowing out of the
suspension cylinder is clean and free of air stop Tooling (B) and turn the check
valve on the chuck of Tooling (A) at port (3) counterclockwise. This will close
the charging valve. Remove Tooling (A) .

6. Remove the valve cap from the charging valve in port (2) that is located on top
side of the suspension cylinder. Before installing Tooling (A), turn the check
valve on the chuck counterclockwise in order to ensure that the charging valve
will not open during installation. Make sure that the needle valve on the opposite
end is fully closed. Install Tooling (A) with the chuck on the charging valve and
the needle valve into a suitable approved container.

7. Turn the check valve on the chuck clockwise. This opens up the charging valve.
Open the needle valve into the suitable container.

8. Use Tooling (B) in order to inject oil into the suspension cylinder. The oil will
flow through the suspension cylinder then out of the charging valve in port (2)
and Tooling (A) into a suitable container. When the oil that is flowing out of the
suspension cylinder is clean and free of air stop Tooling (B) and turn the check
valve on the chuck of Tooling (A) at port (2) counterclockwise. This will close
the charging valve. Remove Tooling (A) and Tooling (B) .

9. Remove the valve cap from the charging valve in port (1) that is located on the
top side of the suspension cylinder. Before installing Tool (A), turn the check
valve on the chuck counterclockwise in order to ensure that the charging valve
will not open during installation. Make sure that the needle valve on the opposite
end is fully closed. Install Tooling (A) with the chuck on the charging valve and
the needle valve into a suitable approved container.

10. Turn the check valve on the chuck clockwise. This opens up the charging valve.
Open the needle valve into the suitable container.

11. Install Tooling (C) onto the charging valve at port (2) .

12. On the nitrogen cylinder, adjust the regulated pressure to 6895 kPa (1000 psi).

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13. Open the needle valve on Tooling (C) and allow nitrogen to flow through the
chuck which is connected to the charging valve at port (2). Turn the check valve
on the chuck clockwise. This allows nitrogen to flow through the charging valve
and into the suspension cylinder. A small amount of oil will flow out of Tooling
(A) and into the suitable container.

14. When the flow of oil stops and only nitrogen is flowing through Tooling (A), turn
the check valve on the chuck at port (2) counterclockwise on Tooling (C). This
will close the charging valve in order to stop the flow of nitrogen. Remove
Tooling (C). Turn the check valve on the chuck at port (1) counterclockwise
before removing Tooling (A) .

Nitrogen Charging Procedure (Setting the Suspension

Ride Height)
Table 4
Required Tools
Tool Part Number Part Description Qty
C 175-5507 Nitrogen Charging Group 1
D 175-7410 Nitrogen Charging Fitting Gp 1
E 1S-8938 (2) Chuck 1
(2)
Type 2 charging valves

Dry nitrogen is the only gas approved for use in the

suspension cylinders. Charging the suspension cylinders with
oxygen gas will cause an explosion. This danger will not
happen if nitrogen cylinders with standard CGA
(Compressed Gas Association, Inc.) Number 580 Connections
are used.

When you order nitrogen gas, be sure that the cylinders are
equipped with CGA No. 580 Connections. Do not use color
codes or other methods of identification to tell the difference
between nitrogen cylinders and oxygen cylinders.

Never use an adapter to connect your nitrogen charging

group to a valve outlet used on both nitrogen, oxygen or other
gas cylinders. Be sure you use dry nitrogen (99.8% purity).

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Illustration 8 g01041196

1. Measure Dimension (A) on both sides of the machine. Dimension (A) is the
distance from the top of the rim to the bottom of the fender. Dimension (A) will
be different for each side of the machine. Record this number for both sides of the
machine.

Illustration 9 g00995672

Typical example

(1) Port (O)

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(2) Port (N)

(3) Side Port

2. Remove the cover which protects the charging valves at port (1) and port (2) (not
shown) on both suspension cylinders. Remove the valve cap from the charging
valve in port (2) that is located on top side of each suspension cylinder. Before
installing Tooling (C) and Tooling (D), turn the check valves on the chucks
counterclockwise in order to ensure that the charging valves will not open during
installation. Make sure that the needle valves on the opposite ends are fully
closed.

3. On the nitrogen cylinder, adjust the regulated pressure to 6900 kPa (1000 psi).

4. Open the main needle valve. Open the needle valve which is in the line to the
suspension cylinder on the left side. Turn the check valve on the left side chuck
clockwise. This opens up the charging valve in order to allow nitrogen to flow
into the suspension cylinder. Allow the suspension to raise the machine
approximately 10 mm (0.40 inch) and then close the needle valve for the left side.

5. Open the needle valve which is in the line to the suspension cylinder on the right
side. Turn the check valve on the right side chuck clockwise. This opens up the
charging valve in order to allow nitrogen to flow into the suspension cylinder.
Allow the suspension to raise the machine approximately 10 mm (0.40 inch) and
then close the needle valve for the right side.

6. Alternate between the needle valve for the left side and the needle valve for the
right side in order to allow the suspension to rise in increments of 10 mm (0.40
inch) until the correct suspension ride height is achieved. The correct suspension
height is Dimension (A) plus Dimension (B). Refer to Step 1 and Table 5.

Table 5
Suspension Height is Dimension (A) Plus Dimension (B).
Model Dimensions (B)

725
105 ± 10 mm (4.15 ± 0.4 inch)
730
730 Ejector 105 ± 10 mm (4.15 ± 0.4 inch)

735
75 ± 10 mm (3 ± 0.4 inch)
740
740 Ejector 75 ± 10 mm (3 ± 0.4 inch)

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7. Operate the machine for several load cycles after the suspension has been
properly charged. Recheck the ride height of the suspension. If necessary, adjust
the height of the suspension.

Copyright 1993 - 2018 Caterpillar Inc. Mon Aug 20 13:37:38 UTC+0800 2018
All Rights Reserved. j210bs14
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