Manual de Operacin y Mantenimiento

735 y 740 Camiones articulados

Nmero de medio -SSBU781513

Fecha de publicacin 01/01/2013

Fecha de actualizacin 25/03/2013

i02025100

Sistema de suspensin - Comprobar

SMCS - 7200-535
/sisw eb/sisw eb/

/sisw eb/products

El sistema de suspensin puede fallar y hacer que la mquina caiga

repentinamente, eliminando el espacio libre entre la caja del eje, el
bastidor principal, los neumticos y los guardabarros.
Trabajar en estas reas puede dar como resultado lesiones personales o
la muerte por aplastamiento.
Estacione la mquina en una superficie horizontal y coloque bloques en
el bastidor delantero antes de trabajar debajo de la mquina.
1. Desconecte las trabas del diferencial. Lleve la mquina a una parada suave en un
terreno horizontal firme.
2. Desconecte el freno de servicio. Espere un segundo antes de conectar el freno de
estacionamiento.
3. Instale soportes adecuados debajo del bastidor delantero.

Ver imagen

Ilustracin 1

g01043895

4. Mida la distancia (A). La distancia (A) es la distancia entre los pasadores de

montaje del cilindro de la suspensin. La dimensin (A) debe ser de 700 10
mm (27,6 0,39 pulg).
Nota: Mida la distancia (A) cuando la mquina est fra.
5. Si la altura de la suspensin no es correcta, consulte a su distribuidor Caterpillar.
Se necesitan herramientas y procedimientos especiales para ajustar la altura de la
suspensin delantera.
6. Quite los soportes.

Pruebas y Ajustes
735 and 740 Articulated Trucks Steering, Suspension, and Body Hoist
Hydraulic Systems
Nmero de medio -RENR512606

Fecha de publicacin 01/01/2009

Fecha de actualizacin 12/01/2009

i02555266

Suspension Cylinder (Front) - Purge and Charge

SMCS - 7201-045; 7201-542
Nmero de pieza S/N - B1P1-UP

Nmero de pieza S/N - AXM1183-UP

Nmero de pieza S/N - AWR589-UP
Nmero de pieza S/N - B1N1-UP
/sisw eb/sisw eb/

/sisw eb/mediase

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.
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
725
730
730 Ejector
735
740
740 Ejector

Qty
4 L (1.0567 US gal)
4 L (1.0567 US gal)
3.92 L (1.0355 US gal)
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)

Ver imagen

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.
Ver imagen

Illustration 2
Suspension cylinder with Type 2 charging valve

g01142834

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 Nm (5 0.7 lb ft).
3. Remove the chuck from the charging valve.

Charging Tools
Ver imagen

Illustration 3
9U-5617 Oil Refill Pump
(1) Shutoff valve for the regulator
(2) 7S-5106 Chuck

g00295778

(3) Shutoff valve

(4) Charging hoses

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

Illustration 4
175-5507 Nitrogen Charging Group

g00831850

(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

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

Ver imagen

Illustration 5
175-7410 Nitrogen Charging Fitting Gp

g00833037

(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
Tool

Part Number

Part Description

Qty

1S-8937

Needle Valve

175-6857

Hose As

8S-7169

Coupling

1S-8941

Hose As

Chuck

Chuck

7S-5106
B
(1)
(2)

(1)

1S-8938 (2)
Type 1 charging valves
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.
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.

Ver imagen

Illustration 6
Typical example

g00995672

(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

175-6857

Hose As

8S-7169

Coupling

1S-8941

Hose As

7S-5106 (1)

Chuck

9U-5617

Oil Refill Pump

175-5507

Nitrogen Charging Group

1S-8938 (2)

Chuck

(1)
(2)

Type 1 charging valves

Type 2 charging valves

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.
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.

Ver imagen

Illustration 7
Typical example

g00995672

(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.
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).
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

175-5507

Nitrogen Charging Group

175-7410

Nitrogen Charging Fitting Gp

1S-8938 (2)

Chuck

(2)

Part Description

Qty

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).

Ver imagen

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.

Ver imagen

Illustration 9
Typical example

g00995672

(1) Port (O)

(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
725
730
730 Ejector
735
740
740 Ejector

Dimensions (B)
105 10 mm (4.15 0.4 inch)
105 10 mm (4.15 0.4 inch)
75 10 mm (3 0.4 inch)
75 10 mm (3 0.4 inch)

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.