RENR5126

June 2001

Systems Operation
Testing and Adjusting
735 and 740 Articulated Trucks
Hoist, Steering, Suspension, and
Fan Drive Systems
AXM1-Up (Machine)
AWR1-Up (Machine)
 i01097883

Important Safety Information

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 should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
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Hoist, Steering, Suspension, and Fan Drive Systems
Table of Contents

Table of Contents
Systems Operation Section
Graphic Color Codes .............................................. 4
General Information ................................................ 4
Steering System .................................................... 7
Piston Pump (Steering) ......................................... 10
Signal and Pressure Reducing Valve (Steering) ... 13
Metering Pump (Steering) .................................... 14
Secondary Steering System ................................ 16
Hoist System ......................................................... 17
Hoist Control Valve ............................................... 23
Fan Drive System ................................................. 26
Suspension System .............................................. 28
Suspension Cylinder (Front) ................................. 31

Testing and Adjusting Section

Troubleshooting
General Information .............................................. 32
Visual Inspection ................................................... 33
Operational Checks .............................................. 33
Steering System Troubleshooting ......................... 34
Suspension System Troubleshooting .................... 39
Hoist System Troubleshooting .............................. 39
Fan Drive System Troubleshooting ....................... 41

Testing and Adjusting

Hydraulic Oil Contamination - Test ....................... 43
Pump Flow - Test .................................................. 43
Steering System Pressure - Test and Adjust ........ 44
Load Sensing Pressure (Steering) - Test .............. 48
Signal and Pressure Reducing Valve (Steering) -
Check .................................................................. 48
Metering Pump (Steering) - Test ........................... 50
Electric Drive Pump (Secondary Steering) -
Check .................................................................. 51
Gear Pump (Hoist) - Test ...................................... 52
Hoist System Pressure - Test and Adjust ............. 53
Hoist Control Valve - Test ...................................... 56
Hoist Pilot Pressure - Test and Adjust .................. 58
Fan Drive System Pressure - Test ........................ 59
Suspension Accumulator - Test and Charge ........ 60
Suspension Height (Front) - Check and Adjust ..... 64
General Information Table ..................................... 66

Index Section
Index ..................................................................... 67
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Hoist, Steering, Suspension, and Fan Drive Systems
Systems Operation Section

Systems Operation Section i01526151

General Information
i01481554
SMCS Code: 4250; 4300; 5050; 7200
Graphic Color Codes
SMCS Code: 4250; 4300; 5050

g00771291
Illustration 1

(A) Red ........................... Pump discharge pressure

(B) Red Stripes and White

Stripes .......................... First pressure reduction

(C) Red Dots ................ Second pressure reduction

(D) Orange ............................. Pilot system pressure

(E) Orange Stripes and White

Stripes .............. Reduced pilot system pressure

(F) Blue .................................................. Blocked oil

(G) Green .. Suction oil, return oil, and case drain oil

(H) Yellow ..................................... Moving parts and

activated valve sections

(I) Purple ........................................ Pressurized gas

(J) Gray ............................... Cutaway sections, and

non-activated valve sections
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Hoist, Steering, Suspension, and Fan Drive Systems
Systems Operation Section

g00792792
Illustration 2
The steering wheel is stationary. the hoist control is in the HOLD position.
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Hoist, Steering, Suspension, and Fan Drive Systems
Systems Operation Section

(A) Hydraulic tank for the hoist and braking

systems
(B) Hydraulic tank for the steering and fan
drive systems

The machine has two hydraulic tanks. Tank (A)
contains oil for the hoist and braking systems.
Tank (B) contains oil for the steering and fan drive
systems.
On the 735, the gear pumps for the hoist system
and the fan drive system and the piston pump
for the steering system are driven by the torque
converter.
On the 740, the gear pumps for the hoist system
and the fan drive system and the piston pump for
the steering system are driven by the engine.
Lowering control valve (stopped engine) (1a) can
be opened in order to connect the piston side of the
hoist cylinders to the tank. Lowering control valve
(13) can be opened in order to connect the electric
drive pump to the rod sides of the hoist cylinders.
These components can be used to lower the body
if the engine is not operational.
Suspension cylinders (17) are connected to
accumulators (16) which act as suspension springs.
The suspension system is a closed system. The oil
is blocked by manual valve (10) and manual valve
(18).

Piston pump (15) is a variable displacement pump.
The piston pump supplies oil to the steering system.
The output of the piston pump, which is controlled
by load sensing pressure, passes through signal
and pressure reducing valve (6).
Electric drive pump (24) supplies oil to the
secondary steering system. The electric drive
pump, which is a gear pump, is driven by an
electric motor which is connected to the battery. The
electric drive pump is activated if pressure switch
(5) senses a low pressure from piston pump (15) or
if a switch in the operator’s compartment is pressed.
The outlet ports of piston pump (15) and electric
drive pump (24) are connected to steering check
and combiner valve (14). The steering check and
combiner valve supplies metering pump (4). The
metering pump is a gerotor pump which supplies
oil to steering cylinders (7). The metering pump
contains two makeup valves and two relief valves
which protect the steering cylinder lines and the
steering cylinders. The metering pump rotates as
the steering wheel rotates.
Manual valve (10) and manual valve (18) can
connect the piston pump for the braking system
to the suspension system. The manual valves can
also connect the suspension system to the tank.
The manual valves are used to set the ride height
of the front suspension.
Gear pump (20) supplies oil in order to drive fan
motor (19). The fan motor is connected to the
cooling fan.
The speed of the cooling fan is controlled by
thermal valve (11). Bypass valve (21) directs hot
oil through the oil cooler.
Gear pump (23), which is driven by the engine,
drives gear motor (22). Gear motor (22) is attached
to the ATAAC fan.

Gear pump (8) supplies oil to the hoist system. The

gear pump is a fixed displacement pump.

Hoist control valve (1) controls hoist cylinders (2)

and tailgate cylinder (3). Counterbalance valve
(12) ensures that the tailgate cylinder operates
with the hoist cylinders. The hoist control valve
is operated by pilot pressure, which is supplied
by the braking system. The hoist control valve is
electrically controlled. Relief valve (1b) limits the
system pressure.
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Hoist, Steering, Suspension, and Fan Drive Systems
Systems Operation Section

i01487815

Steering System
SMCS Code: 4300

Stationary Steering Wheel

g00776179
Illustration 3

Piston pump (5) supplies oil to the steering system.

The piston pump is a variable displacement pump.

Oil flows from the piston pump through signal

and pressure reducing valve (3) and through
steering check and combiner valve (11). Oil from
the steering check and combiner valve is blocked
at the metering pump. The steering system is at
standby pressure. This standby pressure holds the
contacts of pressure switch (6) open.

Oil flows from the signal and pressure reducing

valve into the load sensing line. Pressure is
maintained in the load sensing line by an orifice in
the metering pump and by check valve (10). This
pressure ensures a rapid response to a steering
input. Oil also flows from the signal and pressure
reducing valve to the metering pump and combines
with the oil from the piston pump.
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Hoist, Steering, Suspension, and Fan Drive Systems
Systems Operation Section
Rotating Steering Wheel
Illustration 4
Oil from piston pump (5) flows to metering pump
(1) through signal and pressure reducing valve (3)
and through steering check and combiner valve
(11). The metering pump supplies oil to steering
cylinders (4). The metering pump contains a rotary
spool and a gerotor pump. The system pressure
holds the contacts of pressure switch (6) open.
As the steering wheel is rotating, the rotary spool of
the metering pump is offset. This opens up a flow
path to the gerotor pump within the metering pump.
The gerotor pump rotates with the steering wheel.
As the gerotor pump rotates, the gerotor pump
transfers oil to the steering cylinders. Return oil
flows from the steering cylinders to the tank.
Pressure is transmitted into the load sensing line
through an orifice in the metering pump. This load
sensing pressure is proportional to the rotational
speed of the steering wheel and the load sensing
pressure is also proportional to the resistance to the
turn. The load sensing pressure causes the output
of the piston pump to increase in order to match the
requirements of the steering system.
g00776174
The spool of the signal and pressure reducing
valve moves. This allows more oil to flow to the
metering pump. Oil also flows from the signal and
pressure reducing valve to the metering pump
which supplements the flow from the piston pump.
As the rotational speed of the steering wheel is
increased, a greater flow rate from the piston
pump causes a greater flow rate of oil to bypass
the gerotor pump and flow directly to the steering
cylinders. This reduces the amount of rotations that
are required to articulate the machine.
The illustration shows oil flow from the left turn port
of the metering pump. Oil flows to the piston side
of the steering cylinder on the right side of the
machine. Oil flows to the rod side of the steering
cylinder on the left side of the machine. This will
articulate the machine to the left.
The system pressure is limited by pressure and flow
compensator valve (5a) which is part of the piston
pump.
Relief valves (4a), which are part of the steering
cylinders, provide damping for the steering
cylinders when the steering cylinders are retracting.
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Hoist, Steering, Suspension, and Fan Drive Systems
Systems Operation Section

Component Locations

g00795049
Illustration 8
g00776755 Steering cylinder (4) on the left side of the machine. Relief valve
Illustration 5
(4a) is installed in the piston side of each steering cylinder.
Metering pump (1) is located at the front of the cab and beneath
the windshield.

g00776750
Illustration 9
g00776754
Illustration 6 Piston pump (5) on the 735 is located on top of the transmission.
The piston pump can be accessed by raising the cab. Pressure
Signal and pressure reducing valve (3) is located on the right side
and flow compensator valve (5a) is part of the piston pump.
of the machine next to the hydraulic tank for the steering and fan
Check valve (2) is located in the line from the pressure and flow
drive systems. Check valve (7) is installed in the line from the
compensator valve.
signal and pressure reducing valve which is marked “PP”.

g00795047
Illustration 7
Steering cylinder (4) on the right side of the machine. Relief valve
(4a) is installed in the piston side of each steering cylinder.
g00776751
Illustration 10
Piston pump (5) on the 740 is located on top of the transmission.
The piston pump can be accessed by raising the cab. Pressure
and flow compensator valve (5a) is part of the piston pump.
Check valve (2) is located in the line from the pressure and flow
compensator valve.
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Hoist, Steering, Suspension, and Fan Drive Systems
Systems Operation Section

g00776759 g00776753
Illustration 11 Illustration 14
Shuttle valve (8) is located behind the steering check and combiner Electric drive pump (12) is located beneath the hood and on the
valve. right side of the engine. Check valve (9) is in the load sensing
line from the electric drive pump.

i01484399

Piston Pump (Steering)

SMCS Code: 5070-ZH

g00776758
Illustration 12
Check valve (10) is located on the hydraulic tank for the steering
and fan drive systems.

g00776752
Illustration 13
Steering check and combiner valve (11) is located to the left of the
hydraulic tank for the steering and fan drive systems. Pressure
switch (6) is located in the steering check and combiner valve.