Caterpillar Cat 725C2 Articulated Truck (Prefix 2L6) Service Repair Manual (2L600001 and up).pdf

Service Repair Manual
Models
725C2 Articulated Truck

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Product: ARTICULATED TRUCK
Model: 725C2 ARTICULATED TRUCK 2L6
Configuration: 725C2 Articulated Truck 2L600001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly
C9.3 Engines for Caterpillar Built Machines
Media Number -UENR0135-06 Publication Date -01/08/2015 Date Updated -21/02/2017
i04394238
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
Removal Procedure
Illustration 1 g02566239
1. Disconnect clamp assemblies (2) and remove hose (1).
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725C2 Articulated Truck 2L600001-UP (MACHINE) POWERED BY C9.3 Engine(M...
2020/1/28
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2. Disconnect harness assembly (3). Remove nuts (4) and the washers. Position harness
assembly (3) and bracket assembly (5) out of the way.
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
3. Remove two studs (6). Remove washers (7) and springs (8).
4. Remove eight bolts (9). Remove washers (7) and springs (8).
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Note: Ensure that all stud bolts, bolts, washers, and springs have been fully removed from
the valve mechanism cover prior to the removal of the cover. This action will help prevent
any foreign material from being lost in the engine compartment, or in the engine.
5. Remove valve mechanism cover (10).
6. Remove cap (11) and the O-ring seal.
7. Remove clamp assembly (13) and remove breather assembly (12).
8. Remove adapter (14) and remove both O-ring seals (not shown).
Installation Procedure
1. Install valve mechanism cover (10) in the reverse order of removal.
a. Tighten clamp (13) to a torque of 4.5 ± 0.5 N·m (40 ± 5 lb in).
b. Tighten adapter (14) to a torque of 15 ± 3 N·m (132 ± 26 lb in).
c. Hand tighten cap (11).
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Tightening sequence for the valve mechanism cover
d. Tighten bolts (9) and stud bolts (6) in the above sequence.
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All Rights Reserved.
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Tue Jan 28 23:48:46 UTC+0800 2020
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i04394476
Compression Brake - Remove and Install
SMCS - 1129-010
Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
1. Disconnect harness assembly (3).
2. Remove bolts (1) and remove compression brake (2).
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Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-7234 Feeler Gauge 1
1. Adjust the engine valve lash. Refer to Testing and Adjusting, "Engine Valve Lash -
Inspect/Adjust".
2. Loosen mounting nuts (4) that hold down the harness assembly to give the compression
brake more clearance during installation.
Note: Check the O-ring seals for wear or for damage. Replace the components, if necessary.
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3. Lubricate the O-ring seal (5) that is found on compression brake (2) sparingly with clean
engine oil.
Torque Sequence
4. Position compression brake (2).
5. Connect harness assembly (3) and install bolts (1) finger tight.
6. Tighten bolts (1) to a torque of 55 ± 10 N·m (41 ± 7 lb ft) in the above sequence.
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7. Tighten mounting nuts (4) that hold down the harness assembly.
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Note: Failure to adjust lash properly could result in engine damage.
8. Set the brake lash for the compression brake on cylinders one, three and five. Position the
number one piston to the top center position of compression stroke. Refer to Testing and
Adjusting, "Finding Top Center Position for No. 1 Piston".
9. Thread adjuster (7) clockwise until the brake piston (8) touches valve bridge (9).
10. Turn adjuster (7) counterclockwise until the adjuster has turned one full rotation.
11. Use Tooling (A) in order to verify the brake lash of 0.9 ± 0.2 mm (0.035 ± 0.008 inch). The
brake lash is measured between brake piston (8) and valve bridge (9).
12. Tighten the locknut (6) to a torque of 50 ± 10 N·m (37 ± 7 lb ft). Do not allow the
adjustment screw to turn while you are tightening the adjustment locknut. Recheck the valve
lash after tightening the adjustment locknut.
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Note: Failure to adjust lash properly could result in engine damage.
13. On cylinders two, four, and six, set the lash on the compression brake. Position the number
six piston to the top center position of compression stroke.
14. Thread adjuster (7) clockwise until the brake piston (8) touches valve bridge (9).
15. Turn adjuster (7) counterclockwise until the adjuster has turned one full rotation.
16. Use Tooling (A) in order to verify the brake lash of 0.9 ± 0.2 mm (0.035 ± 0.008 inch). The
brake lash is measured between brake piston (8) and valve bridge (9).
17. Tighten locknuts (6) to a torque of 50 ± 10 N·m (37 ± 7 lb ft). Do not allow adjuster (7) to
turn while you are tightening locknut (6). Recheck the valve lash after tightening the
locknut.
Tue Jan 28 23:49:42 UTC+0800 2020
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i02934841
Compression Brake - Disassemble - Valve Assembly
SMCS - 1129-015
Disassembly Procedure
Start By:
a. Remove the compression brake. Refer to Disassembly and Assembly, "Compression Brake -
Remove".
1. Remove bolts (2).
2. Remove valve (3) from compression brake (1).
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3. Remove O-rings (4) from valve (3).
4. Remove O-ring (5) from compression brake (1).
Tue Jan 28 23:50:38 UTC+0800 2020
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i02934849
Compression Brake - Assemble - Valve Assembly
SMCS - 1129-016
Assembly Procedure
Note: Lubricate the O-ring seals sparingly with clean engine oil.
1. Install O-ring seal (5) onto compression brake (1).
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Note: Lubricate the O-ring seals sparingly with clean engine oil.
2. Install O-rings (4) onto valve (3).
3. Install valve assembly (3) into compression brake (1).
4. Install bolts (2). Tighten bolts (2) to a torque of 6 ± 1 N·m (53 ± 9 lb in).
End By:
a. Install the compression brake. Refer to Disassembly and Assembly, "Compression Brake -
Install".
Tue Jan 28 23:51:33 UTC+0800 2020
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i07074602
Rocker Arm and Shaft - Remove and Install
SMCS - 1102-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-2298 Lubricant - Cam 1
Start By:
a. Remove the valve mechanism cover.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Put identification marks on each of the rocker arms and push rods to
identify the proper location for installation.
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1. Disconnect harness assemblies (3).
2. Remove nuts (1) and position harness assembly (2) out of the way.
3. Loosen nuts (5) and loosen rocker arm adjustment screws (6).
4. Remove bolts (7) and remove the rocker arm shaft assembly (8).
5. Remove pushrods (4).
1. Install rocker arm shaft assembly (8) in the reverse order of removal.
a. Apply Tooling (A) to both ends of the pushrods and to the bottom faces of the rocker
arms.
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b. Align rocker arm shaft assembly (8) with Locating Dowel (X). Position rocker arm
shaft assembly (8) and install bolts (7). Tighten bolts (7) to standard torque.
c. Position rocker arm adjustment screws (6) and tighten nuts (5).
d. Adjust the valve lash of the rocker arms. Refer to Testing and Adjusting, "Engine
Valve Lash - Inspect/Adjust".
Tue Jan 28 23:52:29 UTC+0800 2020
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i02544763
Rocker Arm - Disassemble
SMCS - 1123-015
Disassembly Procedure
Start By:
a. Remove the rocker arm and shaft. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Place an identification mark on each of the components of the rocker shaft for installation
purposes.
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Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
1. Remove plug (2) from rocker shaft (1).
2. Remove stand (6), inlet rocker arm (5), spring (4), and exhaust rocker arm (3) from rocker
shaft (1).
Tue Jan 28 23:53:25 UTC+0800 2020
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Caterpillar Cat 725C2 Articulated Truck (Prefix 2L6) Service Repair Manual (2L600001 and up).pdf

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