Caterpillar 735C 740C 745C Articulated Truck Workshop Repair Service Manual PDF LFJ TFJ JE6 JE7 LFN TFN LFK TFK JE8 JE9 - MCAT735C745C.zip

Full workshop repair manuals covering the Caterpillar ARTICULATED TRUCK 735C (Prefix LFJ, TFJ, JE6, JE7), 740C (Prefix LFN, TFN), and 745C (Prefix LFK, TFK, JE8, JE), containing every piece of service documentation needed for maintenance, troubleshooting, repair, and rebuild work.

Repair and Service Manuals for Caterpillar ARTICULATED TRUCKS 735C, 740C, 745C

workshop service manual includes:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,732 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Manual Type: Disassembly & Assembly, Testing & Adjusting, Specifications, Systems Operation, Electrical Schematic, Troubleshooting...

Language: English

735C ARTICULATED TRUCK LFJ

735C ARTICULATED TRUCK TFJ

735C OEM ARTICULATED TRUCK JE6

735C OEM ARTICULATED TRUCK JE7

740C ARTICULATED TRUCK LFN

740C ARTICULATED TRUCK TFN

745C ARTICULATED TRUCK LFK

745C ARTICULATED TRUCK TFK

745C OEM ARTICULATED TRUCK JE8

745C OEM ARTICULATED TRUCK JE9

UENR2354 - Troubleshooting (735C, 740C EJECTOR and 745C Articulated Trucks).......2

Alarm - Test.......4

Axle Lock Clutch Accumulated Thermal Energy Is High.......11

Backup Alarm Always Off.......17

Backup Alarm Always On.......21

Brake System.......24

CAN Data Link - Test.......28

Cat Data Link - Test.......39

Charging System - Test.......44

Condition Switch (Switch to Ground) - Test.......45

Connector Contact Description.......50

Connector Locations.......59

Cross Axle Lock Speed Is Mismatched.......60

Data Link Configuration Status - Test.......64

Determining Diagnostic Trouble Codes.......71

Diagnostic Capabilities.......74

Diagnostic Trouble Codes.......77

Differential and Final Drive.......89

ECM - Configure.......93

ECM - Replace.......95

ECM Location Code - Test.......99

ECM Software - Install.......104

Electrical Connector - Inspect.......107

Electrical Power Supply - Test.......114

Emerging Symptom Information.......121

Event Codes.......122

General Information.......137

Hoist System.......141

Hydraulic Fan System.......148

Indicator Lamp - Test.......152

Interaxle Lock Speed Is Mismatched.......158

Machine Preparation for Troubleshooting.......161

Operational Checks (Hoist System).......165

Operational Checks (Power Train).......168

Operational Checks (Steering System).......170

Operator Control Switch (Switch to Ground) - Test.......172

Relay - Test.......177

Retarding System.......184

Sensor (Data Link Type) - Test.......191

Sensor Signal (Analog, Passive) - Test.......201

Sensor Signal (PWM) - Test.......208

Sensor Supply - Test.......218

Service Tools.......225

Solenoid Return - Test.......229

Solenoid Valve - Test.......235

Speed Sensor - Test.......250

Starting System - Test.......261

Steering System.......265

Suspension System.......276

Symptom Troubleshooting.......278

System Schematic.......280

Torque Converter.......284

Traction Control System.......288

Transmission Clutch Slips.......292

Transmission.......306

Visual Inspection.......316

Wiring Harness (Open Circuit) - Test.......319

Wiring Harness (Short Circuit) - Test.......320

UENR3695 - Systems Operation (735C, 740C EJECTOR and 745C Articulated Trucks Indication Display_CMPD Monitoring).......321

Camera Menu.......322

Data Link.......324

Features.......327

General Information.......329

Indication Display Module.......332

Input Components.......340

Location of Electrical Components.......342

Machine Status Menu.......343

Main Menu.......346

Monitor Display.......349

Operator Menu.......356

Performance Screen.......359

Service Menu.......362

Settings Menu.......370

Totals Menu.......381

Warning Operation.......385

UENR3695 - Testing and Adjusting (735C, 740C EJECTOR and 745C Articulated Trucks Indication Display_CMPD Monitoring).......388

Connector Contact Description.......389

Electrical Connector - Inspect.......391

Module - Flash Program - WinFlash.......400

Module - Replace.......401

Self Test.......403

System Schematic.......404

Wiring Harness (Open Circuit) - Test.......406

Wiring Harness (Short Circuit) - Test.......407

UENR3695 - Troubleshooting (735C, 740C EJECTOR and 745C Articulated Trucks Indication Display_CMPD Monitoring).......408

CAN Data Link - Test.......409

Connector Locations.......418

Determining Diagnostic Trouble Codes.......420

Diagnostic Capabilities.......425

Diagnostic Trouble Codes.......429

Event Codes.......430

General Information.......432

Service Tools.......434

UENR4018-02 - Schematic (735C and 745C Articulated Truck Hydraulic System (Interactive), 372-5278-01 (For Serial Number LFJ1-UP TFJ1-UP LFK1-UP TFK1-UP) .......437

Feature.......437

Cover Page.......438

Information.......0

Component Location.......0

Volume 1 of 2 - Brake, Brake Retarding and Brake Cooling Circuits.......439

Volume 2 of 2 - Fan, Traction Control, Hoist, Suspension and Steering.......0

Page 1 of 2.......440

Page 2 of 2.......441

Tap Location.......0

Volume 1 of 2 - Brake, Brake Retarding and Brake Cooling Circuits.......442

Volume 2 of 2 - Fan, Traction Control, Hoist, Suspension and Steering.......443

Fluid Power Symbols.......444

Electrical Symbols.......445

Schematics.......0

Volume 1 of 2 - Brake, Brake Retarding and Brake Cooling Circuits.......446

Volume 2 of 2 - Fan, Traction Control, Hoist, Suspension and Steering.......447

Machine Views.......0

Volume 1 of 2 - Brake, Brake Retarding and Brake Cooling Circuits.......0

Machine Views.......448

Volume 2 of 2 - Fan, Traction Control, Hoist, Suspension and Steering.......0

Machine Front Left Side View.......449

Machine Views.......450

Main Control Valve.......451

UENR4225 - Specifications (735C, 745C and 740C EJECTOR Articulated Truck Systems).......452

Access Cover.......456

Air Cleaner.......457

Air Conditioner Lines.......459

Air Conditioner and Mounting.......460

Antenna.......462

Axle Housing.......464

Battery and Wiring Group.......466

Brake Accumulator (Mounting).......467

Brake Accumulator (Parking).......468

Brake Accumulator (Service).......469

Brake Control Valve (Parking).......470

Breather (Power Train).......471

Bypass Valve (Hydraulic Oil Cooler).......473

Cab Door.......474

Cab Lighting.......476

Cab Liner.......478

Cab Panel - Mounting.......481

Cab Panel.......482

Cab Tilt Cylinder and Mounting Group.......483

Cab Visor.......485

Cab Window.......486

Center Axle.......488

Center Suspension Frame.......490

Check Valve.......491

Control Valve (Transmission Oil Cooler).......492

Coolant Lines.......493

Coolant Tank.......495

Differential and Bevel Gear (Center).......497

Differential and Bevel Gear (Front and Rear).......499

Differential.......501

Diverter Valve (Hoist).......503

Drive Shaft - Front.......506

Drive Shaft - Hitch.......507

Drive Shaft - Main.......508

Drive Shaft - Rear.......509

Electronic Control Module.......511

Exhaust Pipe.......512

Fender Extension.......517

Fender.......518

Final Drive and Wheel.......521

Front Axle.......523

Front Suspension Frame.......524

Fuel Tank.......526

Gear Motor (Hydraulic Fan).......529

Gear Pump (Aftercooler).......533

Gear Pump (Brake_Axle Oil Cooler).......534

Gear Pump (Transmission).......537

Governor Pedal.......540

Heater Lines.......542

Hoist Control Valve.......544

Hoist Cylinder and Mounting.......547

Hoist Cylinder.......549

Hood Tilt Actuator.......551

Hydraulic Fan Drive Lines.......552

Hydraulic Tank.......553

Main Control Valve.......556

Muffler.......559

Oil Filter (Power Train).......561

Oil Filter (Transmission).......563

Oscillating Hitch.......565

Parking Brake.......567

Piston Pumps (Brake, Ejector, Steering, Fan).......572

Piston Pumps (Brake, Hoist, Steering, Fan).......574

Planetary Carrier (Output Transfer Gear).......576

Position Sensor (Hoist Control).......581

Position Sensor (Transmission Control).......582

Pressure Reducing Valve (Differential Lock).......583

Pressure Reducing Valve (Hoist Pilot Oil).......584

Pump Control Valve (Implement).......585

Radiator - Shroud.......586

Radiator.......588

Rear Axle.......589

Rear Equalizer Suspension (Equalizer Arm).......590

Rear Suspension Frame.......591

Rear View Mirror.......592

Relief Valve (Brake, Hydraulic Fan) - Main.......596

Relief Valve (Gear Pump).......597

Relief Valve (Main).......598

Rim Mounting.......599

Rollover Protective Structure (ROPS) Mounting.......601

Secondary Steering Pump and Electric Motor - Mounting.......604

Secondary Steering Pump and Electric Motor.......605

Service Brake Control.......606

Service Brake.......609

Shuttle Valve.......611

Solenoid Valve (Brake Accumulator Charge).......613

Solenoid Valve (Hoist Control).......615

Solenoid Valve (Hydraulic Fan Speed Control).......616

Solenoid Valve (Hydraulic Fan).......617

Speed Sensor (Wheel).......618

Steering Column.......619

Steering Control.......621

Steering Cylinder.......623

Suction Fan.......625

Suspension Cylinder (Front).......626

Tailgate.......628

Torque Converter.......632

Transmission Planetary.......635

Transmission and Hoist Control.......639

Truck Body Mounting.......643

Window Guard.......645

Window Wiper and Wiper Motor.......646

Wiring (Payload Sensor).......650

Wiring (Payload).......652

UENR4226 - Systems Operation (735C and 745C Articulated Trucks Machine Systems).......653

Automatic Retarder Control (ARC).......655

Brake Accumulator (Parking).......660

Brake Accumulator (Service).......661

Brake Control Valve (Service).......664

Differential (Center Axle).......668

Differential (Front and Rear Axle).......673

Electronic Control (Brake System).......676

Electronic Control (Fan Hydraulic System).......687

Electronic Control (HVAC System).......694

Electronic Control (Hydraulic System).......704

Electronic Control (Steering System).......713

Final Drive.......721

Gear Motor (Hydraulic Fan).......723

Gear Pump (Secondary Steering).......727

Gear Pump (Transmission).......729

Gear Pump - Air to Air After Cooler (ATAAC) Fan System.......732

General Information (Brake System).......734

General Information (Fan Hydraulic System).......737

General Information (HVAC System).......740

General Information (Hydraulic System).......742

General Information (Power Train System).......744

General Information (Steering System).......746

Graphic Color Codes.......748

HVAC System.......750

Hoist Control Valve.......754

Hoist System.......759

Hydraulic Tank.......768

Location of Components (Brake System).......770

Location of Components (Fan Hydraulic System).......771

Location of Components (HVAC System).......773

Location of Components (Hydraulic System).......774

Location of Components (Power Train System).......775

Location of Components (Steering System).......776

Main Control Valve - Combination Valve.......777

Metering Pump (HMU).......783

Modes of Operation (Brake System).......785

Modes of Operation (Fan Hydraulic System).......792

Modes of Operation (Steering System).......798

Oil Cooler (Transmission).......803

Oil Filter (Transmission).......805

Parking Brake.......807

Piston Pump (Brake).......809

Piston Pump (Brake, Hoist, Fan).......810

Piston Pump (Hydraulic Fan).......814

Piston Pump (Steering).......815

Piston Pump (Steering, Hoist).......816

Power Train Electronic Control System.......824

Power Train Hydraulic System.......836

Relief Valve (Transmission Hydraulic Control) - Electronic Main Relief Valve EMRV.......847

Secondary Steering System.......849

Service Brake.......854

Torque Converter.......856