Caterpillar 735 740 745 Articulated Truck Workshop Repair Service Manual PDF - MCAT740GC745.zip

Full workshop service and repair documentation, complete with electrical wiring schematics, covering Caterpillar ARTICULATED TRUCKS 735 (SN Prefix 3F5, 3T5, AWR, B1N, WWC), 740 (SN Prefix AXM, B1P, DTX, WWD, 3F8, 3T8, 3F7, 3T7, AZZ, B1R), and 745 (Prefix 3F6, 3T6, JHW, JHX). Everything needed to service, troubleshoot, fix, and rebuild is included.

Caterpillar ARTICULATED TRUCKS 735, 740, 745 Repair and Service Guides

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: 2,212 pages

File Format: PDF

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

Language: English

M0116183 - Schematic (740 Ejector, 740 GC, and 745 Articulated Truck Electrical System, Cab 493-2550-03, Chassis, Engine and Enigne & Attachments 512-7237-01 Pump Electronics Tank Unit Header (if Equipped) 491-6343-01)....2

M72884 - Troubleshooting (740 GC and 740 EJECTOR & 745 Articulated Truck)....10

Alarm - Test....12

Axle Lock Clutch Accumulated Thermal Energy Is High....19

Backup Alarm Always Off....25

Backup Alarm Always On....29

Brake System....32

CAN Data Link - Test....36

Cat Data Link - Test....47

Charging System - Test....51

Condition Switch (Switch to Ground) - Test....52

Connector Contact Description....57

Connector Locations....67

Cross Axle Lock Speed Is Mismatched....68

Determining Diagnostic Trouble Codes....72

Diagnostic Capabilities....75

Diagnostic Trouble Codes....78

Differential and Final Drive....91

ECM - Configure....95

ECM - Replace....97

ECM Location Code - Test....99

ECM Software - Install....104

Electrical Connector - Inspect....106

Electrical Power Supply - Test....113

Emerging Symptom Information....120

Event Codes....121

General Information....138

Hoist System....142

Hydraulic Fan System....149

Indicator Lamp - Test....153

Interaxle Differential....156

Interaxle Lock Speed Is Mismatched....159

Interaxle Lock Supply Pressure Is High....162

Interaxle Lock Supply Pressure Is Low....165

Machine Preparation for Troubleshooting....168

Operational Checks (Hoist System)....172

Operational Checks (Power Train)....175

Operational Checks (Steering System)....177

Operator Control Switch (Switch to Ground) - Test....179

Relay - Test....189

Retarding System....197

Sensor Signal (Analog, Passive) - Test....204

Sensor Signal (PWM) - Test....214

Sensor Supply - Test....228

Service Tools....236

Solenoid Return - Test....238

Solenoid Valve - Test....244

Speed Sensor - Test....260

Starting System - Test....269

Steering System....273

Suspension System....284

Symptom Troubleshooting....286

System Power - Machine Wake Up....288

System Schematic....291

Torque Converter....295

Traction Control System....299

Transmission Clutch Slips....303

Transmission....318

Visual Inspection....333

Wiring Harness (Open Circuit) - Test....337

Wiring Harness (Short Circuit) - Test....338

M72942 - Specifications (745 and 740 GC & 740 EJECTOR Articulated Truck Systems)....339

Access Cover....344

Air Cleaner....346

Air Conditioner Lines....348

Air Conditioner and Mounting....350

Air Control Valve....351

Air Lines....352

Antenna....353

Battery and Wiring Group....355

Belt Guard....358

Brake Accumulator (Parking)....359

Brake Accumulator (Service)....362

Brake Control Valve (Parking)....363

Brake Control Valve (Service)....364

Cab Door....365

Cab Lighting....368

Cab Panel....372

Center Axle....373

Center Suspension Frame....377

Check Valve....378

Combination Valve....380

Communication Electronic Control Module (Product Link) - PL631e Satellite Radio....382

Communication Electronic Control Module (Product Link)....384

Coolant Lines....386

Coolant Tank....388

Coolant Temperature Sensor....391

Cooling Group....392

Diesel Exhaust Fluid Pump....394

Differential Lock Control....396

Differential and Bevel Gear - Front....397

Differential and Bevel Gear - Rear....399

Differential and Bevel Gear....401

Differential....404

Drain Line (Diesel Exhaust Fluid)....406

Drive Shaft - Center....407

Drive Shaft - Hitch....409

Drive Shaft....410

Electronic Control Module....411

Ether Starting Aid....415

Exhaust Lines....416

Exhaust Pipe....419

Fender Extension....425

Fender....426

Final Drive and Wheel....430

Flood Lamp - (24 Volt), (Suspended)....434

Flood Lamp....435

Front Axle....439

Front Drive Shaft....440

Front Suspension Frame....441

Fuel Filter Base....443

Fuel Lines....446

Fuel Tank - Fast Fill....447

Fuel Tank....449

Gear Motor (Aftercooler)....452

Gear Motor (Hydraulic Fan)....454

Gear Pump (Brake_Axle Oil Cooler)....456

Gear Pump (Pilot)....459

Gear Pump (Secondary Steering)....463

Gear Pump (Transmission)....464

Governor Pedal....467

Grease Lines....468

Heater and Air Conditioner Lines....474

Hitch Drive Shaft....476

Hoist Control Valve....477

Hoist Cylinder and Mounting....480

Hoist Cylinder....482

Hood Tilt Actuator....484

Hood....485

Hydraulic Fan Drive Lines....487

Hydraulic Tank....488

Lubrication Lines....491

Lubrication Pump - Mounting....495

Main Drive Shaft....496

Mud Guard....498

Oscillating Hitch....499

Output Transfer Gears....501

Parking Brake....502

Piston Pumps (Brake, Ejector, Steering, Fan)....505

Piston Pumps (Brake, Hoist, Steering, Fan)....507

Planetary Carrier (Output Transfer Gear)....509

Position Sensor (Throttle)....514

Pressure Reducing Valve (Differential Lock)....515

Pressure Reducing Valve (Hoist Pilot Oil)....516

Pressure Sensor - Heating, Ventilation, and Air Conditioning (HVAC)....517

Pressure Sensor - Service Brake Warning, Parking Brake Warning....518

Pressure Sensor....519

Pressure Switch (Filter Bypass) - Differential....521

Pressure Switch (Oil Filter Bypass)....522

Pressure Switch (Steering)....523

Pressure Switch - Oil Filter Bypass....524

Radiator - Shroud....525

Radiator Guard....527

Radiator....531

Rear Axle....533

Rear Drive Shaft....534

Rear Equalizer Suspension (Equalizer Arm)....535

Rear Suspension Frame....536

Rear View Mirror....537

Refrigerant Compressor....540

Relief Valve (Gear Pump)....542

Rim Mounting....543

Seat Mounting....545

Secondary Steering Pump and Electric Motor - Mounting....546

Secondary Steering Pump and Electric Motor....547

Service Brake Lines....548

Service Brake....549

Solenoid Valve (Hoist Control)....551

Solenoid Valve (Hydraulic Fan Speed Control)....552

Solenoid Valve (Hydraulic Fan)....553

Solenoid Valve - Park Brake Control, Brake Charge Control....554

Solenoid Valve....555

Speed Sensor (Wheel)....559

Steering Control Group....560

Steering Cylinder....563

Suction Fan....565

Suspension Cylinder (Front)....566

Tailgate....568

Temperature Sensor - Brake Cooling Oil and Hydraulic Tank....572

Toggle Switch (Ground Level Shutdown)....573

Torque Converter....574

Transmission Case....577

Transmission Control - Hydraulic....579

Transmission Oil Filter....583

Transmission Oil Lines....585

Transmission Planetary....586

Truck Body Mounting....589

Walkway - Auto-Lube....591

Walkway....592

Water Lines....593

Window Washer....594

Window Wiper - Rear....596

Window Wiper and Wiper Motor....598

Wiring (Payload Sensor)....600

Wiring (Payload)....602

M73366 - Systems Operation (740 GC & 745 Articulated Truck)....605

Automatic Retarder Control (ARC)....607

Brake Accumulator (Parking)....612

Brake Accumulator (Service)....613

Brake Control Valve (Service)....616

Differential (Center Axle)....620

Differential (Front and Rear Axle)....623

Electronic Control (Brake System)....625

Electronic Control (Fan Hydraulic System)....638

Electronic Control (HVAC System)....647

Electronic Control (Hydraulic System)....659

Electronic Control (Power Train System)....668

Electronic Control (Steering System)....679

Final Drive....687

Gear Motor (Hydraulic Fan)....689

Gear Pump (Secondary Steering)....693

Gear Pump (Transmission)....695

Gear Pump - Air to Air After Cooler (ATAAC) Fan System....698

General Information (Brake System)....700

General Information (Fan Hydraulic System)....703

General Information (HVAC System)....706

General Information (Hydraulic System)....708

General Information (Power Train System)....710

General Information (Steering System)....712

Graphic Color Codes....714

HVAC System....716

Hoist Control Valve....721

Hoist System....726

Hydraulic Tank....735

Location of Components (Brake System)....737

Location of Components (Fan Hydraulic System)....738

Location of Components (HVAC System)....739

Location of Components (Hydraulic System)....740

Location of Components (Power Train System)....741

Location of Components (Steering System)....742

Main Control Valve - Combination Valve....743

Metering Pump (HMU)....749

Modes of Operation (Brake System)....752

Modes of Operation (Fan Hydraulic System)....759

Modes of Operation (Steering System)....766

Oil Cooler (Transmission)....771

Oil Filter (Transmission)....773

Parking Brake....775

Piston Pump (Brake)....777

Piston Pump (Brake, Hoist, Fan)....778

Piston Pump (Hydraulic Fan)....782

Piston Pump (Steering)....783

Piston Pump (Steering, Hoist)....784

Power Train Hydraulic System....792

Relief Valve (Transmission Hydraulic Control) - Electronic Main Relief Valve EMRV....803

Secondary Steering System....805

Service Brakes....810

Torque Converter....812

Traction Control System - Automatic Traction Control System Operation....816

Transfer Gear Lubrication System....827

Transfer Gears - Output Transfer Gears (OTG)....830

Transmission Hydraulic Control....833

Transmission Planetary....837

M73366 - Testing and Adjusting (740 GC & 745 Articulated Truck)....840

Brake Accumulator (Parking) - Test and Charge....842

Brake Accumulator (Service) - Test and Charge....850

Brake Line Pressure for Center and Rear Axle - Test....857

Brake Line Pressure for Front Axle - Test....863

Brake System Charging Pressure - Test....869

Calibration Error Codes....875

Calibrations (Cat ET)....884

Cross Axle Differential Lock - Test....891

Cycle Counter - Reset....905

Electric Drive Pump (Secondary Steering) - Test....920

Fan Drive System - Test....927

Gear Pump (Brake Cooling) - Test....936

Hoist Control Valve - Test....940

Hydraulic Oil Contamination - Test....944

Interaxle Differential - Test....949

Machine Preparation for Testing and Adjusting....958

Metering Pump (HMU) - Check....963

Operational Checks....967

Parking Brake Air - Purge....972

Piston Pump (Brake, Hoist, Fan) - Test and Adjust....973

Piston Pump (Steering, Hoist) - Test and Adjust....986

Pressure Reducing Valve (Hoist Pilot Pressure) - Test and Adjust....1001

Pump Flow - Test....1007

Release Pressure for Parking Brake - Test....1011

Relief Valve (Brake Oil Cooler) - Test....1016

Relief Valve (Transmission Main) Pressure - Test....1021

Relief Valve (Transmission Main) Pressure Compensation - Reset - Bias File....1038

Service Brake Air - Purge....1043

Service Brake Wear Indicator (New Brake Disc) - Reset....1048

Service Brake Wear Indicator - Check and Adjust....1052

Solenoid Valve (Parking Brake) - Test....1058