Caterpillar ARTICULATED TRUCK 735C, 740C, 745C Repair Service Manuals
Complete service repair manuals for Caterpillar ARTICULATED TRUCK 735C (Prefix LFJ, TFJ, JE6, JE7), 740C (Prefix LFN, TFN), 745C (Prefix LFK, TFK, JE8, JE) with all the workshop service information to maintain, diagnostic, repair, rebuild.
Caterpillar ARTICULATED TRUCKS 735C, 740C, 745C Repair Service Manuals
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
Traction Control System - Automatic Traction Control System Operation.......860
Transfer Gear Lubrication System.......873
Transfer Gears - Output Transfer Gears (OTG).......876
Transmission Hydraulic Control.......879
Transmission Planetary.......883
UENR4226 - Testing and Adjusting (735C and 745C Articulated Trucks Machine Systems).......886
Brake Accumulator (Parking) - Test and Charge.......888
Brake Accumulator (Service) - Test and Charge.......894
Brake Line Pressure for Center and Rear Axle - Test.......898
Brake Line Pressure for Front Axle - Test.......903
Brake System Charging Pressure - Check.......908
Calibrations (Cat ET).......915
Cross Axle Differential Lock - Test.......920
Electric Drive Pump (Secondary Steering) - Check.......933
Fan Drive System - Test.......939
Gear Pump (Brake Cooling) - Test.......942
Hoist Control Valve - Test.......946
Hydraulic Oil Contamination - Test.......949
Interaxle Differential - Test - IAD Lock Pressure.......953
Machine Preparation for Testing and Adjusting.......960
Metering Pump (HMU) - Test.......965
Operational Checks.......969
Parking Brake Air - Purge.......973
Piston Pump (Brake, Hoist, Fan) - Test and Adjust.......974
Piston Pump (Steering, Hoist) - Test and Adjust.......986
Power Train Pressures.......1000
Pressure Reducing Valve (Hoist Pilot Pressure) - Test and Adjust.......1009
Pressure Tap Locations.......1012
Pump Flow - Test.......1016
Release Pressure for Parking Brake - Test.......1018
Relief Valve (Brake Oil Cooler) - Test.......1023
Relief Valve (Transmission Main) Pressure - Test - Electronic Main Relief Valve.......1028
Relief Valve (Transmission Main) Pressure Compensation - Reset - Bias File.......1041
Service Brake Air - Purge.......1046
Service Brake Wear Indicator (New Brake Disc) - Reset.......1049
Service Brake Wear Indicator - Check.......1053
Solenoid Valve (Parking Brake) - Test.......1059
Suspension Height (Front) - Check and Adjust.......1063
System Pressure - Release.......1084
Transmission Oil Supply.......1087
Visual Inspection.......1089
UENR4227 - Disassembly and Assembly (735C, 740C EJECTOR and 745C Articulated Trucks Power Train).......1092
Axle Shaft - Remove and Install.......1094
Center Axle - Remove and Install.......1103
Center Axle Yoke - Assemble.......1109
Center Axle Yoke - Disassemble.......1112
Center Axle Yoke - Remove and Install.......1116
Center Drive Shaft - Remove and Install.......1117
Differential and Bevel Gear (Center) - Assemble.......1120
Differential and Bevel Gear (Center) - Disassemble.......1144
Differential and Bevel Gear (Center) - Remove and Install.......1159
Differential and Bevel Gear (Front and Rear) - Assemble.......1162
Differential and Bevel Gear (Front and Rear) - Disassemble.......1182
Differential and Bevel Gear (Front and Rear) - Remove and Install.......1196
Front Axle - Remove and Install.......1199
Front Drive Shaft - Remove and Install.......1204
Gear Pump (Output Transfer Gear) - Assemble.......1207
Gear Pump (Output Transfer Gear) - Disassemble.......1212
Gear Pump (Output Transfer Gear) - Remove and Install.......1216
Gear Pump (Transmission Scavenge) - Remove and Install.......1218
Hitch Drive Shaft - Remove and Install.......1219
Hitch Drive Shaft Bearings - Install.......1222
Hitch Drive Shaft Bearings - Remove.......1227
Main Drive Shaft - Remove and Install.......1232
Output Transfer Gears - Assemble.......1236
Output Transfer Gears - Disassemble.......1265
Output Transfer Gears - Remove and Install.......1284
Parking Brake - Remove and Install.......1287
Rear Axle - Remove and Install.......1291
Rear Drive Shaft - Remove and Install.......1297
Solenoid Valve (Differential Lock) - Remove and Install.......1300
Speed Sensor (Transmission) - Remove and Install.......1306
Spindle, Service Brake, and Wheel - Assemble.......1309
Spindle, Service Brake, and Wheel - Disassemble.......1332
System Pressure - Release.......1342
Tire and Rim - Remove and Install.......1344
Torque Converter - Assemble.......1346
Torque Converter - Disassemble.......1355
Torque Converter - Install.......1362
Torque Converter - Remove.......1366
Transmission - Remove and Install.......1369
Transmission Hydraulic Control Valve - Remove and Install.......1378
Transmission Oil Filter - Remove and Install.......1383
Transmission Planetary - Assemble.......1385
Transmission Planetary - Disassemble.......1418
UENR4228 - Disassembly and Assembly (735C, 740C EJECTOR and 745C Articulated Trucks Machine Systems).......1448
Accelerator - Remove and Install.......1450
Air Conditioner and Heater - Remove and Install.......1452
Brake Accumulator (Parking) - Remove and Install.......1458
Brake Accumulator (Service) - Remove and Install.......1461
Brake Control Valve (Parking) - Remove and Install.......1464
Brake Control Valve (Service) - Remove and Install.......1467
Cab - Remove and Install.......1469
Cab Door - Remove and Install.......1477
Cab Tilt Cylinder - Remove and Install.......1479
Cab Tilt Pump - Remove and Install.......1481
Center Axle Stabilizer Rod - Remove and Install.......1483
Center Suspension Frame - Remove and Install.......1486
Control Valve (Hoist) - Remove and Install.......1491
Door Handle and Latch - Remove and Install.......1494
Equalizer Arm - Remove and Install.......1499
Fender - Remove and Install.......1504
Front Frame and Rear Frame - Connect.......1510
Front Frame and Rear Frame - Separate.......1516
Front Suspension Cylinder - Remove and Install.......1523
Front Suspension Frame - Remove and Install.......1539
Fuel Tank - Remove and Install.......1549
Gear Pump (Brake Cooling) - Assemble.......1553
Gear Pump (Brake Cooling) - Disassemble.......1560
Gear Pump (Hydraulic Fan) - Assemble.......1564
Gear Pump (Hydraulic Fan) - Disassemble.......1569
Gear Pump (Hydraulic Fan) - Remove and Install.......1574
Hoist Cylinder - Remove and Install.......1577
Hydraulic Tank (Brake, Hoist, Steering) - Remove and Install.......1581
Metering Pump (Steering) - Assemble.......1586
Metering Pump (Steering) - Disassemble.......1591
Metering Pump (Steering) - Remove and Install.......1595
Oil Cooler (Brake, Torque Converter) - Remove and Install.......1600
Oscillating Hitch - Remove and Install.......1604
Piston Pump (Brake, Fan, Hoist) - Assemble.......1612
Piston Pump (Brake, Fan, Hoist) - Disassemble.......1624
Piston Pump (Brake, Fan, Hoist) - Remove and Install.......1634
Piston Pump (Hoist, Steering) - Assemble.......1636
Piston Pump (Hoist, Steering) - Disassemble.......1648
Piston Pump (Hoist, Steering) - Remove and Install.......1658
Rear Axle Stabilizer Rod - Remove and Install.......1660
Rear Suspension Frame - Remove and Install.......1662
Seat - Remove and Install.......1667
Seat Support - Remove and Install.......1669
Secondary Steering Pump and Electric Motor - Assemble.......1671
Secondary Steering Pump and Electric Motor - Disassemble.......1678
Secondary Steering Pump and Electric Motor - Remove and Install.......1685
Sensor - Remove and Install - Payload.......1688
Steering Column - Assemble.......1693
Steering Column - Disassemble.......1698
Steering Column - Remove and Install.......1703
Steering Cylinder - Remove and Install.......1708
System Pressure - Release.......1719
Tailgate (Scissors) - Remove and Install.......1721
Truck Body - Remove and Install.......1727
Window Guard - Remove and Install.......1731
Window Wiper and Wiper Motor (Front) - Remove and Install.......1735
Window Wiper and Wiper Motor (Rear) - Remove and Install.......1738
Caterpillar ARTICULATED TRUCK 735C, 740C, 745C Repair Service Manuals
