Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-18
Foreword
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
WARNING - This product can expose you to chemicals including ethylene glycol, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to:
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands after handling to avoid incidental ingestion.
WARNING - This product can expose you to chemicals including lead and lead compounds, which are known to the State of California to cause cancer, birth defects, or other reproductive harm. For more information go to:
www.P65Warnings.ca.gov
Wash hands after handling components that may contain lead.
Literature Information
s03548206
This manual should be stored in the operator's compartment in the literature holder or seat back literature storage area.
This manual contains safety information, operation instructions, transportation information, lubrication information, and maintenance information.
Some photographs or illustrations in this publication show details or attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication. Read, study, and keep this manual with the machine.
Whenever a question arises regarding your machine, or this publication, please consult your Cat dealer for the latest available information.
Safety
The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning signs and labels used on the machine.
Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance, and repair on this machine.
Operation
The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, machine controls, attachment controls, transportation, and towing information.
Photographs and illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the machine.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment care. The Maintenance Interval Schedule (MIS) lists the items to be maintained at a specific service interval. Items without specific intervals are listed under the "When Required" service interval. The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or "one safe source" for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if the calendar intervals
provide more convenient servicing schedules and approximate the indicated service hour meter reading. Perform the recommended service at the interval that occurs first.
Under severe, dusty, or wet operating conditions, more frequent lubrication than is specified in the maintenance intervals chart might be necessary.
Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily.
Certified Engine Maintenance
Proper maintenance and repair are essential to keep the engine and machine systems operating correctly. As the heavy-duty off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual.
It is prohibited for any person engaged in the business of repairing, servicing, selling, leasing, or trading engines or machines to remove, alter, or to render inoperative, any emission-related device or element of design installed on or in an engine or machine that is in compliance with all applicable regulations of the intended country to which it has been shipped. Certain elements of the machine and engine such as the exhaust system, fuel system, electrical system, intake air system, and cooling system may be emission-related and should not be altered unless approved by Caterpillar.
Machine Capacity
Additional attachments or modifications may exceed machine design capacity which can adversely affect performance characteristics. Included would be stability and system certifications such as brakes, steering, and rollover protective structures (ROPS). Contact your Cat dealer for further information.
Product Identification Number
Effective First Quarter 2001 the Product Identification Number (PIN) has changed from 8 to 17 characters. To provide uniform equipment identification, construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard. Non-road machine PINs are defined by ISO 10261. The new PIN format will apply to all machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the following:
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Illustration 1 g03891925
Where:
1. World Manufacturing Code (characters 1-3)
2. Machine Descriptor (characters 4-8)
3. Check Character (character 9)
4. Machine Indicator Section (MIS) or Product Sequence Number (characters 10-17). These were previously referred to as the Serial Number.
Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format.
Components such as engines, transmissions, axles, and work tools will continue to use an 8 character Serial Number (S/N).
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Thu Jul 11 22:33:40 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15
Date -01/03/2015 Date Updated -08/02/2017
Aftercooler Core - Inspect/Clean
SMCS - 1064-571
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
Illustration 1 g00792092
Raise the hood. Refer to Operation and Maintenance Manual, "Hood Control". Remove two bolts (1) from each side of grill (2). Remove grill (2) in order to access the aftercooler core.
i01524136
Illustration 2
Inspect the aftercooler core and clean the aftercooler core. You can use compressed air, high pressure water or steam to remove dust and other debris from the aftercooler core. However, the use of compressed air is preferred.
Install grill (2) and four bolts (1). Lower the hood.
Copyright 1993 - 2024 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15 Publication Date -01/03/2015 Date Updated -08/02/2017
i06933407
Automatic Lubrication Filler Filter - Clean - Autolube - If
Equipped
SMCS - 7540-070-HR
Illustration 1 g02494037
(1) Reservoir
(2) Dust Cap (3) Filler Tube Assembly
1. Remove dust cap (2) from reservoir (1).
2. Clean filler tube assembly (3) and the coupling on the filler tube assembly.
3. Remove filler tube assembly (3) and the coupling.
4. Remove the grease fitting from the filter and clean the filter.
5. Clean the filter with solvent and compressed air. Check the filter for cracks. If any cracks exist, replace the filter.
6. Replace the grease fitting in the filter.
7. Fill the filter with grease.
8. Install the filter.
9. Install the filter assembly onto filler tube assembly (3).
10. Install filler tube assembly (3) and dust cap (2).
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Thu Jul 11 22:23:23 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15 Publication Date -01/03/2015 Date Updated -08/02/2017 i05310889
Automatic Lubrication Grease Tank - Fill - If Equipped
SMCS - 7540-544-TNK
If the yellow LED on the signal lamp is illuminated, the minimum grease level in the reservoir has been reached.
1. Ensure that the filler hose is primed with grease in order to prevent air from being introduced in the grease reservoir.
1 g03331394
Illustration
2. Remove the dust cap from the coupling (1) for the filler. Carefully clean the coupling for the filler and the coupling on the filler hose. The coupler for the filler hose is supplied with each automatic lubrication system.
3. Connect the filler hose to coupling.
4. Fill the reservoir up mark (2) for the maximum level of grease that is indicated on the reservoir.
5. Disconnect the filler hose and refit the dust cap to coupling.
6. Place the filler hose back in the proper place in order to ensure that the coupling of the filler hose remains clean.
Every 500 service hours replace the filter or every 500 service hours clean the filter for the filler on the lubrication pump. The filter is behind the connector on the reservoir.
If the pumping action seems to go heavy, check the filter behind the coupling for the filler on the lubrication pump. Gently clean the filter or replace the filter. If the filter is damaged, the filter must be replaced.
If too much grease is pumped into the reservoir, the surplus grease will exit the vent at the side of the lubrication pump. Any air that is introduced during the filling procedure will also escape via this route.
Note: Due to the slow capability of a hand held grease gun, the use of a grease gun is not recommended in order to fill the reservoir.
Note: When you use high-pressure water or high-pressure air to clean the machine, do not spray directly onto the lubrication pump. Water or dirt may enter the lubrication pump through the deaerating openings.
Note: The automatic lubrication system reduces the time and effort that is taken in order to grease the machine significantly. However, do not neglect grease points that are not served by the automatic lubrication system.
Note: Check the conditions of the grease points that are served by the system. Sufficient fresh grease should be present.
Note: Refer to Systems Operation, RENR6739, "Testing and Adjusting" for information on locations of the grease metering units, the points of the grease metering units supply, part numbers, and volume of grease supplied by the grease metering units.
If a non-factory fit automatic lubrication system is installed, the system must meet or exheed the performance requirements detailed in Systems Operation, RENR6739, "Testing and Adjusting".
Periodic Inspections
Inspect each of the following:
• Grease level in the reservoir. Refill the reservoir on time.
• Signal lamp is functioning.
• Inspect the duty cycle that is indicated on the signal lamp is correct for the operating conditions.
• Lubrication pump for damage and leakage.
• Grease lines for damage and leakage.
• Conditions of the grease points that are served by the system. Sufficient fresh grease should be present.
• Operation of the system. Perform a cycle test. Refer to Systems Operation, RENR6739, "Testing and Adjusting".
• Clean lubrication pump and surrounding area.
Grease Recommendations
Refer to "Lubricant Viscosities". Copyright 1993 - 2024 Caterpillar Inc.
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15
Axle Breathers - Clean/Replace
SMCS - 3278-070-BRE; 3278-510-BRE
Park the machine on a level surface. Move the parking brake control to the ENGAGED position. Lower the body and shut off the engine. Block the wheels.
Install the Steering Frame Lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".
Illustration 1 g00781670
Front axle breather (1) is located on the front frame above the front axle.
i01951783
Illustration 2
g00633489
Center axle breather (2) is located in the manifold for the brake cooling oil. The manifold is located on the rear frame above the center axle.
Illustration 3
g00781678
Rear axle breather (3) is located on the right side of the rear frame above the rear axle.
Use the following procedure to clean the breathers.
Note: Before you remove the breathers, block the front frame of the machine.
1. Remove each breather.
2. Wash each breather in clean, nonflammable solvent.
3. Shake each breather and allow each breather to dry.
4. Install each breather.
If any of the axle breathers are damaged, replace the damaged breather.
Remove the Steering Frame Lock after all the axle breathers are installed. Refer to Operation and Maintenance Manual, "Steering Frame Lock".
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15
Publication Date -01/03/2015
Backup Alarm - Test
SMCS - 7406-081
The backup alarm is on the rear of the machine.
Date Updated -08/02/2017
i02305428
Turn the engine start switch to the ON position in order to perform the test.
Apply the service brakes. Move the transmission control lever to the REVERSE position.
The backup alarm should start to sound immediately. The backup alarm will continue to sound until the transmission control lever is moved to the NEUTRAL position or to the FORWARD position.
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Thu Jul 11 22:24:00 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15
Publication Date -01/03/2015 Date Updated -08/02/2017
Battery - Recycle
SMCS - 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following locations:
• A battery supplier
• An authorized battery collection facility
• Recycling facility
i06543763
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Thu Jul 11 22:24:12 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15
Battery or Battery Cable - Inspect/Replace
SMCS - 1401-510; 1402-510
i01951790
Inspect the condition of the cables to the batteries and inspect the condition of the batteries.
Note: When you replace the batteries, always use the same type of battery.
Use the following procedure in order to isolate the batteries if any repairs are necessary.
1. Turn the engine start switch to the OFF position. Turn all switches to the OFF position.
2. Turn the battery disconnect switch to the OFF position. Remove the key.
3. At the battery disconnect switch, disconnect the negative battery cable that is connected to the frame.
Note: Do not allow the disconnected battery cable to contact the disconnect switch.
4. Disconnect the negative battery cable from the terminals of the batteries.
5. Perform the necessary repairs. Replace the cables or the batteries, as needed.
6. Connect the negative battery cable to the terminals of the battery.
7. Connect the negative battery cable at the battery disconnect switch.
8. Install the key for the battery disconnect switch. Turn the key to the ON position.
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved.
Private Network For SIS Licensees. Thu Jul 11 22:24:24 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15
Belts - Inspect/Adjust/Replace
SMCS - 1357-040; 1357-510; 1357-025
The engine is equipped with a belt that drives the alternator and the air conditioner.
i02240445
Note: The engine is equipped with a belt tensioner that automatically adjusts the belt to the correct tension.
1. Park the machine on a level surface. Engage the parking brake. Shut off the engine.
2. Raise the hood. Refer to Operation and Maintenance Manual, "Hood Control".
3. Inspect drive belt (1). Check the belt for wear, fraying or cracking. If the belt is damaged, replace the belt.
Illustration 1
4. If belt (4) requires replacement, insert a square drive into the hole in tensioner (1) and turn clockwise in order to release the tension from the belt.
5. Remove the belt from the engine.
6. In order to Install a new belt, insert a square drive into the hole in tensioner (2) and turn clockwise.
7. Install belt (4) in the following order: drive pulley (2), pulley (3), alternator pulley (5) and tensioner (1).
8. Lower the hood. Refer to Operation and Maintenance Manual, "Hood Control". Copyright 1993 - 2024 Caterpillar Inc.
Rights Reserved.
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Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15
Date -01/03/2015 Date Updated -08/02/2017
Body Pivot Bearings - Lubricate
SMCS - 7258-086-BD; 7424-086
i01486572
Park the machine on a level surface. Ensure that the parking brake is fully engaged. Lower the dump body and stop the engine.
Illustration 1
g00772828
1. Remove the caps and wipe clean grease fittings (1) on the left side of the machine and on the right side of the machine.
2. Lubricate the body pivot bearings through the fittings on the left side of the machine and on the right side of the machine. One or two shots will be required at each fitting if lubrication is carried out at the recommended interval. Install the caps after lubricant has been applied.
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Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15
Brake Accumulator (Service) - Check
SMCS - 4263-535
-08/02/2017
i02253515
Personal injury or death can result from improper accumulator charging.
Dry Nitrogen is the only gas approved for use in the accumulator. Charging the accumulator with oxygen will cause an explosion. This danger will not happen if nitrogen cylinders with standard CGA (Compressed Gas Association, Inc.) Number 580 connections are used.
When ordering nitrogen gas, be sure that the cylinders are equipped with CGA Number 580 connections. Do not use color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders
Never use an adapter to connect your nitrogen charging group to a valve outlet used on both nitrogen, oxygen, or other gas cylinders. BE SURE YOU USE DRY NITROGEN (99.8% purity).
Refer to Systems Operation, Testing and Adjusting, "Brake Accumulator (Service) - Test and Charge" for more information.
Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Thu Jul 11 22:24:58 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK B1N
Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine
Operation and Maintenance Manual
735 and 740 Articulated Trucks
Media Number -SEBU7815-15
Brake Control Valve Damper Breather - Replace
SMCS - 4251-510-BRE; 4265-510-BRE
S/N - B1N1155-UP
S/N - B1P3884-UP
Personal injury can result from oil under high pressure.
DO NOT allow high pressure oil to contact skin.
Wear appropriate protective equipment while working with high pressure oil systems.
NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and mandates.
i03308961
Illustration 1
1. Lift the hood.
2. Remove the breather (1).
3. Replace the breather (1).
4. Lower the hood.
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