CAT + Caterpillar 745 Articulated Truck Operation & Maintenance Manual by Heavy Equipment Manual

Product:ARTICULATEDTRUCK

Model:745ARTICULATEDTRUCK3T6

Configuration:745ArticulatedTruck3T600001-UP(MACHINE)POWEREDBYC18Engine

OperationandMaintenanceManual

745ArticulatedTruck

MediaNumber-M0069236-02PublicationDate-01/06/2015DateUpdated-18/12/2017

Foreword

LiteratureInformation

s00037320

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machine.

Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthismachine.

Operation

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportationandtowinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingthemachine.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS)lists theitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsarelisted underthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhepage numberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance.Usethe MaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenanceprocedures.

MaintenanceIntervals

Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehourmeterintervalsiftheyprovidemoreconvenient servicingschedulesandapproximatetheindicatedservicehourmeterreading.Recommendedservice shouldalwaysbeperformedattheintervalthatoccursfirst.

Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthemaintenanceintervalschartmightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.

CaliforniaProposition65Warning

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhandsafter handling.

CertifiedEngineMaintenance

Propermaintenanceandrepairisessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavydutyoff-roaddieselengineowner,youareresponsiblefortheperformanceof therequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.

Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,orrenderinoperativeanyemissionrelateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewiththeregulations (40CFRPart89).Certainelementsofthemachineandenginesuchastheexhaustsystem,fuel system,electricalsystem,intakeairsystemandcoolingsystemmaybeemissionrelatedandshould notbealteredunlessapprovedbyCaterpillar.

MachineCapacity

Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcanadversely affectperformancecharacteristics.Includedwouldbestabilityandsystemcertificationssuchas brakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerforfurther information.

CatProductIdentificationNumber

EffectiveFirstQuarter2001theCatProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Inanefforttoprovideuniformequipmentidentification,Caterpillarandotherconstruction equipmentmanufacturersaremovingtocomplywiththelatestversionoftheproductidentification numberingstandard.Non-roadmachinePINsaredefinedbyISO10261.ThenewPINformatwill applytoallCatmachinesandgeneratorsets.ThePINplatesandframemarkingwilldisplaythe17 characterPIN.Thenewformatwilllooklikethefollowing:

2.MachineDescriptor(characters4-8)

3.CheckCharacter(character9)

4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.

MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPIN format.

Componentssuchasengines,transmissions,axles,etc.andworktoolswillcontinuetousean8 characterSerialNumber(S/N).

TueNov2310:54:58UTC+05302021

This is the sample of the manual if you need complete manual Click Here to download

Product:ARTICULATEDTRUCK

Model:745ARTICULATEDTRUCK3T6

Configuration:745ArticulatedTruck3T600001-UP(MACHINE)POWEREDBYC18Engine

OperationandMaintenanceManual

745ArticulatedTruck

MediaNumber-M0069236-02PublicationDate-01/06/2015DateUpdated-18/12/2017 i06017359

AftercoolerCore-Inspect/Clean

SMCS-1064-571

Personalinjurycanresultfromairpressure.

Personalinjurycanresultwithoutfollowingproperprocedure.When usingpressureair,wearaprotectivefaceshieldandprotectiveclothing.

Maximumairpressureatthenozzlemustbelessthan205kPa(30psi) forcleaningpurposes.

Illustration1g03486517

Illustration2g03777057

1.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"Prepare theMachineformaintenance".

2.Raisethehood.RefertoOperationandMaintenanceManual,"HoodControl".

3.Removefourboltsfromgrill(1).

4.Removegrillinordertoaccesstheaftercoolercore(2).

5.Theairconditionercondenser(3)ishingedandcanbeloweredbyremovingthetwobolts(4)to providebetteraccess.

Inspecttheaftercoolercoreandcleantheaftercoolercore.Youcanusecompressedair,highpressurewater,orsteamtoremovedustandotherdebrisfromtheaftercoolercore.However, theuseofcompressedairispreferred.

6.Raiseairconditionercondenser(3)andinstalltwobolts(4).

7.Installgrillandtightenfourbolts.Lowerthehood.

TueNov2311:02:04UTC+05302021

Product:ARTICULATEDTRUCK

Model:745ARTICULATEDTRUCK3T6

Configuration:745ArticulatedTruck3T600001-UP(MACHINE)POWEREDBYC18Engine

OperationandMaintenanceManual

745ArticulatedTruck

MediaNumber-M0069236-02PublicationDate-01/06/2015DateUpdated-18/12/2017

AirFilterElements-Clean/Replace

SMCS-1054-070;1054-510

PrimaryElement NOTICE

Servicetheaircleaneronlywiththeenginestopped.Enginedamage couldresult.

Servicetheprimaryairfilterelementunderthefollowingconditions:

i06982585

•Theindicatorfortheairfilterisilluminated.RefertoOperationandMaintenanceManual, "MonitoringSystem".

•Theprimaryairfilterelementhasbeeninservicefor1000hours. Parkthemachineonalevelsurface.Ensurethattheparkingbrakeisengagedandshutofftheengine.

1.Raisethehood.RefertotheOperationandMaintenanceManual,"HoodControl".

Illustration1g03490859

2.Releasethesixlatches(1)andremovetheaircleanercover(2).

3.Removeprimaryfilterelement(3)fromtheairfilterhousing(4).

4.Cleantheinsideoftheairfilterhousing.

5.Cleanthedustvalvesonthebottomfortheairfilterhousing.

6.Cleantheprimaryairfilterelementandinspecttheprimaryairfilterelement.

7.Installthecleanprimaryairfilterelement.Installthecoverfortheairfilterhousing.

8.Lowerthehood.

9.Starttheengine.Iftheindicatorfortheairfilterisilluminated,replacethesecondaryairfilter element.

Caterpillarrecommendscertifiedairfiltercleaningservicesavailable atparticipatingCaterpillardealers.TheCaterpillarcleaningprocess usesprovenprocedurestoassureconsistentqualityandsufficientfilter life.

Observethefollowingguidelinesifyouattempttocleanthefilter element:

Donottaporstrikethefilterelementinordertoremovedust.

Donotwashthefilterelement.

Uselowpressurecompressedairinordertoremovethedustfromthe filterelement.Airpressuremustnotexceed207kPa(30psi).Directthe airflowupthepleatsanddownthepleatsfromtheinsideofthefilter element.Takeextremecareinordertoavoiddamagetothepleats.

Donotuseairfilterswithdamagedpleats,gaskets,orseals.Dirt enteringtheenginewillcausedamagetoenginecomponents.

Aprimaryairfilterelementcanbeuseduptosixtimesiftheelementisproperlycleanedandthe elementisproperlyinspected.Whenaprimaryairfilterelementiscleaned,checkforripsortearsin thefiltermaterial.Theprimaryairfilterelementshouldbereplacedatleastonetimeperyear.This replacementshouldbeperformedregardlessofthenumberofcleanings.

Visuallyinspecttheprimaryairfilterelementbeforecleaning.Inspecttheairfilterelementfor damagetotheseal,thegaskets,andtheoutercover.

Therearetwocommonmethodsthatareusedtocleantheprimaryairfilterelement:

•Pressurizedair

•Vacuumcleaning

VacuumCleaning

Vacuumcleaningisanothermethodforcleaningtheprimaryairfilterelementwhichrequiresdaily cleaningbecauseofadry,dustyenvironment.Cleaningwithpressurizedairisrecommendedpriorto vacuumcleaning.Vacuumcleaningwillnotremovedepositsofcarbonandoil.

InspectingthePrimaryAirFilterElement

Inspecttheclean,dryprimaryairfilterelement.Usea60Wbluelightinadarkroomorinasimilar facility.Placethebluelightintheprimaryairfilterelement.Rotatetheprimaryairfilterelement. Inspecttheprimaryairfilterelementfortearsand/orholes.Inspecttheprimaryairfilterelementfor lightthatmayshowthroughthefiltermaterial.Ifitisnecessarytoconfirmtheresult,comparethe primaryairfilterelementtoanewprimaryairfilterelementthathasthesamepartnumber.

Donotuseaprimaryairfilterelementthathasanytearsand/orholesinthefiltermaterial.Donotuse aprimaryairfilterelementwithdamagedpleats,gaskets,orseals.Discardadamagedprimaryair filterelement.

SecondaryElement

NOTICE

Alwaysreplacethesecondaryelement.Donotattempttoreuseitby cleaning.Enginedamagecouldresult.

NOTICE

Servicetheaircleaneronlywiththeenginestopped.Enginedamage couldresult.

Replacethesecondaryairfilterelementunderthefollowingconditions.

•Theprimaryairfilterelementisservicedforthethirdtime.

•Theindicatorfortheairfilterisilluminatedaftertheprimaryairfilterelementhasbeen serviced.RefertoOperationandMaintenanceManual,"MonitoringSystem".

1.Parkthemachineonalevelsurface.Ensurethattheparkingbrakeisfullyengagedandshutoff theengine.

2.Raisethehood.RefertoOperationandMaintenanceManual,"HoodControl".

3.Removetheairfiltercoverandremovetheprimaryfilterelementfromtheairfilterhousing.

Illustration3g01903515 (1)Secondaryfilterelement

4.Removesecondaryfilterelement(1)andproperlydiscardthesecondaryelement.

5.Covertheairinletopening.Cleantheinsideoftheaircleanerhousing.

6.Uncovertheairinletopening.Installthenewsecondaryfilterelement.

7.Installtheprimaryfilterelementandinstalltheairfiltercover.

8.Lowerthehood.

TueNov2311:01:43UTC+05302021

Product:ARTICULATEDTRUCK

Model:745ARTICULATEDTRUCK3T6

Configuration:745ArticulatedTruck3T600001-UP(MACHINE)POWEREDBYC18Engine

OperationandMaintenanceManual

745ArticulatedTruck

MediaNumber-M0069236-02PublicationDate-01/06/2015DateUpdated-18/12/2017

ARDSparkPlug-Clean-IfEquipped

SMCS-1555-070

S/N-3T61-UP

NOTICE

IftheengineisrunningorthekeyisintheONpositiontheARDplug willcontinuetofire.TurnthekeytotheOFFpositionbeforeservicing theARDplug.

i05921782

Illustration1g03486537

LocationoftheARDsparkplug

1.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"Prepare theMachineformaintenance".

2.Stoptheengine.

3.Allowtheexhaustsystemtocoolbeforeperformingthisprocedure.

4.Raisethehood.RefertoOperationandMaintenanceManual,"HoodControl".

5.RemoveanydirtordebrisfromtheareaaroundARDsparkplug.

6.RemovesparkplugwirefromtheARDsparkplug.

7.UseadeepwellsocketandabreakerbartoloosentheARDsparkplug.Ifnecessary,seeyour Catdealerforthepartnumberofthesocket.Afterthesparkplughasbeenloosened,usethe sockettoremovethesparkplugbyhandinordertodetectproblemswiththethreads.

8.Afterremovingsparkplug,cleanthegroundprobeinsidetheARDcombustionheadbyrunning aplugborebrushthroughtheholeintheARDcombustionhead.Runthebrushthroughthe holeseveraltimes.

9.Carefullycleanthesparkplugusinganonmetalliccleaningpad.Iftheprobeappearstobebent, replacethesparkplug.Otherwise,installtheoriginalsparkplug.

Note:Thesparkplugmaybedamagedifthesparkplugisdropped.Donotinstallasparkplug thathasbeendropped.

NOTICE

Donotovertightenthesparkplug.Theshellcanbecrackedandthe gasketcanbedeformed.Themetalcandeformandthegasketcanbe damaged.Theshellcanbestretched.Thiswillloosenthesealthatis betweentheshellandtheinsulator,allowingcombustionpressureto blowpasttheseal.Seriousdamagetotheenginecanoccur.

Usethepropertorque.

10.InstallthesparkplugbyhanduntilthesparkplugcontactstheARD.Tightenthesparkplugto 43.4N·m(32lbft)to51.5N·m(38lbft).

11.Connectthesparkplugwire.

12.Lowerthehood.

TueNov2311:02:23UTC+05302021

Product:ARTICULATEDTRUCK

Model:745ARTICULATEDTRUCK3T6

Configuration:745ArticulatedTruck3T600001-UP(MACHINE)POWEREDBYC18Engine

OperationandMaintenanceManual

745ArticulatedTruck

MediaNumber-M0069236-02PublicationDate-01/06/2015DateUpdated-18/12/2017

SMCS-7540-070-HR

Illustration1g02494037

(1)Reservoir (2)DustCap (3)FillerTubeAssembly

1.Removedustcap(2)fromreservoir(1).

2.Cleanfillertubeassembly(3)andthecouplingonthefillertubeassembly.

3.Removefillertubeassembly(3)andthecoupling.

4.Removethegreasefittingfromthefilterandcleanthefilter.

5.Cleanthefilterwithsolventandcompressedair.Checkthefilterforcracks.Ifanycracksexist, replacethefilter.

6.Replacethegreasefittinginthefilter.

7.Fillthefilterwithgrease.

8.Installthefilter.

9.Installthefilterassemblyontofillertubeassembly(3).

10.Installfillertubeassembly(3)anddustcap(2).

TueNov2311:02:42UTC+05302021

Product:ARTICULATEDTRUCK

Model:745ARTICULATEDTRUCK3T6

Configuration:745ArticulatedTruck3T600001-UP(MACHINE)POWEREDBYC18Engine

OperationandMaintenanceManual

745ArticulatedTruck

MediaNumber-M0069236-02PublicationDate-01/06/2015DateUpdated-18/12/2017

i06693035

AutomaticLubricationGreaseTank-Fill-IfEquipped

SMCS-7540-544-TNK

Filltheautomaticlubricationgreasetank(reservoir)whenthemonitoringsystemindicatesthatthe minimumgreaselevelinthereservoirhasbeenreached.

1.Ensurethatthefillerhoseisprimedwithgreaseinordertopreventairfrombeingintroducedin thegreasereservoir.

2.Removethedustcapfromthecoupling(1)forthefiller.Carefullycleanthecouplingforthe fillerandthecouplingonthefillerhose.Thecouplerforthefillerhoseissuppliedwitheach Autolubesystem.

3.Connectthefillerhoseonthecouplingforthefiller.

4.Fillthereservoiruptomaximumlevel(2)thatisindicatedonthereservoir.

5.Disconnectthefillerhoseandfitthedustcap

6.Placethefillerhosebackintheproperplaceinordertoensurethatthecouplingofthefiller hoseremainsclean.

Note:Every500servicehoursreplacethefilterorevery500servicehourscleanthefilterforthe filleronthelubricationpump.Thefilterisbehindtheconnectoronthereservoir.

Note:Ifthepumpingactionseemstogoheavy,checkthefilterbehindthecouplingforthefilleron thelubricationpump.Gentlycleanthefilterorreplacethefilter.Ifthefilterisdamaged,thefilter mustbereplaced.

Note:Iftoomuchgreaseispumpedintothereservoir,thesurplusgreasewillexittheventattheside ofthelubricationpump.Anyairthatisintroducedduringthefillingprocedurewillalsoescapevia thisroute.

Note:Duetotheslowcapabilityofahandheldgreasegun,theuseofagreasegunisnot recommendedinordertofillthereservoir.

PeriodicChecks

•Checkthegreaselevelinthereservoir.Refillthereservoirontime.

•Checkthatthesignallampisfunctioning.

•Checkthatthedutycyclethatisindicatedonthesignallampiscorrectfortheoperating conditions.

•Checkthelubricationpumpfordamageandcheckthelubricationpumpforleakage.

•Checkthegreaselinesfordamageandcheckthegreaselinesforleakage.

•Checktheconditionsofthegreasepointsthatareservedbythesystem.Sufficientfreshgrease shouldbepresent.

•Checktheoperationofthesystem.Performacycletest.RefertoSystemOperation,Testingand Adjusting,RENR6739formoreinformation.

•Cleanthelubricationpumpandcleanthesurroundingsofthelubricationpump.

•Every500hoursreplacethefilterorevery500hourscleanthefilter.

Note:Whenyouusehigh-pressurewaterorhigh-pressureairtocleanthemachine,donotspray directlyontothelubricationpump.Waterordirtmayenterthelubricationpumpthroughthedearatingopenings.

Note:Theautomaticlubricationsystemreducesthetimeandeffortthatistakeninordertogreasethe machinesignificantly.However,donotneglectgreasepointsthatarenotservedbytheautomatic lubricationsystem.

GreaseRecommendations

GreaseshouldnotcontaingraphiteorPTFE.Usethecorrectgreaseintheautomaticlubrication system.

TheuseofapartiallyfluidgreasethatisabovethemaximumtemperaturethatisindicatedinTable1 isnotpermitted.Useofapartiallyfluidgreasethatisabovethemaximumindicatedtemperaturecan leadtothefollowing.

•Excessivecomponentwear

•Areductionintheefficiencyofthesystem

Table1

Minimumoperatingtemperature ofthesystem

Maximumoperatingtemperature ofthesystem

PrescribedNLGI Grade

80°C(176°F) 2

0°C(32°F) 0/1

80°C(176°F) SYNTHETIC2

0°C(32°F) SYNTHETIC0/1

TueNov2311:03:01UTC+05302021

Product:ARTICULATEDTRUCK

Model:745ARTICULATEDTRUCK3T6

Configuration:745ArticulatedTruck3T600001-UP(MACHINE)POWEREDBYC18Engine

OperationandMaintenanceManual

745ArticulatedTruck

MediaNumber-M0069236-02PublicationDate-01/06/2015DateUpdated-18/12/2017 i05990791

AxleBreathers-Clean/Replace

SMCS-3278-070-BRE;3278-510-BRE

1.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"Prepare theMachineforMaintenance".

2.Stoptheengine.

Illustration1g03751856

Illustration2g03751858

3.Removebreather(1)foreachaxle.

4.Washeachbreatherinclean,nonflammablesolvent.

5.Shakeeachbreatherandalloweachbreathertodry.

6.Installeachbreather.

Ifanyoftheaxlebreathersaredamaged,replacethedamagedbreather.

RemovetheSteeringFrameLockafteralltheaxlebreathersareinstalled.RefertoOperationand MaintenanceManual,"SteeringFrameLock".

TueNov2311:03:18UTC+05302021

Product:ARTICULATEDTRUCK

Model:745ARTICULATEDTRUCK3T6

Configuration:745ArticulatedTruck3T600001-UP(MACHINE)POWEREDBYC18Engine

OperationandMaintenanceManual

745ArticulatedTruck

MediaNumber-M0069236-02PublicationDate-01/06/2015DateUpdated-18/12/2017 i02305428

BackupAlarm-Test

SMCS-7406-081

Thebackupalarmisontherearofthemachine.

TurntheenginestartswitchtotheONpositioninordertoperformthetest.

Applytheservicebrakes.MovethetransmissioncontrollevertotheREVERSEposition.

Thebackupalarmshouldstarttosoundimmediately.Thebackupalarmwillcontinuetosounduntil thetransmissioncontrolleverismovedtotheNEUTRALpositionortotheFORWARDposition.

Product:ARTICULATEDTRUCK

Model:745ARTICULATEDTRUCK3T6

Configuration:745ArticulatedTruck3T600001-UP(MACHINE)POWEREDBYC18Engine

OperationandMaintenanceManual

745ArticulatedTruck

MediaNumber-M0069236-02PublicationDate-01/06/2015DateUpdated-18/12/2017 i06982591

BatteryorBatteryCable-Clean/Inspect/Replace

SMCS-1401-510;1401-040;1401-070;1402-040;1402-070;1402-510

Personalinjurymayoccurfromfailuretoproperlyservicethebatteries.

Batteriesgiveoffflammablefumesthatcanexplode.Electrolyteisan acidandcancausepersonalinjuryifitcontactstheskinoreyes.

Preventsparksnearthebatteries.Sparkscouldcausevaporstoexplode. Donotallowjumpercableendstocontacteachotherortheengine. Improperjumpercableconnectionscancauseanexplosion.

Alwayswearprotectiveglasseswhenworkingwithbatteries.

Inspecttheconditionofthecablestothebatteriesandinspecttheconditionofthebatteries.

Note:Whenyoureplacethebatteries,alwaysusethesametypeofbattery.

Usethefollowingprocedureinordertoisolatethebatteriesifanyrepairsarenecessary.

1.TurntheenginestartswitchtotheOFFposition.TurnallswitchestotheOFFposition.

2.TurnthebatterydisconnectswitchtotheOFFposition.Removethekey.

3.Atthebatterydisconnectswitch,disconnectthenegativebatterycablethatisconnectedtothe frame.

Note:Donotallowthedisconnectedbatterycabletocontactthedisconnectswitch.

4.Disconnectthenegativebatterycablefromtheterminalsofthebatteries.

5.Performthenecessaryrepairs.Replacethecablesorthebatteries,asneeded.

6.Connectthenegativebatterycabletotheterminalsofthebattery.

7.Connectthenegativebatterycableatthebatterydisconnectswitch.

8.Installthekeyforthebatterydisconnectswitch.TurnthekeytotheONposition.

RecycletheBattery

Alwaysrecycleabattery.Neverdiscardabattery.

Alwaysreturnusedbatteriestooneofthefollowinglocations:

•Abatterysupplier

•Anauthorizedbatterycollectionfacility

•Recyclingfacility

TueNov2311:03:49UTC+05302021

This is the sample of the manual if you need complete manual Click Here to download