Caterpillar Cat 740 Articulated Truck (Prefix 3F8) Service Repair Manual (3F800001 and up).pdf

Service Repair Manual
Models
740 Articulated Truck

Shutdown SIS
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Product: ARTICULATED TRUCK
Model: 740 GC ARTICULATED TRUCK 3F8
Configuration: 740 Articulated Truck 3F800001-UP (MACHINE) POWERED BY C15 Engine
Disassembly and Assembly
740 GC, 740 Ejector, 745 Articulated Truck Machine System
Media Number -M0082510-04 Publication Date -01/09/2015 Date Updated -23/08/2018
i06282774
Piston Pump (Hoist, Steering) - Assemble
SMCS - 5070-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1
C 8T-5096 Dial Indicator Gp 1
Note: Apply a light film of 10W oil to all components before assembly.
Illustration 1 g02726753
1. Install retaining ring (46) to pump housing (44).
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2. Use Tooling (A) in order to install lip seal (48) to the pump housing. The sealing lip of the
lip seal should face toward the bearing cup. The lip seal must seat against the retaining ring.
3. Lower the temperature of bearing cup (47). Use Tooling (A) in order to install bearing cup
(47) to pump housing (44). Install bearing cup (47) until the bearing cup seats.
4. Install brass bearings (45) into pump housing (44).
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5. Use the following steps to determine the preload on the bearings of the pump assembly.
a. Lower the temperature of shaft (35). Use a suitable press in order to install shaft (35)
into bearing cone (32). Install shaft (35) until bearing cone (32) is seated onto shaft
(35).
b. Install shaft (35) into pump housing (31).
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c. Install shim (30) and bearing cone (29) on shaft (35).
d. Lower the temperature of bearing cup (24). Use Tooling (A) and a suitable press in
order to install bearing cup (24) in pump head (21). Install the bearing cup until the
cup is seated.
e. Position pump head (21). Install bolts (20) but do not tighten bolts (20) at this time.
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f. Use a feeler gauge to measure the distance between the pump head and the pump
housing. Take measurements at three equal locations on the surface between the
pump head and the pump housing.
g. The average of the three dimension should be zero to 0.050 mm (0.0020 inch).
h. If the dimension is not correct remove shim (30). Refer to Illustration 7. To achieve
the correct dimension, grind the shim or replace shim (30).
i. When the correct dimension is achieved, tighten bolts (20) and then invert the pump
assembly.
j. Use Tooling (C), a suitable screwdriver, and a set of slip joint pliers to check the end
play on shaft (35). If end play exists on the shaft, repeat Step 5 until the correct
dimension is reached.
k. Remove bolts (20) and pump head (21). Remove bearing cone (29) and shim (30)
from shaft (35). Remove shaft (35).
6. Install pins (40) into barrel (38).
7. Install seat (43) in order to secure pins (40) in barrel (38).
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8. Position barrel (38) in a suitable press. Install spring (42) in barrel (38). Position retaining
ring (41) on top of the spring.
Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
9. Position Tooling (A) and the suitable press on top of the spring and inside of retaining ring
(41). Use Tooling (A) in order to depress the spring that is in barrel (38). Install retaining
ring (41) that secures the spring in barrel (38). Remove Tooling (A).
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10. Install collar bearing (39) to pins (40) and barrel (38).
11. Install pistons (37) to the original positions in retraction plate (36). Install pistons (37) and
retraction plate (36) to barrel (38). Pistons (38) must be installed to the original positions.
12. Position swashplate (33) to rotating group (34).
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13. Raise the temperature of bearing cone (32).
14. Install bearing cone (32) onto shaft (35).
15. Install shaft (35) and bearing cone (32) into swashplate (33) and rotating group (34).
16. Install pump housing (31) onto bearing cone (32), swashplate (33), and rotating group (34).
Turn the pump housing over 180 degrees and hold the components in the pump housing.
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17. Install shim (30).
18. Install piston (28) and bearing cone (29).
19. Install O-ring seal (25), spring (26), and piston (27).
20. Install O-ring seals (22) and port plate (23).
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
21. Install pump head (21) and bolts (20).
22. Install spool (18) and spool (19).
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Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
23. Install screw (16), retainer (17), spring (15), spring (14), O-ring seal (13), housing (12), nut
(11), and adjustment screw (10).
Personal injury can result from being struck by parts propelled by a
released spring force.
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Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
24. Install retainer (9), spring (8), spring (7), O-ring seal (6), housing (5), and adjustment screw
(4).
25. Install gasket (3).
26. Install valve (2) and bolts (1).
End By:
a. Install the piston pump.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Jan 16 23:04:23 UTC+0800 2020
12/12
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i06238300
Secondary Steering Pump and Electric Motor - Remove and
Install
SMCS - 4324-010
Removal Procedure
1. Turn the battery disconnect switch to the OFF position.
2. Remove cover (1).
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3. Disconnect hose assembly (2).
4. Remove cover (3).
5. Disconnect tube assembly (4) and hose assembly (5).
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6. Disconnect cables (6).
7. Attach a suitable lifting device to secondary steering pump and electric motor (8). The
weight of secondary steering pump and electric motor (8) is approximately 23 kg (50 lb).
8. Remove bolts (7) and secondary steering pump and electric motor (8).
Installation Procedure
1. Install secondary steering pump and electric motor (8) in the reverse order of removal.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Jan 16 23:05:19 UTC+0800 2020
3/3
2020/1/16

Shutdown SIS
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i07493571
Steering Cylinder - Remove and Install
SMCS - 4303-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Description Qty
A
8S-7620 Base 1
8S-7650 Cylinder 1
350-7768 Electric Hydraulic Pump Gp 115V 1
B
1U-7552 Hydraulic Cylinder 1
C 9X-8257 Washer 2
D 155-3597 Wheel Chock 4
Cylinders equipped with lock valves can remain pressurized for very
long periods of time, even with the hoses removed.
Failure to relieve pressure before removing a lock valve or
disassembling a cylinder can result in personal injury or death.
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Ensure all pressure is relieved before removing a lock valve or
disassembling a cylinder.
At operating temperature, the hydraulic tank is hot and under pressure.
Hot oil and components can cause personal injury. Do not allow hot oil
or components to contact skin.
Remove the filler cap only when the engine is stopped, and the filler cap
is cool enough to touch with your bare hand. Remove the filler cap
slowly in order to relieve pressure.
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, PERJ1017, "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.
1. Use Tooling (D) to chock the front and rear of the machine.
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2. If necessary, disconnect grease hose assembly (2). Remove bolt (3) and the washer. Set the
grease line bracket to the side. Remove washer (4).
3. Place Tooling (C) on the top of washer (4). Install bolt (3), the washer, and washer (4) back
into the rod end of steering cylinder (1).
4. Use Tooling (A) to exert a force onto pin (6). Strike mounting bracket (5) for steering cylinder
(1) to help release pin (6).
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Caterpillar Cat 740 Articulated Truck (Prefix 3F8) Service Repair Manual (3F800001 and up).pdf

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Caterpillar Cat 740 Articulated Truck (Prefix 3F8) Service Repair Manual (3F800001 and up).pdf