Caterpillar Cat 745 Articulated Truck (Prefix 3T6) Service Repair Manual (3T600001 and up).pdf

Service Repair Manual
Models
745 Articulated Truck

Shutdown SIS
Previous Screen
Product: ARTICULATED TRUCK
Model: 745 ARTICULATED TRUCK 3T6
Configuration: 745 Articulated Truck 3T600001-UP (MACHINE) POWERED BY C18 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
i06262669
Front Suspension Frame - Remove and Install
SMCS - 7050-010-FR; 7200-010-FR
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
334-8414 Plate Assembly 1
5P-5264 Bolt1 1/2 in - 12 UNF 1
B
1P-2322 Combination Puller 1
5P-7377 Step Plate 1
C 1U-9745 Air/Hydraulic Jack Gp 2
D 386-6031 Lever Puller Hoist 2
Start By:
a. Remove the stabilizer rod for the front axle.
Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of
the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
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Approximate weights of the components are shown. Clean all surfaces
where parts are to be installed.
Illustration 1 g01327594
1. Disconnect grease hose assembly (1). Remove clip (2).
2. Remove bolts (3) in order to disconnect bracket (4). Repeat this Step for the opposite side.
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Typical example
3. Position suitable blocking under the front axle.
4. Use Tooling (C) and Tooling (D) in order to support front suspension frame (5) on both
sides. The weight of front suspension frame (5) is approximately 248 kg (545 lb).
5. Remove bolts (6) in order to disconnect bracket (7) and the axle from the front suspension
frame. Use two people in order to remove bracket (7). The weight of bracket (7) is
approximately 35 kg (76 lb).
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6. Remove bolts (8) in order to remove retaining collar (9).
7. Remove bolts (10) in order to remove washer (11).
8. Use Tooling (A) in order to apply force onto the tapered pin that locates the head of the
front suspension frame. Use a suitable hammer and strike the head of the front suspension
frame in order to release the frame from the tapered pin.
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9. Remove Tooling (A).
Typical example
10. Use Tooling (C) and Tooling (D) in order to remove front suspension frame (5). The weight
of front suspension frame (5) is approximately 248 kg (545 lb).
11. Remove bearing seal (12) from the tapered pin.
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12. Use Tooling (B) in order to remove spherical bearing (13) from front suspension frame (5).
Installation Procedure
Table 2
Required Tools
B
1P-2322 Combination Puller 1
5P-7377 Step Plate 1
C 1U-9745 Air/Hydraulic Jack Gp 2
D 386-6031 Lever Puller Hoist 1
E 1P-0502 Driver Group 1
F 7X-7699 Grease 1
H 439-3939 Link Bracket 2
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Typical example
1. Use Tooling (D), Tooling (H), and a suitable lifting device in order to turn over suspension
frame (5). The weight of suspension frame (5) is approximately 247 kg (545 lb).
2. Use Tooling (B) in order to install spherical bearing (13) into suspension frame (5).
Note: Ensure that the tapered sleeve that is on spherical bearing (13) is installed in the
correct orientation.
3. Do not prime the top cavity of spherical bearing (13).
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4. Ensure that the tapered pin is clean, dry, and free from grease. Ensure that there are no burrs
or damage to the tapered pin. Install bearing seal (12) onto the tapered pin facing the rear
right side of the machine
5. Use Tooling (D), Tooling (H), and a suitable lifting device in order to turn over suspension
frame (5). The weight of suspension frame (5) is approximately 247 kg (545 lb).
6. Use Tooling (C) and Tooling (D) in order to install front suspension frame (5).
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7. Position washer (11) onto the tapered pin and install bolts (10).
8. Tighten bolts (10) to a torque of 135 ± 25 N·m (100 ± 18 lb ft) by using equal increments.
Use a suitable hammer in order to strike washer (11). Do not strike the bearing or outer race
or frame. Tighten bolts (10) again to a torque of 135 ± 25 N·m (100 ± 18 lb ft). Repeat
tightening bolts (10) until no loss of torque is evident.
9. Prime the cavity in the center of retaining collar (9) with Tooling (F). Apply Tooling (G) to
the mating faces of retaining collar (9) and the suspension frame. Position retaining collar
(9) and install bolts (8).
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10. Use two people in order to position bracket (7). The weight of bracket (7) is approximately
35 kg (77 lb). Install bolts (6). Tighten bolts (6) to a torque of 800 ± 100 N·m
(590 ± 75 lb ft).
11. Install bolts (3) in order to connect bracket (4). Repeat this Step for the opposite side.
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12. Install clip (2). Connect grease hose assembly (1).
13. Remove the suitable blocking.
14. Recheck the torque of bolts (10) after road test.
End By:
a. Install the stabilizer rod for the front axle.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Jan 3 09:53:21 UTC+0800 2020
11/11
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Shutdown SIS
Previous Screen
Product: ARTICULATED TRUCK
Model: 745 ARTICULATED TRUCK 3T6
Configuration: 745 Articulated Truck 3T600001-UP (MACHINE) POWERED BY C18 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
i06233955
Front Suspension Cylinder - Remove and Install
SMCS - 7201-010-FR
Removal Procedure
Table 1
Required Tools
A
8S-7631 Tube 2
4C-6486 Stand 2
8S-7615 Pin 4
8S-7625 Collar 2
8S-7650 Cylinder 2
8S-7645 Hydraulic Jack Hose 1
350-7768
Electric Hydraulic Pump Gp
(115V)
1
350-7769
(230V)
1
B 439-3939 Link Bracket 1
C 6V-3160 Double Acting Cylinder 1
259-9239 Puller Stud 1
367-6742 Receiver Sleeve 1
6V-7742 Full Nut 2
8T-3282 Hard Washer 2
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350-7768
(115V)
1
350-7769
(230V)
1
D 136-1452 Retaining Ring Pliers 1
E FT-3204 Bearing Driver Kit 1
J 456-9452 Seal Support
K 456-9451 Seal Guide 1
L 456-9453 Seal Guide 1
M 456-9450 Driver 1
Start By:
a. Remove the fender.
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.
Ensure all pressure is relieved before removing a lock valve or
disassembling a cylinder.
Personal injury or death can result from sudden suspension cylinder
movement.
Sudden movement, up or down, can cause the clearance above your
head to change rapidly.
Read all warning labels on the suspension cylinders before servicing. Do
not check the oil in the suspension cylinder until all the nitrogen
pressure has been released.
Do not, under any condition, remove valves, cover or plugs from the
cylinder unless the rod is fully retracted and all the nitrogen pressure is
released.
2/17
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Do not stand under the machine when testing or adjusting the
suspension cylinders.
When the suspension is lowered clearances between the machine frames
and suspension components are reduced.
Persons on or near the machine could be injured by crushing.
Keep all personnel clear of the machine until the suspension has been
lowered.
When you are using hydraulic cylinders and puller studs, always ensure
that the rated capacity of the puller stud meets or exceeds the rated
capacity of the hydraulic cylinder. If the puller stud does not meet or
exceed the rated capacity of the hydraulic cylinder, a sudden failure of
the puller stud could occur. The sudden failure of the puller stud could
result in personal injury or death.
Note: The following procedure will remove one of the suspension cylinders. Repeat the procedure
for the opposite suspension cylinder, if necessary.
1. Lower the front suspension. Refer to Testing and Adjusting, "Suspension Cylinder (Front) -
Purge and Charge".
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2. Put identification marks on all lines, on all hoses and on all tubes for installation purposes.
Plug all lines, all hoses, and all tubes. Plugs help prevent fluid loss and contamination of the
oil system.
3. Install Tooling (A) under the front frame. Use the Tooling to raise the front frame. Do not
raise the front frame more than 50 mm (2 inch).
Typical example
4. Disconnect grease hose assembly (1) from washer (2).
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5. Remove bolt (3) and the washer. Remove bolt (4), the washers, the nut, and washer (2) from
suspension cylinder (5).
Note: Attach Tooling (C) to the nut side of pin (6).
6. Use Tooling (C) in order to extract pin (6) out of the machine frame and suspension cylinder
(5).
7. Install Tooling (B) and a suitable lifting device onto suspension cylinder (5). The weight of
suspension cylinder (5) is approximately 70 kg (154 lb). Move suspension cylinder (5) out
of the machine frame. Remove seal collar (8) and seals (7).
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8. Disconnect grease hose assembly (9) from special washer (11). Remove bolt (10), the
washers, the nut, and the special washer from suspension cylinder (5).
Note: Attach Tooling (C) to the nut side of pin (12).
9. Use Tooling (C) in order to extract pin (12) out of the front axle and the suspension
cylinder.
6/17
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Caterpillar Cat 745 Articulated Truck (Prefix 3T6) Service Repair Manual (3T600001 and up).pdf

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Caterpillar Cat 745 Articulated Truck (Prefix 3T6) Service Repair Manual (3T600001 and up).pdf