cat 740 articulated dump truck parts manual

SEBP3136-34 December 2004 Parts Manual See “General Information” for New Parts Manual Features. 740 Articulated Truck AXM1-Up (Machine) BET200-Up (Engine) 4WY500-Up (Transmission) CJT1-Up (Torque Converter) A5L1-Up (Output Transfer Gear) BBJ1-Up (Output Transfer Gear) Powered By 3406E Engine This Parts Manual is also available in .PDF Format on Compact Disc(CD-ROM)-Caterpillar Form No. SERP3136-34

Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number: Dealer Information Name: Branch: Address: D e a l e r C o n t a c t P h o n e N u m b e r H o u r s Sales: Parts: Service:

Informations produit et concessionnaire Nota: Voir l’emplacement de la plaque signalétique du produit au chapitre “Informations produit” du guide d’utilisation et d’entretien. Date de livraison: Informations produit Modèle: Numéro d’identification produit: Numéro de série du moteur: Numéro de série de la boîte de vitesses: Numéro de série de l’alternateur: Numéros de série d’équipement: Informations sur l’équipement: Numéro matériel client: Numéro matériel concessionnaire: Informations concessionnaire Nom: Agence: Adresse: C o n t a c t c o n c e s s i o n n a i r e N u m é r o d e t é l é p h o n e H e u r e s Ventes: Pièces: Service:

Información del Producto/Distribuidor Nota: Para saber la ubicación de las placas de identificación del producto, ver la sección “Información sobre identificación del producto” en el Manual de Operación y Mantenimiento. Fecha de entrega: Información del producto Modelo: Número de identificación del producto: Número de serie del motor: Número de serie de la transmisión: Número de serie del generador: Números de serie de los accesorios: Información sobre los accesorios: Número del equipo del cliente: Número del equipo del distribuidor: Información del distribuidor Nombre: Sucursal: Dirección: C o m u n i c a c i ó n c o n e l d i s t r i b u i d o r N ú m e r o d e t e l é f o n o H o r a s Ventas: Piezas: Servicio:

Informações Sobre Produto e Revendedor Nota: Para localizações da placa de identificação do produto, consulte a seção, “Informações Sobre Identificação do Produto” no Manual de Operação e Manutenção. Data de Entrega: Informações Sobre o Produto Modelo: Número de Identificação do Produto: Número de Série do Motor: Número de Série da Transmissão: Número de Série do Gerador: Números de Série de Acessórios: Informações Sobre Acessórios: Número do Equipamento do Cliente: Número do Equipamento do Revendedor: Informações Sobre o Revendedor Nome: Filial: Endereço: C o n t a t o d o R e v e n d e d o r T e l e f o n e H o r a s Vendas: Peças: Serviço:

Produkt- und Händlerinformation Anmerkung: Für die Lage der Produkt-Identnummer und Seriennummern siehe Abschnitt “Produkt-Identinformation” im Betriebs- und Wartungshandbuch. Lieferdatum: Produkt-Identinformation Modell: Produkt-Identnummer: Seriennummer des Motors: Seriennummer des Getriebes: Seriennummer des Generators: Seriennummern der Arbeitsgeräte: Arbeitsgeräteinformation: Kundennummer: Händlernummer: Händlerinformation Name: Niederlassung: Adresse: K o n t a k t p e r s o n b e i m H ä n d l e r T e l e f o n D i e n s t s t u n d e n Verkauf: Ersatzteile: Service:

MEMORANDA MEMORANDA SEBP3136-34

TABLE OF CONTENTS Name Page Name Page GENERAL INFORMATION ......... ......... A24 SUPPLEMENTAL COOLANT ADDITIVES .............................. A43 MAINTENANCE PARTS ........... ........... A48 INDEX ...................................... A83 MACHINE ARRANGEMENT ......... ......... 1 GENERAL AR .............. .............. 1 INSTALLATION AR-MACHINE ....... ....... 1 ENGINE ARRANGEMENT ......... ......... 3 ENGINE AR-COMPLETE ......... ......... 3 ENGINE AR-CORE ............ ............ 7 BASIC ENGINE .............. .............. 9 ADAPTER GP-PUMP DRIVE ....... ....... 9 BASE GP-VALVE COVER & INJ HARN ... ... 10 BELT TENSIONER GP .......... .......... 11 CAMSHAFT GP ............. ............. 12 COVER GP-ACCESSORY DRIVE ..... ..... 13 COVER GP-CYLINDER BLOCK ...... ...... 14 COVER GP-FLYWHEEL HOUSING .... .... 17 COVER GP-FRONT HOUSING ...... ...... 18 COVER GP-VALVE MECHANISM ..... ..... 19 CRANKSHAFT GP ............ ............ 20 CYLINDER BLOCK GP .......... .......... 21 CYLINDER HEAD AS ........... ........... 32 CYLINDER HEAD GP .......... .......... 37 DAMPER GP ............................ 45 DRIVE GP-ACCESSORY ......... ......... 46 DRIVE GP-PUMP ............ ............ 48 ENGINE BRAKE GP ........... ........... 49 FASTENER GP-FRONT HOUSING .... .... 51 FLYWHEEL GP ............. ............. 54 GEAR GP-CAMSHAFT .......... .......... 55 GEAR GP-FRONT ............ ............ 56 GEAR GP-REAR .......................... 60 HOUSING GP-ENGINE BRAKE ...... ...... 64 HOUSING GP-FLYWHEEL ........ ........ 68 HOUSING GP-FRONT .......... .......... 70 LIFTING GP-ENGINE ........... ........... 72 MOUNTING GP-ALTERNATOR ...... ...... 74 MOUNTING GP-ENGINE ......... ......... 75 PAN GP-OIL .............................. 76 PISTON & ROD GP ........... ........... 77 PLUG GP-CYLINDER BLOCK ....... ....... 79 PLUG GP-CYLINDER HEAD ....... ....... 80 PULLEY GP-CRANKSHAFT ....... ....... 83 ROCKER ARM GP ............ ............ 84 SUPPORT GP-ENGINE .......... .......... 86 VALVE MECHANISM GP ......... ......... 87 LUBRICATION SYSTEM .......... .......... 88 FASTENER GP-OIL PUMP MOUNTING ............... ............... 88 FILTER GP-ENGINE OIL ......... ......... 89 FUMES DISPOSAL GP .......... .......... 92 GAUGE GP-OIL LEVEL (DIPSTICK) .... .... 93 LINES GP-ENGINE OIL .......... .......... 94 LINES GP-ENGINE OIL FILTER ...... ...... 95 LINES GP-TURBOCHARGER OIL ..... ..... 96 PUMP GP-ENGINE OIL .......... .......... 97 COOLING SYSTEM ............. ............. 98 COOLER GP-ENGINE OIL ........ ........ 98 COOLING AR ............................ 99 FAN GP-SUCTION ............ ............ 100 LINES GP-COOLANT ........... ........... 102 LINES GP-WATER ............ ............ 104 MOTOR & MTG GP-HYDRAULIC FAN ... ... 106 PUMP GP-WATER ............ ............ 107 RADIATOR GP .............. .............. 110 SHROUD GP-RADIATOR ......... ......... 118 TANK GP-COOLANT ........... ........... 120 AIR INLET AND EXHAUST SYSTEM .... .... 125 AFTERCOOLER GP-AIR ......... ......... 125 AIR CLEANER GP ............ ............ 131 ELBOW GP-EXHAUST .......... .......... 133 LINES GP-AIR ............................ 134 MANIFOLD GP-EXHAUST ........ ........ 138 MUFFLER GP .............. .............. 139 PIPE AR-EXHAUST ........... ........... 146 PIPE GP-EXHAUST ........... ........... 147 SHIELD GP-EXHAUST .......... .......... 150 SHIELD GP-MANIFOLD ......... ......... 152 TURBOCHARGER GP .......... .......... 153 FUEL SYSTEM ............... ............... 155 BASE GP-FUEL FILTER ......... ......... 155 CONTROL GP-GOVERNOR ....... ....... 157 FILTER GP-WATER SEP & FUEL ..... ..... 158 INJECTOR GP-FUEL ........... ........... 159 LINES GP-FUEL ............. ............. 160 PUMP & MTG GP-FUEL TRANSFER ... ... 171 PUMP GP-FUEL PRM & SEC FILTER ... ... 173 TANK & MTG GP-FUEL .......... .......... 174 TANK AR-FUEL ............. ............. 184 TANK GP-FUEL ............. ............. 185 VALVE GP-CHECK ........................ 191 VALVE GP-FUEL BYPASS ........ ........ 194 ELECTRICAL AND STARTING SYSTEM ... ... 195 ALARM GP ............... ............... 195 ALTERNATOR GP-CHARGING ...... ...... 196 BATTERY & WIRING GP ......... ......... 202 BLOCK GP-JUNCTION .......... .......... 208 SEBP3136-34 TABLE OF CONTENTS A1

TABLE OF CONTENTS Name Page Name Page CIRCUIT BREAKER GP ......... ......... 209 CONNECTION GP-ELECTRICAL ..... ..... 214 CONTROL & MTG GP-ENGINE ELEK ... ... 215 CONTROL & MTG GP-POWER TRAIN ... ... 219 CONTROL GP-ENGINE ELECTRONIC ... ... 221 CONTROL GP-UNPROGRAMMED .... .... 226 ELECTRONICS GP-MONITOR ...... ...... 228 ELECTRONICS GP-POWER TRAIN .... .... 228 LAMP GP-DOME ............. ............. 229 LAMP GP-FLOOD ............ ............ 230 LAMP GP-HEAD ............. ............. 232 LAMP GP-SIGNAL ............ ............ 234 MOTOR GP-ELECTRIC .......... .......... 239 PANEL GP-CIRCUIT BREAKER ...... ...... 240 SENSOR & MTG GP-PRESSURE ..... ..... 244 SENSOR GP-POSITION ......... ......... 245 SENSOR GP-PRESSURE ........ ........ 246 SENSOR GP-SPEED ........... ........... 250 SENSOR GP-TEMPERATURE ...... ...... 251 STARTING AID GP-ETHER ........ ........ 255 STARTING AR-COLD WEATHER ..... ..... 256 STARTING MOTOR GP-ELECTRIC .... .... 257 SWITCH GP-DISCONNECT ........ ........ 277 SWITCH GP-MAGNETIC ......... ......... 278 WARNING GP-BACKUP ......... ......... 281 WARNING GP-OPERATOR ........ ........ 287 WIRING GP-CAB ............. ............. 288 WIRING GP-ELECTRONIC CONTROL ... ... 299 WIRING GP-FRONT ........... ........... 301 WIRING GP-LIGHTING .......... .......... 308 WIRING GP-REAR ............ ............ 310 WIRING & LIGHTING GP ......... ......... 311 POWER TRAIN ............... ............... 315 ACTUATOR GP-ROTARY ......... ......... 315 AXLE & FRAME AR ........... ........... 317 AXLE AR-CENTER ............ ............ 318 AXLE AR-FRONT ............ ............ 318 AXLE AR-REAR ............. ............. 318 AXLE GP-CENTER ............ ............ 319 AXLE GP-FRONT ............ ............ 325 AXLE GP-REAR ............. ............. 333 BREATHER GP-POWER TRAIN ...... ...... 335 CARRIER GP-DIFFERENTIAL ...... ...... 340 CASE GP-TRANSMISSION ........ ........ 342 CONTROL GP-DIFFERENTIAL LOCK ... ... 346 CONTROL GP-TRANSMISSION HYD ... ... 356 COOLER GP-BRAKE & TORQUE CONV .................. .................. 363 COVER GP-TORQUE CONVERTER .... .... 365 DIFFERENTIAL & BEVEL GEAR GP .... .... 366 DIFFERENTIAL GP ........... ........... 371 DRIVE GP-PUMP ............ ............ 372 FILLER GP-POWER TRAIN OIL ...... ...... 376 FILTER GP-OIL ............. ............. 377 GAUGE GP-OIL LEVEL (DIPSTICK) .... .... 379 GEAR GP-OUTPUT TRANSFER ..... ..... 380 LINES GP-AXLE OIL COOLER ...... ...... 410 LINES GP-POWER TRAIN COOLER ... ... 420 LINES GP-TRANSMISSION OIL ...... ...... 421 MOUNTING GP-TRANSFER GEAR .... .... 424 MOUNTING GP-TRANSMISSION ..... ..... 425 PLANETARY GP-TRANSFER GEAR .... .... 426 PLANETARY GP-TRANSMISSION .... .... 428 POWER TRAIN AR ............ ............ 434 PUMP & MTG GP-TRANSFER GEAR ... ... 435 PUMP GP-GEAR ............. ............. 436 PUMP GP-TRANSMISSION ........ ........ 438 RIM GP-DEMOUNTABLE ......... ......... 439 SCREEN GP-MAGNETIC ......... ......... 441 SHAFT GP-DRIVE ............ ............ 442 SHAFT GP-FRONT DRIVE ........ ........ 443 SHAFT GP-HITCH DRIVE ........ ........ 444 SHAFT GP-REAR DRIVE ......... ......... 448 TIRE & RIM AR ............. ............. 449 TIRE & RIM GP ............. ............. 452 TORQUE CONVERTER GP ........ ........ 457 TRANSMISSION AR ........... ........... 460 UNIVERSAL JOINT GP .......... .......... 461 VALVE GP-CONTROL .......... .......... 466 VALVE GP-PRESSURE CONTROL .... .... 467 VALVE GP-SELECTOR & PRESS CONT .................................... 470 VALVE GP-SOLENOID .......... .......... 473 VALVE GP-SOLENOID & RELIEF ..... ..... 476 WHEEL & FINAL DRIVE GP ....... ....... 477 WHEEL & TIRE AR ............ ............ 479 WHEEL GP-FINAL DRIVE & BRAKE .... .... 480 FRAME AND BODY ............ ............ 486 BAFFLE GP-RADIATOR ......... ......... 486 BODY GP-TRUCK ........................ 488 BUMPER GP-FRONT ........... ........... 494 EXTENSION GP-FENDER ........ ........ 495 FENDER & SUPPORT GP ........ ........ 496 FRAME AR ............... ............... 499 FRAME GP-FRONT ........... ........... 500 FRAME GP-REAR ........................ 501 GUARD GP-BRAKE ........... ........... 503 GUARD GP-BRAKE LINES ........ ........ 504 GUARD GP-CRANKCASE ........ ........ 505 GUARD GP-HYDRAULIC TANK ...... ...... 506 GUARD GP-LINES ............ ............ 510 GUARD GP-MUD ............ ............ 512 GUARD GP-PLATFORM ......... ......... 513 GUARD GP-RADIATOR ......... ......... 517 HITCH GP-OSCILLATING ......... ......... 523 HOOD & GUARD AR ........... ........... 525 HOOD GP-ENGINE ........... ........... 526 LINER GP-BODY ............. ............. 535 A2 TABLE OF CONTENTS SEBP3136-34

TABLE OF CONTENTS Name Page Name Page LINES GP-GREASE ........... ........... 536 LINK GP-STEERING FRAME LOCK .... .... 542 LUBRICATION AR-AUTOMATIC ...... ...... 544 PIN GP-HITCH .............. .............. 545 STEP GP ................................ 546 STOP GP-STEERING .......... .......... 547 SUPPORT GP-HITCH LINES ....... ....... 548 SUPPRESSION AR-SOUND ....... ....... 550 TAILGATE AR ............................ 555 TAILGATE GP .............. .............. 556 TILT GP-HOOD ............. ............. 562 WALKWAY GP ............................ 565 BRAKING SYSTEM ............. ............. 566 ACCUMULATOR GP-BRAKE ....... ....... 566 ACCUMULATOR GP-HYDRAULIC ..... ..... 567 ACCUMULATOR GP-BRAKE ....... ....... 568 BRAKE GP-PARKING .......... .......... 575 BRAKE GP-SERVICE .......... .......... 577 CONTROL GP-PARKING BRAKE ..... ..... 583 CONTROL GP-SERVICE BRAKE ..... ..... 588 CORE GP-OIL COOLER ......... ......... 605 LINES GP-SERVICE BRAKE ....... ....... 606 PUMP & MTG GP-BRAKE ........ ........ 614 SLACK ADJUSTER GP .......... .......... 615 VALVE GP-BRAKE CONTROL ...... ...... 616 VALVE GP-SHUTTLE ........... ........... 617 VALVE GP-SOLENOID .......... .......... 618 STEERING SYSTEM ............ ............ 619 CONTROL GP-STEERING ........ ........ 619 CYLINDER & MTG GP-STEERING .... .... 620 CYLINDER GP-STEERING ........ ........ 623 LINES GP-PUMP ............. ............. 629 LINES GP-STEERING .......... .......... 635 PUMP & MOTOR GP-SEC STEERING ... ... 649 PUMP & MTG GP-SECONDARY STEER .................................. 650 PUMP & MTG GP-STEERING ....... ....... 651 PUMP GP-GEAR ............. ............. 653 PUMP GP-METERING .......... .......... 655 STEERING COLUMN GP- ADJUSTABLE .............. .............. 656 VALVE GP-CHK & PRESS REDUCING ... ... 658 VALVE GP-PRESSURE REDUCING .... .... 660 VALVE GP-STEER CHK & COMBINER ... ... 661 HYDRAULIC SYSTEM ........... ........... 662 ACTUATOR GP-PILOT CONTROL .... .... 662 CONTROL GP-HOIST .......... .......... 664 COOLER & MTG GP-HYDRAULIC OIL ... ... 666 COVER GP-TANK ............ ............ 667 CYLINDER & MTG GP-HOIST ...... ...... 669 CYLINDER & MTG GP-TAILGATE ..... ..... 671 CYLINDER GP-HOIST .......... .......... 672 CYLINDER GP-TAILGATE ........ ........ 673 HYDRAULIC AR-MACHINE ........ ........ 675 LINES GP-DRAIN ............ ............ 676 LINES GP-HOIST ............ ............ 677 LINES GP-HYDRAULIC FAN ....... ....... 680 LINES GP-PILOT ............. ............. 692 LINES GP-PRESSURE TEST ....... ....... 700 LINES GP-PUMP ............. ............. 702 LINES GP-RETURN ........... ........... 711 LINES GP-TAILGATE ...................... 717 MOTOR GP-GEAR ........................ 719 PUMP & MTG GP-HOIST ......... ......... 727 PUMP & MTG GP-HYDRAULIC ...... ...... 728 PUMP & MTG GP-HYDRAULIC FAN .... .... 729 PUMP GP-GEAR ............. ............. 730 PUMP GP-PISTON ............ ............ 733 ROTATING GP-PUMP .......... .......... 739 TANK & MTG GP-HYDRAULIC ...... ...... 741 TANK GP-HYDRAULIC .......... .......... 744 VALVE & MTG GP-HOIST CONTROL ... ... 754 VALVE & MTG GP-HYDRAULIC FAN ... ... 760 VALVE GP-CHECK ........................ 761 VALVE GP-COMBINATION ........ ........ 767 VALVE GP-COUNTERBALANCE ..... ..... 768 VALVE GP-DIVERTER .......... .......... 769 VALVE GP-HOIST CONTROL ....... ....... 771 VALVE GP-LOWERING CONTROL .... .... 775 VALVE GP-PRESSURE REDUCING .... .... 776 VALVE GP-PUMP CONTROL ....... ....... 777 VALVE GP-RELIEF ........................ 782 VALVE GP-SOLENOID .......... .......... 785 SUSPENSION SYSTEM ........... ........... 787 ACCUMULATOR & MTG GP-SUSP .... .... 787 ACCUMULATOR GP-SUSPENSION .... .... 789 CYLINDER & MTG GP-SUSPENSION ... ... 795 CYLINDER GP-SUSPENSION ...... ...... 797 FRAME GP-CENTER SUSPENSION ... ... 801 FRAME GP-FRONT SUSPENSION .... .... 803 FRAME GP-REAR SUSPENSION ..... ..... 805 LINES GP-SUSPENSION ......... ......... 807 SUSPENSION GP-REAR EQUALIZER ... ... 811 OPERATOR STATION ........... ........... 812 ADJUSTER GP-SEAT .......... .......... 812 AIR COMPRESSOR GP-SEAT ...... ...... 813 AIR CONDITIONER & MOUNTING GP ... ... 815 AIR CONDITIONER GP .......... .......... 819 ARMREST GP ............................ 829 CAB AR .................................. 832 COMPRESSOR GP-REFRIGERANT .... .... 834 CONDENSER & MTG GP- REFRIGERANT ............. ............. 836 CONDENSER GP-REFRIGERANT .... .... 837 CONTROL GP-MONITOR ......... ......... 838 SEBP3136-34 TABLE OF CONTENTS A3

cat 740 articulated dump truck parts manual

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