cat 740 Articulated truck operator and maintenance manual

SEBU7498-09 March 2004 Operation and Maintenance Manual 740 Articulated Truck AXM1-Up (Machine)

i01658146 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specifications including, but not limited to, phys- ical dimensions, type, strength and material. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death.

3 Table of Contents Table of Contents Foreword ................................................................. 4 Safety Section Safety Messages .................................................... 6 General Hazard Information ................................. 12 Crushing Prevention and Cutting Prevention ........ 14 Burn Prevention .................................................... 15 Fire Prevention and Explosion Prevention ............ 15 Fire Extinguisher Location .................................... 17 Tire Information ..................................................... 17 Electrical Storm Injury Prevention ......................... 18 Before Starting Engine .......................................... 18 Engine Starting ..................................................... 19 Before Operation .................................................. 19 Operation .............................................................. 19 Engine Stopping ................................................... 19 Parking .................................................................. 20 Equipment Lowering with Engine Stopped ........... 20 Sound Information and Vibration Information ....... 20 Operator Station ................................................... 20 Guards (Operator Protection) ............................... 20 Product Information Section General Information .............................................. 22 Identification Information ....................................... 23 Operation Section Before Operation .................................................. 25 Machine Operation ............................................... 27 Engine Starting ..................................................... 60 Parking .................................................................. 62 Transportation Information .................................... 68 Jacking Location Information ................................ 72 Towing Information ................................................ 73 Engine Starting (Alternate Methods) ..................... 76 Maintenance Section Tire Inflation Information ....................................... 79 Lubricant Viscosities and Refill Capacities ........... 81 Maintenance Support ............................................ 83 Maintenance Interval Schedule ............................ 84 Reference Information Section Reference Materials ............................................ 153 Index Section Index ................................................................... 155

4 Foreword Foreword Literature Information 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 Caterpillar 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 they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first. Under extremely 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. 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. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. Certified Engine Maintenance Proper maintenance and repair is 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.

5 Foreword It is prohibited for any person engaged in the business of repairing, servicing, selling, leasing, or trading engines or machines to remove, alter, or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations (40 CFR Part 89). 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 Caterpillar dealer for further information. Caterpillar Product Identification Number Effective First Quarter 2001 the Caterpillar Product Identification Number (PIN) will change from 8 to 17 characters. In an effort to provide uniform equipment identification, Caterpillar and other 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 Caterpillar machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the following: g00751314 Illustration 1 Where: 1. Caterpillar’s 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, etc. and work tools will continue to use an 8 character Serial Number (S/N).

6 Safety Section Safety Messages Safety Section i02088874 Safety Messages SMCS Code: 7000 There are several specific warning messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Please become familiarized with all warning messages. Make sure that all of the warning messages are legible. Clean the warning messages or replace the warning messages if you cannot read the words. Clean the warning messages or replace the warning messages if the illustrations are not legible. When you clean the warning messages, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the warning messages. Solvent, gasoline, or harsh chemicals could loosen the adhesive that secures the warning message. Loose adhesive will cause the warning message to fall off the machine. Replace any warning messages that are damaged, or missing. If a warning message is attached to a part that is replaced, install a warning message on the replacement part. Any Caterpillar dealer can provide new warning messages. g01065118 Illustration 2

7 Safety Section Safety Messages g01018972 Illustration 3 Do Not Operate (1) This warning message is located in the cab. g00920762 DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUALS. FAILURE TO FOLLOW THE INSTRUCTIONS OR HEED THE WARNINGS COULD RESULT IN IN- JURY OR DEATH. CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS. PROP- ER CARE IS YOUR RESPONSIBILITY.

8 Safety Section Safety Messages Proper Connections for Jump Start Cables (2) This warning message is located on the front of the hood on the left side of the machine. g00038786 Improper jumper cable connections can cause explosion resulting in personal injury. Batteries may be located in separate compart- ments. When using jumper cables, always connect positive (+) cable to positive (+) terminal of battery connected to starter solenoid and negative (−) cable from external source to starter negative (−) terminal (if machine not equipped with starter negative terminal, connect to engine block.) Follow procedure in the operation manual. No Clearance (3) This warning message is located on the fenders on both sides of the machine. g00939335 No clearance for person in this area when machine turns. Severe injury or death from crushing could occur. Connect steering frame lock between front and rear frames before lifting, transporting, or servicing machine in articulation area. Discon- nect lock and secure before resuming operation. High Compressed Spring (4) This warning message is located on the brake actuator. g00939032 Spring force can cause personal injury or death. Do not repair until you have read the Operation and Maintenance Manual.

9 Safety Section Safety Messages Body Prop (5) This warning message is located on both sides of the rear frame. g00939105 Install dump body prop before working under a raised dump body to prevent it from falling which could result in personal injury or death. High Pressure Cylinder (6) This warning message is located on the suspension accumulator. The accumulator is located under panels at each side of the cab. This warning message is located on machines with the following serial numbers: (S/N: AXM1-1182) g00939116 High Pressure Cylinder. Failure to read and follow these instructions can cause rapidly discharg- ing gas and/or hydraulic fluid which can result in death, personal injury and property damage. Suspension Cylinder Strut (7) This warning message is located on the suspension cylinder struts on both sides of the front of the machine. This warning message is located on machines with the following serial numbers: (S/N: AXM1183-UP) g01013110 High Pressure Cylinder. Truck will drop suddenly if not supported when pressure is relieved which can result in personal injury. Always support truck when relieving pressure. Do not remove any valve, hydraulic fitting, or valve core nor disassemble any cylinder parts until pressure is relieved. See service manual for correct procedure to relieve pressure and to charge cylinders.

10 Safety Section Safety Messages Engine Coolant (8) This warning message is located on the left side of the machine behind the operator compartment. g00782457 Pressurized system: Hot coolant can cause seri- ous burn. To open cap, stop engine, wait until ra- diator is cool. Then loosen cap slowly to relieve the pressure. Prop for the Cab (9) This warning message is located above the front left wheel. g00939174 Install cab prop pin before working under raised cab to prevent it from falling which could result in injury or death. Suspension System (10) This warning message is located on the fenders on both sides of the machine. g00939179 Suspension lines and cylinders contain fluid at high pressure. Personal injury or death by crushing can result from improper servicing procedures. The machine must be on hard, level ground with the frame blocked and pressure relieved. See service manual for correct procedure.

cat 740 Articulated truck operator and maintenance manual

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