Caterpillar Cat 735 ARTICULATED TRUCK (Prefix 3T5) Service Repair Manual (3T500001 and up)

Service Repair Manual

Models

735 ARTICULATED TRUCK

735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

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Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i05351533

Flywheel Housing - Remove and Install SMCS - 1157-010

Removal Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

138-7574

Link Brackets

2

B

8C-8422

Sealant

-

Start By: A. Remove the flywheel.

B. Remove the crankshaft rear seal.

Illustration 1

g02175589

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1. If necessary, remove fuel filter base (1) and reposition fuel filter base (1). Remove bracket (2) .

Illustration 2

g01870417

2. If necessary, remove oil filter base (3) and reposition oil filter base (3). Remove bracket (4) .

Illustration 3

g01870418

3. Install Tooling (A) and a suitable lifting device to flywheel housing (6). The weight of flywheel housing (6) is approximately 64 kg (140 lb). Remove bolts (5) and flywheel housing (6) .

Installation Procedure 1. Install flywheel housing (6) in the reverse order of removal. a. Apply Tooling (B) to the backside of flywheel housing (6). Install within 10 minutes of application.

Mon Dec 2 22:50:40 UTC+0800 2019

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735 ARTICULATED TRUCK 3T5 Configuration: 735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine

Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i03542628

Vibration Damper and Pulley - Remove and Install SMCS - 1205-010

Removal Procedure Table 1 Required Tools Tool

Part Number

A

8T-0514

Part Description

Qty

Guide Stud

1

1. Remove the belt. Refer to Operation and Maintenance Manual, "Belt Inspect/Adjust/Replace".

Illustration 1

g01870577

2. Remove one of bolts (1). Install Tooling (A). Remove remaining bolts (1) and pulley assembly (2).

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

Illustration 2

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g01870580

3. Remove vibration damper (3).

Installation Procedure 1. Install vibration damper (3) and pulley assembly (2) in reverse order of removal.

Copyright 1993 - 2019 Caterpillar Inc.

Mon Dec 2 22:51:36 UTC+0800 2019

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735 ARTICULATED TRUCK 3T5 Configuration: 735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine

Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i03542724

Crankshaft Front Seal - Remove and Install SMCS - 1160-010

Removal Procedure Start By: a. Remove the vibration damper and the pulley.

Illustration 1

g01870637

1. Remove nuts (1) and crankshaft front seal (2).

Installation Procedure Note: Leave the shipping sleeve in place in order to install the crankshaft front seal. The crankshaft front seal must be installed dry.

1. Install crankshaft front seal (2) in reverse order of removal.

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

Illustration 2

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g01870695

a. Tighten nuts (1) in a numerical sequence.

Copyright 1993 - 2019 Caterpillar Inc.

Mon Dec 2 22:52:32 UTC+0800 2019

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735 ARTICULATED TRUCK 3T5 Configuration: 735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine

Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i05351534

Front Cover - Remove and Install SMCS - 1166-010

Removal Procedure Start By: A. Remove the accessory drive.

B. Remove the vibration damper and the pulley.

Illustration 1

g02851277

1. Remove bolts (2) and remove front support (1) .

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

Illustration 2

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g01872517

2. Remove bolts (4) and (5).

3. Remove studs (3), front cover (6), and the gasket.

Installation Procedure 1. Install front cover (6) in the reverse order of removal. a. Tighten bolts (2) to a torque of 105 ± 20 N·m (77 ± 14 lb ft).

Copyright 1993 - 2019 Caterpillar Inc.

Mon Dec 2 22:53:28 UTC+0800 2019

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735 ARTICULATED TRUCK 3T5 Configuration: 735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine

Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i03545506

Gear Group (Front) - Remove and Install SMCS - 1206-010

Removal Procedure Start By: a. Remove the front cover.

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

Illustration 1

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g01014874

1. Remove the following items from the front housing: bolt (3), the bearing and shaft (2) and gear (1).

2. Remove the following items from the front housing: bolt (6), the bearing and shaft (5) and gear (4).

Installation Procedure Note: Make sure that the timing marks on the gears are in alignment.

1. Install the gear group in reverse order of removal.

Copyright 1993 - 2019 Caterpillar Inc.

Mon Dec 2 22:54:24 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735 ARTICULATED TRUCK 3T5 Configuration: 735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine

Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i05016499

Housing (Front) - Remove and Install SMCS - 1151-010

Removal Procedure Table 1 Required Tools Tool

Part Number

A

-

Part Description

Qty

Loctite 5900

-

Start By: a. Remove the fuel transfer pump. b. Remove the engine oil pump. c. Remove the water pump. d. Remove the camshaft. e. Remove the front gear group. f. Remove the crankshaft position sensor.

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

Illustration 1

g01011130

1. Disconnect sensor (1).

2. Attach a suitable lifting device to the lifting bracket on the front of the engine. The weight of the engine is approximately 680 kg (1500 lb).

3. Remove front engine mount (4).

4. Loosen the oil pan bolts in order to allow the front of the oil pan to drop.

5. Remove bolts (2).

6. Remove front housing (3).

Installation Procedure 1. Install front housing (3) in reverse order of removal.

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a. Apply Tooling (A) in order to fill the space at the cylinder block, front housing (3), and the oil pan.

Copyright 1993 - 2019 Caterpillar Inc.

Mon Dec 2 22:55:19 UTC+0800 2019

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735 ARTICULATED TRUCK 3T5 Configuration: 735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine

Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i03600501

Accessory Drive - Remove and Install - Brackets and Pulleys SMCS - 1207-010

Removal Procedure Start By: a. Remove the alternator. b. Remove the refrigerant compressor.

Illustration 1

g01924915

1. Remove bolts (5) and bracket (4). Remove bolts (1), nuts (2), and plate assembly (3).

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

Illustration 2

2/2

g01924916

2. Remove nut (1) and the clip. Remove bolts (7) and support bracket (8).

Installation Procedure 1. Install the accessory drive in the reverse order of removal.

Copyright 1993 - 2019 Caterpillar Inc.

Mon Dec 2 22:56:15 UTC+0800 2019

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735 ARTICULATED TRUCK 3T5 Configuration: 735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine

Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i04524140

Fumes Disposal Filter - Remove and Install SMCS - 1317-010

Removal Procedure

Illustration 1

g01917115

1. Loosen hose clamps (1) and (4) . Remove clamp assembly (3) and fumes disposal filter (2) .

2. Remove bracket (5) .

Installation Procedure 1. Install fumes disposal filter (2) in reverse order of removal.

Copyright 1993 - 2019 Caterpillar Inc.

Mon Dec 2 22:57:11 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

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2019/12/2

735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735 ARTICULATED TRUCK 3T5 Configuration: 735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine

Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i03533021

Valve Mechanism Cover - Remove and Install SMCS - 1107-010

Removal Procedure

Illustration 1

g01861337

1. Remove bolts (2) and valve cover (1).

2. Remove isolation seal (3).

Installation Procedure

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

Illustration 2

2/2

g01861338

Tightening sequence for the valve cover.

1. Install valve cover (1) in reverse order of removal.

Copyright 1993 - 2019 Caterpillar Inc.

Mon Dec 2 22:58:07 UTC+0800 2019

All Rights Reserved.

Private Network For SIS Licensees.

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2019/12/2

735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735 ARTICULATED TRUCK 3T5 Configuration: 735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine

Disassembly and Assembly C13 Engine for Caterpillar Built Machines Media Number -UENR0131-06

Publication Date -01/05/2015

Date Updated -27/06/2018

i03533151

Valve Mechanism Cover Base - Remove and Install SMCS - 1120-010

Removal Procedure Start By: a. Remove the valve cover.

Illustration 1

g01861473

1. Disconnect harness assembly (1).

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735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...

Illustration 2

g01861475

2. Loosen hose clamp (4). Remove bolts (3) and remove breather (2).

Illustration 3

g01861477

3. Remove element (5).

Illustration 4

g01861478

4. Disconnect harness assemblies (6) and (8). Remove valve cover base (7).

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