Caterpillar Cat 735B ARTICULATED TRUCK (Prefix L4D) Service Repair Manual (L4D00001 and up)

Service Repair Manual

Models

735B ARTICULATED TRUCK

735B Articulated Truck L4D00001-UP (MACHINE) POWERED BY C15 Engine(SE...

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Shutdown SIS Previous Screen Product: ARTICULATED TRUCK Model: 735B ARTICULATED TRUCK L4D Configuration: 735B Articulated Truck L4D00001-UP (MACHINE) POWERED BY C15 Engine

Disassembly and Assembly 735B, 740B and 740B EJECTOR Articulated Trucks Power Train Media Number -UENR0207-03

Publication Date -01/06/2015

Date Updated -08/05/2017

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Output Transfer Gears - Disassemble SMCS - 3159-015-OJ

Disassembly Procedure Table 1 Required Tools Tool

Part Number

Part Description

Qty

A

180-3033

Stand

1

B

138-7574

Link Bracket

2

C

1P-2420

Transmission Repair Stand

1

D

138-7575

Link Bracket

2

E

1P-2321

Combination Puller

1

F

1P-0520

Driver Gp

1

G

1P-2322

Combination Puller

1

H

8B-7554

Bearing Cup Puller

1

8B-7549

Puller Leg

2

5B-0637

High Idle Nut

1

5F-7353

Washer

1

1B-4207

Full Nut

2

3H-0465

Push-Puller Plate

4

5F-7366

Forcing Screw

1

5P-4808

Cap

2

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735B Articulated Truck L4D00001-UP (MACHINE) POWERED BY C15 Engine(SE...

1U-9895 I

Crossblock

1

Forcing Screw

3

J

1P-2320

Combination Puller

1

K

154-6181

Forcing Screw

3

Start By: A. Remove the output transfer gears.

Illustration 1

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1. Use Tooling (A) and suitable cribbing in order to support the output transfer gears.

Illustration 2

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2. Disconnect harness assembly (1) .

3. Remove lines and hoses (2) .

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Illustration 3

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4. Remove bolts (2a) and valve (2b) .

Illustration 4

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5. Remove hose assemblies (3) .

Illustration 5

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6. Remove bolts (4) and the washers in order to remove oil filler tube (5) . Remove bolt (6) , the washer, and the clip that secures dipstick tube (7) to the output transfer gears. Loosen the retaining nut and remove tube (7) .

Illustration 6

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7. Install Tooling (B) and a suitable lifting device onto the top of the output transfer gears. The weight of the output transfer gears is approximately 630 kg (1390 lb). Carefully lift the output transfer gears and remove Tooling (A) . Refer to step 1.

Illustration 7

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8. Use the suitable lifting device in order to place the output transfer gears on Tooling (C) .

Use suitable cribbing to support the output transfer gears.

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Illustration 8

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9. Remove bolt (8) , retainer (9) , yoke (10) and O-ring seal (11) .

Illustration 9

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10. Remove bolts (12) and the washers in order to remove retainer (13) from cage (14) .

Illustration 10

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11. Place retainer (13) on suitable cribbing before using a pin punch to remove lip seal (15) .

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Illustration 11

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g00822608

12. Remove O-ring seals (16) from cage (14) . Remove bolts (17) and the washers. Remove bolts (18) .

Note: Bolts (18) are used to blank two threaded holes in cage (14) . These threaded holes are used in the following step.

Illustration 12

g01174978

13. Attach a suitable lifting device and Tooling (D) to cage (14) . The weight of cage (14) is approximately 28 kg (62 lb). Install bolts (17) that were removed in Step 12 into the threaded holes in cage (14) . Use bolts (17) in order to force cage (14) away from housing (19) . Remove the cage.

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Illustration 13

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14. Remove shim pack (20) and O-ring seal (21) from cage (14) .

Illustration 14

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15. Place cage (14) on suitable cribbing before using a suitable punch in order to remove bearing cup (22) from the cage.

Illustration 15

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16. Remove sleeves (23) from housing (19) . Remove O-ring seals (24) from the sleeves.

Illustration 16

g02604998

17. Install yoke (10) , retainer (9) and bolt (8) . Tighten the bolt to a torque of 20 N·m (15 lb ft).

Note: Yoke (10) must be installed before planetary (25) is removed. If the yoke is not installed damage to the internal gears may result.

18. Attach a suitable lifting device and Tooling (D) to planetary (25) . The weight of planetary (25) is approximately 152 kg (335 lb). Remove planetary (25) .

Illustration 17

g00822683

19. Remove bolts (26) , the washers, Tooling D, and plate (27) from planetary (25) .

20. Use the suitable lifting device in order to turn planetary (25) onto the opposite side. The weight of planetary (25) is approximately 150 kg (331 lb).

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Illustration 18

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21. Place the planetary on suitable cribbing. Remove bolts (28) and the washers in order to remove housing (29) .

Note: A piston is installed into housing (29) . Make sure that the piston does not fall when the housing is removed.

Illustration 19

g01191429

22. Remove piston (30) from housing (29) . Remove ring seals (31) from the piston.

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Illustration 20

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23. Install two of the bolts (28) that were removed in Step 21 into the threaded holes in housing (29) . Use the bolts in order to force bearing cone (32) off housing (29) and remove the bearing cone.

Illustration 21

g01191443

24. Remove O-ring seal (35) , thrust washer (33) , and hub (34) .

Illustration 22

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25. Remove four discs (36) and three friction discs (37) .

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Illustration 23

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26. Remove spacer (38) .

Illustration 24

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Illustration 25

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27. Use a suitable pin punch in order to remove spring pin (40) into shaft (43) . Remove shaft (43) , planetary gear (39) , two thrust discs (41) , roller bearings (42) and spacer (44) .

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28. Repeat Step 27 in order to remove the remaining two planetary gears.

Illustration 26

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Illustration 27

g01191500

29. Use a suitable pin punch in order to drive spring pin (47) out of the carrier and into shaft (50) . Remove shaft (50) , planetary gear (45) , spacer (46) , thrust disc (48) , and two roller bearings (49) .

30. Repeat Step 29 in order to remove the remaining two planetary gears.

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Illustration 28

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31. Remove gear (51) and gear (52) from the carrier.

32. Turn the carrier onto the side.

Illustration 29

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Illustration 30

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33. Remove bolt (8) , retainer (9) and yoke (10) before sliding shaft (53) out of the carrier.

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Illustration 31

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34. Remove seal rings (54) from ring carrier (55) . Use a suitable pin punch in order to drive dowel (56) into the carrier.

Illustration 32

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35. Use Tooling (E) and Tooling (F) in order to remove ring carrier (55) from the carrier.

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Illustration 33

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36. Use Tooling (G) and Tooling (F) in order to remove bearing cone (57) from the carrier.

Illustration 34

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37. Remove shaft (58) and shaft (59) out of housing (19) .

Illustration 35

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38. Remove lip seal (60) from shaft (59) .

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Illustration 36

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39. Remove tube (61) , flared connector (62) and flared elbow (63) from housing (19) .

Illustration 37

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40. Remove bolt (64) , retainer (65) , O-ring seal (66) , and yoke (67) .

Illustration 38

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41. Remove bolts (68) and the washers from cage (70) . Remove two bolts (69) .

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Note: Bolts (69) are used to blank two threaded holes in cage (70) . These threaded holes are used in the following step.

Illustration 39

g00829503

42. Install two of the bolts (68) that were removed in Step 41 into the threaded holes in cage (70) . Use the bolts to force the cage away from housing (19) . Remove cage (70) and shim pack (71) .

Illustration 40

g00829551

43. Place cage (70) on suitable cribbing. Use a suitable punch in order to remove lip seal (72) from the cage. Remove O-ring seal (73) .

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735B Articulated Truck L4D00001-UP (MACHINE) POWERED BY C15 Engine(S...

Illustration 41

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44. Turn cage (70) onto the opposite side. Use a suitable punch in order to remove bearing cup (74) from the cage.

Illustration 42

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45. Remove gear (75) and shaft (76) out of housing (19) .

Illustration 43

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46. Slide shaft (76) out of gear (75) .

Illustration 44

g00829836

47. Place gear (75) on suitable cribbing. Use Tooling (E) and Tooling (F) in order to remove bearing cone (77) from the gear. Turn the gear onto the opposite side and use the same tools to remove the bearing cone.

Illustration 45

g00829838

48. Use Tooling (H) in order to remove bearing cup (78) out of housing (19) .

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Illustration 46

g00829851

49. Remove elbows (79) from housing (19) .

Illustration 47

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50. Use the following procedure to disassemble two elbows (79) : a. Loosen flared nut (80) in order to remove tube (81) from flared connector (82) . b. Remove the flared connector from elbow (79) . c. Remove O-ring seal (83) from the elbow.

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Illustration 48

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51. Remove bolts (84) and the washers from shaft (86) . Remove three bolts (85) .

Note: Bolts (85) are used to blank three threaded holes in shaft (86) . These threaded holes are used in the following step.

Illustration 49

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52. Install Tooling (K) into the three threaded holes in shaft (86) . Use Tooling (K) to force the shaft away from housing (19) . Remove the shaft and shim pack (87) .

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