Caterpillar cat 735 articulated truck (prefix 3 t5) service repair manual (3t500001 and up)

Service Repair Manual
Models
735 ARTICULATED TRUCK

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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
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
1/3735 Articulated Truck 3T500001-UP (MACHINE) POWERED BY C13 Engine(M009...
2019/12/2https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

1. If necessary, remove fuel filter base (1) and reposition fuel filter base (1). Remove bracket
(2) .
2. If necessary, remove oil filter base (3) and reposition oil filter base (3). Remove bracket
(4) .
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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i03542628
Vibration Damper and Pulley - Remove and Install
SMCS - 1205-010
Removal Procedure
Table 1
Required Tools
A 8T-0514 Guide Stud 1
1. Remove the belt. Refer to Operation and Maintenance Manual, "Belt -
Inspect/Adjust/Replace".
2. Remove one of bolts (1). Install Tooling (A). Remove remaining bolts (1) and pulley
assembly (2).

3. Remove vibration damper (3).
1. Install vibration damper (3) and pulley assembly (2) in reverse order of removal.
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Mon Dec 2 22:51:36 UTC+0800 2019

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i03542724
Crankshaft Front Seal - Remove and Install
SMCS - 1160-010
Removal Procedure
Start By:
a. Remove the vibration damper and the pulley.
1. Remove nuts (1) and crankshaft front seal (2).
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.

a. Tighten nuts (1) in a numerical sequence.
Mon Dec 2 22:52:32 UTC+0800 2019

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

2. Remove bolts (4) and (5).
3. Remove studs (3), front cover (6), and the gasket.
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).
Mon Dec 2 22:53:28 UTC+0800 2019

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i03545506
Gear Group (Front) - Remove and Install
SMCS - 1206-010
Removal Procedure
Start By:
a. Remove the front cover.

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).
Note: Make sure that the timing marks on the gears are in alignment.
1. Install the gear group in reverse order of removal.
Mon Dec 2 22:54:24 UTC+0800 2019

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i05016499
Housing (Front) - Remove and Install
SMCS - 1151-010
Removal Procedure
Table 1
Required Tools
A - 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.

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

a. Apply Tooling (A) in order to fill the space at the cylinder block, front housing (3),
and the oil pan.
Mon Dec 2 22:55:19 UTC+0800 2019

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

2. Remove nut (1) and the clip. Remove bolts (7) and support bracket (8).
1. Install the accessory drive in the reverse order of removal.
Mon Dec 2 22:56:15 UTC+0800 2019

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i04524140
Fumes Disposal Filter - Remove and Install
SMCS - 1317-010
Removal Procedure
1. Loosen hose clamps (1) and (4) . Remove clamp assembly (3) and fumes disposal filter (2) .
2. Remove bracket (5) .
1. Install fumes disposal filter (2) in reverse order of removal.
Mon Dec 2 22:57:11 UTC+0800 2019

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i03533021
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
Removal Procedure
1. Remove bolts (2) and valve cover (1).
2. Remove isolation seal (3).

Tightening sequence for the valve cover.
1. Install valve cover (1) in reverse order of removal.
Mon Dec 2 22:58:07 UTC+0800 2019

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i03533151
Valve Mechanism Cover Base - Remove and Install
SMCS - 1120-010
Removal Procedure
Start By:
a. Remove the valve cover.
1. Disconnect harness assembly (1).

2. Loosen hose clamp (4). Remove bolts (3) and remove breather (2).
3. Remove element (5).
4. Disconnect harness assemblies (6) and (8). Remove valve cover base (7).

Caterpillar cat 735 articulated truck (prefix 3 t5) service repair manual (3t500001 and up)

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Caterpillar cat 735 articulated truck (prefix 3 t5) service repair manual (3t500001 and up)