Service Repair Manual for 735C Articulated Truck

Service Repair Manual
Models
735C ARTICULATED TRUCK

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Product: ARTICULATED TRUCK
Model: 735C ARTICULATED TRUCK TFJ
Configuration: 735C Articulated Truck TFJ00001-UP (MACHINE) POWERED BY C15 Engine
Disassembly and Assembly
735C, 740C EJECTOR and 745C Articulated Trucks Power Train
Media Number -UENR4227-04 Publication Date -01/09/2015 Date Updated -02/07/2018
i06222650
Hitch Drive Shaft Bearings - Install
SMCS - 3253-012-BD
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0520 Driver Group 1
B 136-1452 Internal Tip Pliers 1
C 5P-0960 Grease Cartridge 1
D 5P-3931 Anti-Seize Compound 1
Note: The machine has the ability to split, ensure wheel chocks are in place.
Note: Cleanliness is an important factor. Before the installation procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
1/6735C Articulated Truck TFJ00001-UP (MACHINE) POWERED BY C15 Engine(SEB...
2019/12/9https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g00783742
1. Install O-ring seal (21) onto bearing carrier (8).
2. Use Tooling (A) in order to install new lip seal (20) into the bearing carrier (8). Fill in 1/3 of
the cavity bearing carrier (8) with Tooling (C) in order to lubricate lip seal (20).
View from the hitch area.
3. Position bearing carrier (8) onto the hitch tube. Install bolts (19) in order to connect bearing
carrier (8) to the hitch tube.

4. Raise the temperature of bearing (16) in order to install bearing (16) onto hitch drive shaft
(14). Turn over hitch drive shaft (14) and install retaining ring (15) that is used to secure
bearing (16) to bearing carrier (4) in step 6. Repeat the procedure in order to install the
bearing onto the opposite end of the hitch drive shaft (14).
5. Use Tooling (A) in order to install new lip seal (18) into bearing carrier (4). Fill in 1/3 of the
cavity bearing carrier (4) with Tooling (C) in order to lubricate lip seal (18).
6. Install O-ring seal (17) onto bearing carrier (4). Install hitch drive shaft (14) and roller
bearing (16) into bearing carrier (4). Use Tooling (B) in order to install retaining ring (15)
into bearing carrier (4).

7. Coat the splines at the end of hitch drive shaft (14) with grease. Install shaft yoke (13) and
the O-ring seal onto hitch drive shaft (14). Install bolt (11) and washer (12) in order to
secure shaft yoke (13) to the bearing carrier (4) and the hitch drive shaft (14).
Typical Example
View from the underside of the rear frame.
8. Use two people in order to install bearing carrier (4) and hitch drive shaft (14) to the hitch
tube. The weight of bearing carrier (4) and hitch drive shaft (14) is approximately 45 kg
(100 lb).
9. Install bolts (9) in order to secure bearing carrier (4) to the hitch tube.
Note: Ensure that the two remaining bolt holes in the bearing carrier are adjacent to each
other for installation of the locking plate in step 13.
10. Note the orientation of lip seal (10), and install lip seal (10) onto bearing housing (4).

11. Coat the splines at the end of hitch drive shaft (14) with grease. Install shaft yoke (7) and
the O-ring seal onto hitch drive shaft (14). Install bolt (5) and washer (6) in order to connect
the shaft yoke (7) to bearing carrier (8) and hitch drive shaft (14).
12. Apply Tooling (D) to the threads of thrust flange (3). Install thrust flange (3) onto bearing
carrier (4). Insert locking plate (2) and a suitable 3/4 inch breaker bar into the holes in thrust
flange (3) in order to tighten the thrust flange.
Note: For the correct setting procedure, refer to Operation and Maintenance Manual,
"Oscillating Hitch - Adjust".

13. Install the two dowels in locking plate (2) into the two holes in thrust flange (3). Install bolts
(1) in order to secure the locking plate to bearing carrier (4) and the thrust flange.
Note: After disassembly of the hitch drive shaft bearings, the adjustment of the oscillating hitch
should be checked after the subsequent 500 service hours have been completed. For further
information on the service intervals for the oscillating hitch, refer to the Operation and
Maintenance Manual, "Maintenance Interval Schedule".
End By:
a. Install the hitch drive shaft.
b. Install the center drive shaft.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Dec 9 20:16:37 UTC+0800 2019

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i06222655
Center Drive Shaft - Remove and Install
SMCS - 3253-010-CE
Removal Procedure
Table 1
Required Tools
A
8S-7610 Base 1
396-9840 Cylinder 1
350-7768 Electric Hydraulic Pump (115V) 1
350-7769 Electric Hydraulic Pump Gp (230V) 1
8S-7615 Pin 1
B 155-3597 Wheel Chock 2
C 1U-7505 Hydraulic Jack 1
Personal injury can result from driveline torque windup under load.
Unequal wheel speed can result in driveline torque windup which can
cause driveline components to be under load during disassembly.
Relieve the driveline torque windup before disassembly.

1. Install the steering frame lock.
2. Install Tooling (B) to stabilize the machine.
3. Use tool (A) in order to raise the front axle until one of the wheels clears the ground. This
will release the drive line torque windup in the drive train. Lower the front axle and remove
Tooling (A).

4. Secure Tooling (C) and suitable cribbing to center drive shaft (2). The weight of center
drive shaft (2) is approximately 90 kg (200 lb).
5. Remove bolts (1) in order to disconnect drive shaft (2) from the center axle.
6. Remove bolts (3) in order to disconnect center drive shaft (2) from the hitch drive shaft.
7. Remove bolts (4) in order to remove universal joint (5) from center drive shaft (2).

8. Remove bolts (6) in order to remove universal joint (7) from center drive shaft (2) .
1. Install center drive shaft (2) in the reverse order of removal.
a. Tighten bolts (6) and (4) to a torque of 117 ± 10 N·m (86 ± 7 lb ft).
b. Tighten bolts (1) and (3) to a torque of 117 ± 10 N·m (86 ± 7 lb ft).
Mon Dec 9 20:17:33 UTC+0800 2019

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i06224205
Rear Drive Shaft - Remove and Install
SMCS - 3253-010-RE
Removal Procedure
Table 1
Required Tools
A 1U-7505 Jack 1
B
8S-7610 Base 1
396-9840 Cylinder 1
350-7768 Electric Hydraulic Pump (115V) 1
350-7769 Electric Hydraulic Pump Gp (230V) 1
8S-7615 Pin 1
C 155-3597 Wheel Chock 2
Personal injury can result from driveline torque windup under load.
Unequal wheel speed can result in driveline torque windup which can
cause driveline components to be under load during disassembly.
Relieve the driveline torque windup before disassembly.

1. Install the steering frame lock.
2. Use Tooling (C) in order to stabilize the machine.
3. 3. Use Tooling (B) in order to raise the front axle until one of the wheels clears the ground.
This will release the drive line torque windup in the drive train. Lower the front axle and
remove Tooling (B).
4. Position Tooling (A) and suitable cribbing and secure rear drive shaft (1) to Tooling (A).

5. Remove bolts (2) in order to disconnect rear drive shaft (1) from the rear axle.
6. Remove bolts (3) in order to disconnect rear drive shaft (1) from the center axle.
7. Use Tooling (A) in order to remove rear drive shaft (1) from the machine. The weight of
rear drive shaft (1) is approximately 43 kg (95 lb).

8. Remove bolts (4) in order to remove universal joint (5) from rear drive shaft (1).
9. Remove bolts (6) in order to remove universal joint (7) from rear drive shaft (1).
1. Install rear drive shaft (1) in the reverse order of removal.
a. Tighten bolts (6) and (4) to a torque of 117 ± 10 N·m (86 ± 7 lb ft).
b. Tighten bolts (2) and (3) to a torque of 117 ± 10 N·m (86 ± 7 lb ft).
Mon Dec 9 20:18:28 UTC+0800 2019

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i06187336
Output Transfer Gears - Remove and Install
SMCS - 3159-010-OJ
Removal Procedure
Start By:
a. Install the steering frame lock.
b. Remove the radiator package.
c. Remove the main drive shaft.
d. Remove the front drive shaft.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat®
products.
Dispose of all fluids according to local regulations and mandates.
1. Drain the transfer gear oil into a suitable container. Refer to Operations and Maintenance
Manual, "Transfer Gear- Oil Change" for the correct procedure.

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2. Disconnect the hitch drive shaft. Refer to "Hitch Drive Shaft - R&I'' for the correct
procedure.
3. If equipped with rear exhaust group (1), use suitable cribbing and crib exhaust group (1) and
remove tube (2).
4. Disconnect hose assemblies (3) and (5). Disconnect harness assembly (4).

Note: Steering frame lock removed for photo purposes.
5. Attach a suitable lifting device to transfer gear (6). The weight of transfer gear (6) is
approximately 204 kg (450 lb).
6. Remove bolt (7) and the washer. Repeat for the opposite side.
7. Remove bolts (8) and the washers. Loosen bolts (9). Repeat for the opposite side.
8. Remove transfer gear (6). Remove top mount assemblies if necessary.
1. Install transfer gear (6) in the reverse order of removal.
Mon Dec 9 20:19:24 UTC+0800 2019

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i07142939
Output Transfer Gears - Disassemble
SMCS - 3159-015-OJ
Disassembly Procedure
Table 1
Required Tooling
A 1P-2322 Combination Puller 1
B
1H-3107 Push-Puller Tool Gp 1
5F-7343 Bearing Puller Gp 1
C 1P-0520 Driver Gp 1
D 8T-0644 Bolt(1)
3
E 6V-5696 Bolt 2
F 422-5473 Lifting Eye Assembly 2
(1)
Cut off the threaded ends of Bolts (D).
Start By:
a. Remove the output transfer gears.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers

before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat®
products.
Dispose of all fluids according to local regulations and mandates.
Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of
the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
Approximate weights of the components are shown. Clean all surfaces
where parts are to be installed.
Note: Exercise caution when you handle the case and the covers for the output transfer gears. The
case and the covers are aluminum, therefore more susceptible to damage during handling. Avoid
using lifting eyes, chains, and tooling, that directly contact the sealing surfaces.
1. Drain the oil from the output transfer gears into a suitable container.
2. Position output transfer gears (1) on suitable cribbing. The weight of output transfer gears
(1) is approximately 363 kg (800 lb).

Service Repair Manual for 735C Articulated Truck

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Service Repair Manual for 735C Articulated Truck