Caterpillar cat 735 articulated truck (prefix awr) service repair manual (awr00001 and up)

Service Repair Manual
Models
735 ARTICULATED TRUCK

Shutdown SIS
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Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK AWR
Configuration: 735 Articulated Truck AWR00001-UP (MACHINE) POWERED BY 3406E Engine
Disassembly and Assembly
735, 740 and 740 EJECTOR
Articulated Trucks Machine Systems
Media Number -RENR5140-09 Publication Date -01/05/2012 Date Updated -02/05/2012
i02399138
Piston Pump (Steering) - Assemble
SMCS - 5070-016-ZH
S/N - AWR1-UP
S/N - B1N1-UP
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1857 Retaining Ring Pliers 1
B 1P-1858 Retaining Ring Pliers 1
C 1P-0510 Driver Group 1
D 8T-5096 Dial Indicator Gp 1
E 9S-3263 Thread Lock Compound 1
Note: You must replace bearing cups and bearing cones together. Lubricate the bearing cups and
the bearing cones with clean lubricant in order to prevent the formation of rust.
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new Caterpillar parts for replacement.
Note: Apply a light film of 10W oil to all components before assembly.
1/12735 Articulated Truck AWR00001-UP (MACHINE) POWERED BY 3406E Engine(S...
2019/12/5https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

1. Check all of the O-ring seals and the components for wear or damage. Replace the
components, if necessary.
2. Lubricate all of the O-ring seals lightly with the lubricant that is being sealed.
Illustration 1 g01204839
3. Lower the temperature of bearing cup (58) in order to install bearing cup (58) into pump
housing (33) .
4. Use Tooling (C) to install lip seal (59) into pump housing (33). The side of lip seal (59) that
is equipped with the spring should be installed toward bearing cup (58) .
5. Invert pump housing (33) .
6. Use Tooling (A) in order to Install retaining ring (55) into pump housing (33) .
7. Install O-ring seal (56) onto pump housing (33).
8. Invert pump housing (33) and support the pump housing on suitable cribbing.

9. Raise the temperature of bearing cone (54) in order to install bearing cone (54) onto pump
shaft (53). Install bearing cone (54) and the pump shaft into pump housing (33) .
10. Use the following steps to determine the preload on the bearing of the pump assembly.
a. Install bearing cone (42) and adjustment spacer (48) on pump shaft (53) .

b. Lower the temperature of bearing cup (39) in order to install bearing cup (39) and
spacer (40) into break off plug (34). Install pin (41) into brake off plug (34) .
c. Apply Tooling (E) to the threads on piston guide (36) and plunger guide (38). Install
the piston guide and the plunger guide into break off plug (34) and tighten both
guides to a torque of 180 N·m (130 lb ft).
d. Position break off plug (34) onto pump housing (33). Install four socket head bolts
(35) but do not tighten at this point.
e. Use a feeler gauge to measure the distance between the break off plug and the pump
housing. Take measurements at three equal locations on the surface between the break
off plug and the pump housing.
f. The average of the three dimensions should be zero to 0.050 mm (0.0020 inch).
Adjustment spacer (48) must be replaced or ground to this dimension.
g. When the correct dimension is achieved tighten bolts (35) to 250 ± 40 N·m (185 ± 30
lb ft).
h. Invert the pump.

i. Use Tooling (D), a suitable screwdriver and a set of slip joint pliers to check the end
play on pump shaft (53). If end play exists on the shaft assembly, repeat Steps 10.a to
10.g until the correct dimension is reached.
j. Remove socket head bolts (35) and break off plug (34) from the pump housing (33).
Remove bearing (42) and adjustment spacer (48) from pump shaft (53) .
k. Proceed with the assembly of the piston pump.
11. Install bearing cups (57) into pump housing (33) .

Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
12. Install spring seat (65) and spring (64) into barrel (47), as shown.
13. Position barrel (47) in a suitable press, as shown. Use Tooling (C) and the press to compress
spring (64). Use Tooling (B) to install ring (63) .
14. Install pin (62) into barrel (47) .

15. Install plug (61) and O-ring seal (60) .
16. Install swashplate assembly (51) into pump housing (33) .

17. Install nine piston assemblies (50), retraction plate (49) and bearing (52) onto swashplate
assembly (51) .
18. Install barrel (47) and spacer (48) into pump housing (33) .
19. Raise the temperature of bearing cone (42) in order to install bearing cone (42) onto the
pump shaft.
20. Install valve plate (45) onto the barrel.
21. Position spring (44) and control piston (43) onto the swashplate assembly.
22. Install O-ring seal (46) onto pump housing (33) .

23. Install O-ring seals (37) onto break off plug (34) .
injury.
24. Position break off plug (34) on pump housing (33), as shown. Install socket head bolts (35).
Tighten the socket head bolts to a torque of 250 ± 40 N·m (185 ± 30 lb ft).

injury.
25. Install valve stem (28), spring retainer (29), spring (30), spring (31) and seat (32) into
pressure and flow compensator valve (2) .
26. Install adjustment screw (23), seal (21), adjustment nut (22), seal (24) and cap nut (25) into
plug (20) .
27. Install O-ring seal (19) onto plug (20). Install the plug into pressure and flow compensator
valve (2) .
28. Install seal (27) and plug (26) into pressure and flow compensator valve (2) .
10/12735 Articulated Truck AWR00001-UP (MACHINE) POWERED BY 3406E Engine...

injury.
29. Install valve stem (5), spring retainer (6), spring (7), spring (8), and seat (15) into pressure
and flow compensator valve (2) .
30. Install adjustment screw (18), seal (9), adjustment nut (10), seal (11) and cap nut (12) onto
plug (17) .
31. Install O-ring seal (16) onto plug (17). Install the plug into pressure and flow compensator
valve (2) .
32. Install seal (14) and plug (13) into pressure and flow compensator valve (2) .
33. Install three O-ring seals (4) onto pressure and flow compensator valve (2) .

34. Position pressure and flow compensator valve (2) on steering piston pump (1), as shown.
Install four socket head bolts (3) .
End By: Install the piston pump (steering). Refer to Disassembly and Assembly, "Piston Pump
(Steering) - Install".
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
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Thu Dec 5 01:02:33 UTC+0800 2019

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i01560288
Piston Pump (Steering) - Install
SMCS - 5070-012-ZH
S/N - AWR1-UP
S/N - B1N1-UP
Installation Procedure
1. Inspect all parts and clean all parts. If any parts are worn or damaged, use new Caterpillar
parts for replacement.
2. Replace the O-ring seal on the piston pump.
3. Attach a suitable nylon lifting sling to piston pump (1) and to a suitable lifting hoist. Lift the
piston pump into position on the machine. The weight of the pump is 54 kg (119 lb).

4. Align the splines on the shaft of the piston pump with the splines in the gear at the pump
drive housing. Slide the piston pump into position, before installing two bolts (14) and two
washers (15) that secure the piston pump to the machine.
5. Connect hose (10) to the piston pump. Install four bolts (11), four washers (12) and two half
clamps (13) in order to secure the hose to the pump.
6. Connect hose (5) to the piston pump. Install four bolts (7), four washers (8) and two half
clamps (9) in order to secure the hose to the pump. Connect hose (4) to tee (6). Connect
hose (2) to the other side of tee (6) and connect hose (3) to the pump.
End By:
a. Install the cab. Refer to Disassembly and Assembly, "Cab - Install".
b. Check the hydraulic oil level. Refer to Operation and Maintenance Manual, "Hoist, Steering
and Brake Systems Oil - Change".
Thu Dec 5 01:03:29 UTC+0800 2019

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i01556684
Gear Pump (Hoist) - Remove
SMCS - 5073-011; 5083-011
S/N - AWR1-UP
Removal Procedure
Start By:
A. Remove the cab. Refer to Disassembly and Assembly, "Cab - Remove".
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.
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, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Put identification marks on all lines, hoses, wires and tubes for installation purposes. Plug
all lines, hoses and tubes. This helps prevent fluid loss and contamination of the oil system.
2. Remove two bolts (1), two washers (2) and spacer (3) in order to disconnect the bracket for
electrical connector (4). Remove four bolts (5), four washers (6) and two half clamps (7) in
order to disconnect hose (8). Move the hose aside.

3. Remove bolt (9), washer (10) and spacer (11) in order to remove clamp (12). Remove the
remaining three bolts (14) and three washers (15) that secure two half clamps (16) to the
gear pump. Remove two half clamps (16) in order to disconnect hose (17). Move the hose
aside.
4. Attach a suitable nylon lifting sling around gear pump (13) and to a suitable hoist. Remove
two bolts (18) and washers (19) in order to remove the gear pump from the machine.
Remove the O-ring from the gear pump. The weight of the gear pump is 43.5 kg (96 lb).
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Thu Dec 5 01:04:24 UTC+0800 2019

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i02498680
Gear Pump (Hoist) - Disassemble
SMCS - 5073-015
Disassembly Procedure
Start By:
a. Remove the gear pump. Refer to Disassembly and Assembly, "Gear Pump (Hoist) -
Remove".

Caterpillar cat 735 articulated truck (prefix awr) service repair manual (awr00001 and up)

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