2. Shutdown SIS
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Product: ARTICULATED TRUCK
Model: 745C ARTICULATED TRUCK TFK
Configuration: 745C Articulated Truck TFK00001-UP (MACHINE) POWERED BY C18 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
i07142939
Output Transfer Gears - Disassemble
SMCS - 3159-015-OJ
Disassembly Procedure
Table 1
Required Tooling
Tool Part Number Part Description Qty
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
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3. 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.
Illustration 1 g03842407
2. Position output transfer gears (1) on suitable cribbing. The weight of output transfer gears
(1) is approximately 363 kg (800 lb).
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4. Illustration 2 g06235277
3. Remove bolt (2), retainer plate (3), O-ring seal (4), and yoke (5). Remove wear seal (5a)
from yoke (5).
Illustration 3 g03842485
4. Remove bolt (6), washer (7), O-ring seal (7a), plate (8), O-ring seal (9), and yoke (10).
Remove wear seal (10a) from yoke (10). Remove lip seal (10b).
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5. Illustration 4 g03842503
5. Remove bolts (11), manifold (12), and gasket (12a).
Illustration 5 g03842515
(12) manifold
Note: Do not remove carrier (20) from manifold (12). Carrier (20) is shown only for
reference. Carrier (20) is not serviceable.
6. Remove plug (13) and O-ring seal (15). Remove plug (14) and O-ring seal (16).
7. Remove bolts (17), solenoid valve (18), and the O-ring seals. Remove check valve (19) and
the O-ring seals.
8. Remove seals rings (21) from carrier (20).
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7. 11. Remove clip (25a). Remove bolts (24). Use two people or a suitable lifting device to
remove cover (25). The weight of cover (25) is approximate 34 kg (75 lb). Remove the
gasket for cover (25).
Illustration 9 g03844527
12. Remove screws (28) from the underside of cover (25). Remove screw (28a). Remove tube
assembly (26) and O-ring seal (27). Remove P-clip (28b) from tube assembly (26).
Illustration 10 g03844528
13. Remove bearing cup (29), bearing cone (30), bearing cone (33), and bearing cup (35).
Remove O-ring seals (38a)
14. Remove lip seal (32). Remove bearing cup (38).
15. Remove plug (31) and O-ring seal (34). Remove setscrew (36) and setscrew (37).
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8. Illustration 11 g03845170
16. Remove transfer gear (39).
Illustration 12 g03845641
17. Use Tooling (A) to remove bearing cone (40) from transfer gear (39).
18. Use Tooling (B) bearing cone (41).
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10. Illustration 15 g03846519
Note: Do not remove carrier (49). Carrier (49) is shown only for reference. Carrier (49) is
not serviceable.
21. Remove shims (46) and bearing cup (50) from cage (44). Remove O-ring seal (48) and plug
(47) from carrier (49). Remove O-ring seals (51).
Illustration 16 g03846522
22. Remove bolt (56) and yoke (54). Remove O-ring seal (55) and O-ring seal (52). Remove
wear seal (53).
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11. Illustration 17 g03846881
23. Attach Tooling (F) and a suitable lifting device to threaded holes (58a) in differential group
(57). The weight of differential group (57) is approximately 133 kg (293 lb). Remove bolt
(58). Remove differential group (57).
Illustration 18 g03846900
24. Remove retainer plate (59). Remove shims (60). Remove bolts (61).
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12. Illustration 19 g03846960
25. Remove bearing cone (61). Remove clutch housing (62). Remove piston (63). Remove seal
ring (64) and ring seal (65).
Illustration 20 g03847099
Note: As you remove discs (66) and friction discs (67), take note of the order of discs (66)
and friction discs (67) for assembly purposes.
26. Remove discs (66) and friction discs (67). Remove spacer (68).
Illustration 21 g03847882
27. Remove hub assembly (70). Remove seal ring (69) and seal ring (71).
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13. Illustration 22 g03847883
28. Remove gear (72). The weight of gear (71) is approximately 23 kg (51 lb).
Illustration 23 g03847888
Illustration 24 g03862659
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14. 29. Place gear (72) in a suitable press. Use Tooling (D), Tooling (C), and a suitable press to
remove bearing cone (73) from gear (72).
30. Remove Tooling (C) and Tooling (D). Remove gear (72) from the suitable press.
Illustration 25 g03849151
31. Turn over gear (72). The weight of gear (72) is approximately 23 kg (51 lb).
32. Remove retaining ring (74), thrust washer (75), and bearing (76). Remove seal ring (77).
Illustration 26 g03849122
33. Remove thrust washer (78) from gear (72).
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15. Illustration 27 g03849124
34. Remove shaft assembly (79) from transfer gear (80). Use a suitable lifting device to turn
over transfer gear (80). The weight of transfer gear (80) is approximately 59 kg (130 lb).
Illustration 28 g03849125
35. Remove retaining ring (81).
36. Install Tooling (E) in ring gear (84). Evenly rotate Tooling (E) clockwise in order to move
spacer (82) and bearing cup (83) away from ring gear (84). As a unit, remove spacer (82)
and bearing cup (83) from transfer gear (80).
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16. Illustration 29 g03849126
37. Remove dowel (85). Use Tooling (E) to assist with the removal of ring gear (84).
Illustration 30 g03849127
38. Remove planet carrier (86) from transfer gear (80).
Illustration 31 g03850044
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18. Illustration 32 g03850045
39. Drive spring pin (87b) into planet carrier (86) in order to remove shaft assembly (87).
Remove planet gear (88) from planet carrier (86).
40. Remove thrust disc (89) and thrust disc (91). Remove roller bearings (90) from planet gear
(88). Repeat Step 39 and Step 40 for remaining planet gears (88).
Illustration 33 g03864344
41. Remove bearing cup (91a). Remove spacer (91b) from transfer gear (80).
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19. Illustration 34 g03850046
Note: Do not remove sleeve (92) unless you need to replace sleeve (92). Sleeve (92) will be
damaged during removal.
42. Inspect sleeve (92) for damage. If necessary, remove sleeve (92) from shaft assembly (79).
Remove bearing cone (93). Remove bearing race (94).
Illustration 35 g03850048
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20. Illustration 36 g03850050
Note: Plate (96) is not reusable. You will have to replace plate (96) with a new part.
43. Remove plugs (97a). Remove screws (95). Use a suitable hammer and a suitable punch to
remove plate (96). Remove roller bearing (97). Remove lip seal (98).
44. Remove bolts (99) and the washers. Remove cage assembly (100).
Illustration 37 g03852043
Note: Plate (102) is not reusable. You will have to replace plate (102) with a new part.
45. If necessary, remove screws (101) and plate (102). Remove seal ring carrier (103). Remove
seal ring (104). Remove O-ring seal (105).
Illustration 38 g03852045
46. Remove O-ring seal (107). Remove shims (106).
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21. Illustration 39 g03852201
47. Remove transfer gear (108). The weight of transfer gear (108) is approximately 68 kg
(150 lb).
Illustration 40 g03852205
48. Remove bearing cone (109) and bearing cone (110) from transfer gear (108).
Illustration 41 g03852500
Note: Plate (112) is not reusable. You will have to replace plate (112) with a new part.
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22. 49. If necessary, remove screws (111) and plate (112). Remove bearing cup (113). Remove lip
seal (114).
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