Caterpillar cat 735 b articulated truck (prefix l4d) service repair manual (l4d00001 and up)

Service Repair Manual
Models
735B ARTICULATED TRUCK

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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
i05486620
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
1/39735B Articulated Truck L4D00001-UP (MACHINE) POWERED BY C15 Engine(SE...
2019/11/29https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

1U-9895 Crossblock 1
I 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 g02604597
1. Use Tooling (A) and suitable cribbing in order to support the output transfer gears.
2. Disconnect harness assembly (1) .
3. Remove lines and hoses (2) .

4. Remove bolts (2a) and valve (2b) .
5. Remove hose assemblies (3) .

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) .
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.
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.

9. Remove bolt (8) , retainer (9) , yoke (10) and O-ring seal (11) .
10. Remove bolts (12) and the washers in order to remove retainer (13) from cage (14) .
11. Place retainer (13) on suitable cribbing before using a pin punch to remove lip seal (15) .

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.
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.

14. Remove shim pack (20) and O-ring seal (21) from cage (14) .
15. Place cage (14) on suitable cribbing before using a suitable punch in order to remove
bearing cup (22) from the cage.

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

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

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.
24. Remove O-ring seal (35) , thrust washer (33) , and hub (34) .
25. Remove four discs (36) and three friction discs (37) .
10/39735B Articulated Truck L4D00001-UP (MACHINE) POWERED BY C15 Engine(S...

26. Remove spacer (38) .
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) .

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

31. Remove gear (51) and gear (52) from the carrier.
32. Turn the carrier onto the side.
33. Remove bolt (8) , retainer (9) and yoke (10) before sliding shaft (53) out of the carrier.

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

36. Use Tooling (G) and Tooling (F) in order to remove bearing cone (57) from the carrier.
37. Remove shaft (58) and shaft (59) out of housing (19) .
38. Remove lip seal (60) from shaft (59) .

39. Remove tube (61) , flared connector (62) and flared elbow (63) from housing (19) .
40. Remove bolt (64) , retainer (65) , O-ring seal (66) , and yoke (67) .
41. Remove bolts (68) and the washers from cage (70) . Remove two bolts (69) .

Note: Bolts (69) are used to blank two threaded holes in cage (70) . These threaded holes
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) .
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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44. Turn cage (70) onto the opposite side. Use a suitable punch in order to remove bearing cup
(74) from the cage.
45. Remove gear (75) and shaft (76) out of housing (19) .

46. Slide shaft (76) out of gear (75) .
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.
48. Use Tooling (H) in order to remove bearing cup (78) out of housing (19) .

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

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
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) .

Caterpillar cat 735 b articulated truck (prefix l4d) service repair manual (l4d00001 and up)

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