Caterpillar cat 745 c articulated truck (prefix tfk) service repair manual (tfk00001 and up)

Service Repair Manual
Models
745C Articulated Truck

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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
1/20745C Articulated Truck TFK00001-UP (MACHINE) POWERED BY C18 Engine(SE...
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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).

3. Remove bolt (2), retainer plate (3), O-ring seal (4), and yoke (5). Remove wear seal (5a)
from yoke (5).
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).

5. Remove bolts (11), manifold (12), and gasket (12a).
(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).

9. Remove bolts (22).
10. Remove retainer plate (22a) and shims (23).

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).
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).
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).

16. Remove transfer gear (39).
17. Use Tooling (A) to remove bearing cone (40) from transfer gear (39).
18. Use Tooling (B) bearing cone (41).

19. Remove screws (42) and shroud (43).
20. Remove bolts (45) and cage (44).

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).
22. Remove bolt (56) and yoke (54). Remove O-ring seal (55) and O-ring seal (52). Remove
wear seal (53).

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).
24. Remove retainer plate (59). Remove shims (60). Remove bolts (61).
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25. Remove bearing cone (61). Remove clutch housing (62). Remove piston (63). Remove seal
ring (64) and ring seal (65).
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).
27. Remove hub assembly (70). Remove seal ring (69) and seal ring (71).

28. Remove gear (72). The weight of gear (71) is approximately 23 kg (51 lb).

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.
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).
33. Remove thrust washer (78) from gear (72).

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).
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).

37. Remove dowel (85). Use Tooling (E) to assist with the removal of ring gear (84).
38. Remove planet carrier (86) from transfer gear (80).

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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).
41. Remove bearing cup (91a). Remove spacer (91b) from transfer gear (80).

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).

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).
45. If necessary, remove screws (101) and plate (102). Remove seal ring carrier (103). Remove
seal ring (104). Remove O-ring seal (105).
46. Remove O-ring seal (107). Remove shims (106).

47. Remove transfer gear (108). The weight of transfer gear (108) is approximately 68 kg
(150 lb).
48. Remove bearing cone (109) and bearing cone (110) from transfer gear (108).

49. If necessary, remove screws (111) and plate (112). Remove bearing cup (113). Remove lip
seal (114).
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Jan 1 19:49:54 UTC+0800 2020

Caterpillar cat 745 c articulated truck (prefix tfk) service repair manual (tfk00001 and up)

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