CAT + Caterpillar 735 Articulated Truck Service Repair Manual by Heavy Equipment Manual

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Product: ARTICULATED TRUCK

Model: 735 ARTICULATED TRUCK B1N

Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine

Disassembly and Assembly

C15 and C18 Engines for Caterpillar Built Machines

Media Number -RENR8261-31 Publication Date -01/08/2015 Date Updated -13/10/2020

Air Compressor - Remove and Install - If Equipped

SMCS - 1803-010

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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, PERJ1017, "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.

i07498912

Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.

1. Loosen the purge valves, and release the air pressure in the air tank.

Illustration 1

Typical example

g00620850

2. Disconnect coolant supply line (1) and air supply line (2) from the air compressor.

3. Disconnect oil supply line (3) from the air compressor.

Illustration 2

Typical example

g00620840

4. Remove coolant line (4) from the air compressor.

5. Remove nuts (5) that hold the air compressor to the accessory drive.

6. Remove the air compressor from the engine.

Illustration 3

Typical example

7. Remove seal (6) from the air compressor.

g00620856

Installation Procedure NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 4

Typical example

1. Install new seal (6) on the air compressor.

2. Install the air compressor on the engine.

g00620856

Illustration 5

Typical example

g00620840

3. Install nuts (5) to hold the air compressor on the engine.

4. Connect coolant line (4) to the air compressor.

Illustration 6

Typical example

g00620850

5. Connect coolant supply line (1) to the air compressor.

6. Connect air supply line (2) to the air compressor.

NOTICE

To prevent water from collecting and freezing in the air compressor lines, ensure that the air compressor lines are sloping downward and away from the air compressor.

7. Connect oil line (3) to the air compressor.

Product: ARTICULATED TRUCK

Model: 735 ARTICULATED TRUCK B1N

Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine

Disassembly and Assembly

C15 and C18 Engines for Caterpillar Built Machines

Media Number -RENR8261-31 Publication Date -01/08/2015 Date Updated -13/10/2020

Air Compressor Drive Gear - Remove and Install

SMCS - 1803-010-GE

Removal Procedure Table 1 Required Tools Tool Part Number Part

A 132-5451 Holding Fixture 1

Start By:

a. Remove the air compressor. Refer to Disassembly and Assembly, "Air CompressorRemove and Install".

i07498917

Illustration 1 g01148907

1. Install Tooling (A) on air compressor drive gear (1).

2. Remove nut (2).

3. Remove air compressor drive gear (1).

Installation Procedure

Table 2

Required Tools

Tool Part Number Part Description Qty

A 132-5451 Holding Fixture 1

Note: Caterpillar may use air compressors that have a tapered shaft or a straight shaft. The torque for the nut on the air compressor crankshaft is different for each type of crankshaft.

Note: Identify the manufacturer of the air compressor for your particular application.

Illustration 2 g01148907

1. Install air compressor drive gear (1) on the air compressor.

2. Install Tooling (A) on air compressor drive gear (1).

3. Install nut (2).

Tapered Shaft on Bendix Air Compressor

1. Tighten nut (2) to a torque of 160 ± 15 N·m (118 ± 11 lb ft).

2. Tap the gear axially with a soft faced hammer to seat the gear onto the tapered crankshaft.

3. Tighten the nut again to a torque of 160 ± 15 N·m (118 ± 11 lb ft).

Straight Shaft on Bendix Air Compressor

1. Tighten nut (2) to a torque of 460 ± 60 N·m (340 ± 44 lb ft).

Wabco 250 Air Compressor

1. Tighten nut (2) to a torque of 150 ± 5 N·m (111 ± 4 lb ft).

2. Place an index mark on the nut and rotate nut (2) an additional 60 ± 5 degrees.

End By:

a. Install the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".

Thu Jul 11 23:39:15 UTC+0530 2024

Product: ARTICULATED TRUCK

Model: 735 ARTICULATED TRUCK B1N

Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine

Disassembly and Assembly

C15 and C18 Engines for Caterpillar Built Machines

Media Number -RENR8261-31

Alternator - Remove and Install

SMCS - 1405-010

Removal Procedure

Personal injury can result from failure to disconnect the battery.

First, disconnect the negative battery cable. Then, disconnect the positive battery cable.

A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire.

1. Disconnect the batteries.

2. Remove the alternator belt.

3. Place identification marks on all of the harness assemblies.

-13/10/2020

i06791558

Illustration 1 g06116692

4. Disconnect the harness assemblies from terminal (4) and terminal (5).

5. Remove bolt (3) and the harness assembly from alternator (2).

6. Remove bolts (1). Remove alternator (2).

7. If necessary, remove nut (6) and remove the pulley from the alternator.

Installation Procedure

Illustration 2 g06116692

1. If necessary, install the pulley on alternator (2). Install nut (6). Tighten the nut to a torque of 127 ± 10 N·m (94 ± 7 lb ft).

2. Position alternator (2) on the alternator mounting bracket. Install bolts (1).

3. Connect the harness assembly to alternator (2) and install bolt (3). Tighten the bolt to a torque of 4.4 ± 1.0 N·m (39 ± 9 lb in).

4. Connect the harness assembly to terminal (5). Tighten the nut to a torque of 18 ± 2 N·m (13 ± 2 lb ft).

5. Connect the harness assembly to terminal (4).

6. Install the alternator belt.

7. Connect the batteries.

Product: ARTICULATED TRUCK

Model: 735 ARTICULATED TRUCK B1N

Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine

Disassembly and Assembly

C15 and C18 Engines for Caterpillar Built Machines

Media Number -RENR8261-31

Publication Date -01/08/2015

Date Updated -13/10/2020

Atmospheric Pressure Sensor - Remove and Install

SMCS - 1923-010 NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01116929 (1) Atmospheric pressure sensor ... 10 ± 2 N·m (89 ± 18 lb in)

i02212192

Product: ARTICULATED TRUCK

Model: 735 ARTICULATED TRUCK B1N

Configuration: 735 Articulated Truck B1N00001-UP (MACHINE) POWERED BY C15 Engine

Disassembly and Assembly

C15 and C18 Engines for Caterpillar Built Machines

Media Number -RENR8261-31

Bearing Clearance - Check

SMCS - 1203-535; 1219-535

Measurement Procedure Table 1

Required Tools

Plastic Gauge (Green)

Plastic Gauge (Red)

Plastic Gauge (Blue)

to 0.229 mm (0.004 to 0.009 inch)

Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)

Note: Plastic gauge may not be necessary when the engine is in the chassis.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

i05977048

Note: Cat does not recommend the checking of the actual bearing clearances particularly on small engines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging the bearing or the journal surfaces. Each Cat engine bearing is quality checked for specific wall thickness.

Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).

NOTICE

Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

The technician must be very careful to use Tooling (A) correctly. The following points must be remembered:

• Ensure that the backs of the bearings and the bores are clean and dry.

• Ensure that the bearing locking tabs are properly seated in the tab grooves.

• The crankshaft must be free of oil at the contact points of Tooling (A).

1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.

Note: Do not allow Tooling (A) to extend over the edge of the bearing.

2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.

Note: Do not turn the crankshaft when Tooling (A) is installed.

3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.

Illustration 1 g01152855

Typical Example

4. Remove all of Tooling (A) before you install the bearing cap.

Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances. Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Thu Jul 11 23:35:16 UTC+0530 2024

Product: ARTICULATED TRUCK

Model: 735 ARTICULATED TRUCK B1N

Configuration: 735 Articulated Truck B1N00001-UP (MACHINE)

Disassembly and Assembly

C15 and C18 Engines for Caterpillar Built Machines Media

BY C15 Engine

Camshaft - Install

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

i02211291

Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine.

NOTICE

Care must be used when removing or installing the camshaft. Do not damage the finshed surfaces of the camshaft or the camshaft bearings.

1. Ensure that the camshaft and camshaft bearings are thoroughly clean. Lubricate the camshaft lobes with a 50/50 mixture of Tooling (J) and clean engine oil. Apply a thin coat of clean engine oil on the camshaft bearings.

2. Install Tooling (A) on the cylinder head at Location (Y).

Illustration

g01056704

Illustration 2 g01056901

3. Install Tooling (B) on front housing (7). Do not tighten the bolts that hold Tooling (B) to front housing (7) at this time.

4. Use Tooling (H) to align Tooling (B) with the camshaft bearings. Tighten the bolts that hold Tooling (B) to front housing (7). Remove Tooling (H).

Note: Tooling (H) should move freely from the bore of Tooling (B).

Illustration 3 g01047961

5. Install Tooling (C) on the rear of the camshaft.

6. Use two technicians to install the camshaft. Use Tooling (D) to assist in aligning camshaft (8) with the camshaft bearings. Carefully slide the camshaft into the cylinder head from the

front of the engine. Keep the camshaft level while the camshaft is being installed in the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).

Note: Rotate the camshaft during installation. This will prevent the camshaft from binding in the camshaft bearings.

7. Remove Tooling (C) and finish installing camshaft (8) in the bore.

Note: Tooling (C) must be removed before the camshaft can be completely installed in the cylinder head.

8. Install the O-ring seal on cover (10). Position the cover on the rear of the cylinder head. Install flat head screws (9) and tighten to a torque of 13 ± 3 N·m (10 ± 2 lb ft).

Illustration

Illustration 5 g01056684

9. Install O-ring seal (5) and O-ring seal (6) in sealing plate (3). Lubricate O-ring seal (6) with a 50/50 mixture of Tooling (J) and clean engine oil.

Illustration 6 g01056682

Illustration 7 g01056681

10. Install sealing plate (3) in front housing (7). Install adapter assembly (4) in the sealing plate. Ensure that the dowel in adapter assembly (4) engages the hole in the camshaft.

11. Install thrust plate (1) . Apply Tooling (K) to bolts (2). Hold the thrust plate in position and install bolts (2). Evenly tighten bolts (2) until sealing plate (3) and the O-ring seal are seated against the cylinder head.

Note: Ensure that the O-ring seal stays in the groove in sealing plate (3).

End By:

a. Install the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker Arms and Shaft - Install".

b. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".

Alternative Installation Procedure

Table 2 Required Tools

K 9S-3263 Thread Lock Compound 1 (1) Part of 177-8003 Engine Tool Group

Note: This is an optional procedure to install the camshaft. The preceding tool list shows the required tooling for installing the camshaft from the front of the engine or the rear of the engine.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE