2006/01/02 Caterpillar

Articulated Truck:

740 (S/N: AXM1-UP; B1P1-UP)

740 EJECTOR (S/N: AZZ1-UP; B1R1-UP)

Description of Change: Improvements have been made to some of the components of the output transfer gear. The changes have improved the reliability and the serviceability of the output transfer gears.

The following components have been changed: The dipstick and spacers in the transfer gear planetary.

Also, the breather has been relocated to the oil filler.

Adaptable To: The 243-4030 Output Transfer Gear, that was previously the 141-6890 Output Transfer Gear, has been improved for the listed machines.

A new 277-8249 Oil Level Gauge replaces the former 212-2017 Oil Level Gauge in the output transfer gears. The new oil level gauge allows the new oil level of the output transfer gear to be maintained. The new oil level gauge should be used in conjunction with the new arrangement of the breather that is detailed in this article.

New 261-0313 Spacers and 261-0314 Spacers replace the former 148-9403 Spacers and 148-9431 Spacers for the planetary gears in the 148-9450 Transfer Gear Planetary that is part of the output transfer gears.

A new 277-5009 Spacer and 277-5008 Tube, that acts as part of the breather, have been added between the 203-0063 Filler Tube and the 201-6665 Cage .

The new components for the 243-4030 Output Transfer Gear, that was previously the 141-6890 Output Transfer Gear, are effective on 740 (S/N: B1P878-UP) and 740 EJECTOR (S/N: B1R206-UP).

The new 277-8249 Oil Level Gauge, 261-0313 Spacers and 261-0314 Spacers are direct replacements to the former components on all earlier machines that are listed for both the 243-4030 Output Transfer Gear and the 141-6890 Output Transfer Gear. Refer to "Checking the Oil Level of the Output Transfer Gear with the New 277-8249 Oil Level Gauge " when you use the new oil level gauge to check the oil level.

The addition of the new 277-5009 Spacer and 277-5008 Tube is adaptable to all earlier machines that are listed for both the 243-4030 Output Transfer Gear and the 141-6890 Output Transfer Gear. Refer to "Installation of the New Arrangement of the Breather on the Output Transfer Gear".

Installation of the New Arrangement of the Breather on the Output Transfer Gear

Refer to Table 1 for the new components that are required to install the new arrangement of the breather. Refer to Table 2 for components that are reused during the installation of the new arrangement of the breather.

Clean all components and inspect all components. If any components are worn or damaged, use new Caterpillar components as replacement. Ensure that no dirt or contaminants can enter the output transfer gear.

Illustration 1	g01184128

Disconnect old breather hose (24) for the output transfer gear. Remove elbow (23). Install plug (1) and O-ring seal (2) in place of the elbow.

Disconnect old breather hose (24) at the other end from filter (25) (not shown). Remove any straps that secure the hose on the machine and remove the hose.

Illustration 2	g01184129
View on left side of the machine

Illustration 3	g01184130
View A-A

Connect new hose (3) to filter (25) and route the hose to the top of the output transfer gear. Secure the hose to the machine with strap (4). Refer to Illustration 2 and Illustration 3.

Illustration 4	g01181861
Partial view from the right side of the output transfer gear

Illustration 5	g01181863
Partial view from the back of the output transfer gear

Illustration 6	g01181862
Partial view from the front of the output transfer gear

In order to install the breather to the output transfer gear, remove two bolts from the cage on the back of the output transfer gear. Retain washers (17) and discard the bolts.

Install plate (5) with bolts (6) and washers (17) .

Remove filler tube (21) with the attached filler cap (18), bolt (19) and washer (20). Retain washers (22) but discard the O-ring seal and the bolts that secure the filler tube to the cage.

Install spacer (11) with a O-ring seal (10) and reinstall filler tube (21) with a new O-ring seal (10). Secure the space and the filler tube in place with bolts (9) and washers (22) .

Install tube (7) to spacer (11) with connector (8) .

Secure tube (7) to plate (5) with clip (12), washers (13), bolt (14) and nut (15) .

Remove any plugs from the end of tube (7) and connect hose (3) to the tube.

Replace the old 212-2017 Oil Level Gauge with new 277-8249 Oil Level Gauge (16) .

Checking the Oil Level of the Output Transfer Gear with the New 277-8249 Oil Level Gauge

Illustration 7	g01227721
Typical example of an 277-8249 Oil Level Gauge

The oil level for the transfer gear should be checked at the beginning of the day. The oil level gauge has markings on only one side. The correct oil level of the output transfer gear must be checked when the oil is at working temperature. Before starting the machine from cold, a base oil level must be checked in order to prevent running the output transfer gear with insufficient oil. Refer to Illustration 7 for a typical example of an 277-8249 Oil Level Gauge .

Checking Oil Level in the Transfer Gear Before Starting the Machine

Check the oil level before the engine is started.

1. The machine should be parked on a level surface. The parking brake must be engaged and the ejector blade retracted.

   Install the steering frame locks. Refer to Operation and Maintenance Manual, "Steering Frame Lock".

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Illustration 8	g00789543

2. The oil level gauge is located in front of the upper pin for the oscillating hitch. Wipe oil level gauge (1) and oil level gauge tube (2) .

3. Turn the handle on the oil level gauge in order to remove the oil level gauge. Remove the oil level gauge.

4. Clean the oil level gauge by wiping.

5. Install the oil level gauge fully.

6. Remove the oil level gauge.

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Illustration 9	g01227722

Note: The oil level gauge is marked: "LOW +2L" (4) and "ENGINE RUNNING MAX HOT" (5) .

7. Check that the oil level on the oil level gauge is anywhere between the tip of the oil level gauge and the level for "ENGINE RUNNING MAX HOT" .

8. If necessary, add oil through oil filler tube (3) until oil is on the oil level gauge. Refer to Operation and Maintenance Manual, "Lubricant Viscosities" and Operation and Maintenance Manual, "Refill Capacities".

9. Install the oil level gauge into the oil level gauge tube.

Checking Oil Level in the Transfer Gear with the Oil at Operating Temperature

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.

1. Park the machine on a level surface. Engage the parking brake and retract the ejector blade. Stop the engine.

   Install the steering frame locks. Refer to Operation and Maintenance Manual, "Steering Frame Lock".

2. Start the engine and run the engine at low idle.

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Illustration 10	g00789543

3. The oil level gauge is located in front of the upper pin for the oscillating hitch. Wipe oil level gauge (1) and oil level gauge tube (2) .

4. Turn the handle on the oil level gauge in order to remove the oil level gauge. Remove the oil level gauge.

5. Clean the oil level gauge by wiping.

6. Install the oil level gauge fully.

7. Remove the oil level gauge.

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Illustration 11	g01227722

Note: The oil level gauge is marked: "LOW +2L" (4) and "ENGINE RUNNING MAX HOT" (5) .

8. Check the oil on the oil level gauge.

9. If necessary, add oil through oil filler tube (3) until the level is on the shaded area of the oil level gauge. Refer to Operation and Maintenance Manual, "Lubricant Viscosities" and Operation and Maintenance Manual, "Refill Capacities".

10. Install the oil level gauge into the oil level gauge tube.