AD45B Underground Articulated Truck Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

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Illustration 1	g01061263

1. Lower the temperature of bearing cups (49) and (50). Install bearing cups (49) and (50) to the transfer gear case.
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   Illustration 2	g01061264

2. Raise the temperature of two bearing cones (51). Install bearing cones (51) to gear (48).

3. Lubricate two bearing cones (51) with the lubricant that is being sealed.
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   Illustration 3	g01061265

4. Attach a suitable lifting device to gear (48). The weight of gear (48) is approximately 29 kg (64 lb). Install gear (48) to transfer gear case (7).
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   Illustration 4	g01061266

5. Raise the temperature of two bearing cones (47). Install bearing cones (47) to gear (46).

6. Lubricate two bearing cones (47) with the lubricant that is being sealed.
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   Illustration 5	g01061267

7. Attach a suitable lifting device to gear (46). The weight of gear (46) is approximately 39 kg (86 lb). Install gear (46) to transfer gear case (7).
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   Illustration 6	g01061268

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   Illustration 7	g03706396

8. Install speed sensor (45) to transfer gear case (7).

9. Install speed sensor (44) to transfer gear case (if equipped).

10. Set the clearance (X) between sensor (45) and gear (48) to 0.71 mm (0.028 inch). Tighten nut (52) to a torque of 25 ± 5 N·m (18 ± 4 lb ft).

11. Repeat Step 10 for speed sensor (44) (if equipped).
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    Illustration 8	g01061699

12. Apply Tooling (K) to the mating surface of the transfer gear case and of gear case cover (27).

13. Install Tooling (C) and a suitable lifting device to gear case cover (27). The weight of gear case cover (27) is approximately 45 kg (100 lb). Install gear case cover (27) to the transfer gear case.
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    Illustration 9	g01061248

14. Install eight bolts (43) to gear case cover (27). Tighten bolts (43) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
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    Illustration 10	g01061247

15. Install drain assembly (42) and bolts (41) to transfer gear case (7).
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    Illustration 11	g01094884

16. Lower the temperature of bearing cup (40). Install bearing cup (40) to bearing cage (35).
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    Illustration 12	g01094885

17. Lower the temperature of bearing cup (32). Install bearing cup (32) to bearing cage (30).
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    Illustration 13	g01094886

18. Install O-ring seal (36) to bearing cage (35).

19. Install cover (34) to bearing cage (35).

20. Install the four nuts (not shown) to cover (34).
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    Illustration 14	g01084241

21. Install bearing cage (30) and bearing cage (35) to gear case cover (27).

    Note: Do not install the O-ring seal to bearing cage (35) or shims (31) (not shown) and (38) (not shown) at this time.

22. Install two bolts (29), 180° apart to bearing cage (30).

23. Install two bolts (37), 180° apart to bearing cage (35).

24. Tighten bolts (29) and (37) evenly to a torque of 20.3 N·m (180 lb in).

25. Rotate gear (48) approximately 30° for three or four times. Tighten bolts (29) and (37) evenly to a torque of 40.7 N·m (360 lb in).

26. Rotate gear (48) approximately 30° for three or four times. Without moving gear (48), loosen bolts (29) and (37).

27. Tighten bolts (29) and (37) evenly until finger tight.

28. Tighten bolts (29) and (37) evenly to a torque of 20.3 N·m (180 lb in).

29. Rotate gear (48) approximately 30° for three or four times. Tighten bolts (29) and (37) evenly to a torque of 20.3 N·m (180 lb in).

30. Repeat Step 29 until bolts (29) and (37) do not move at a torque of 20.3 N·m (180 lb in).

    Note: Steps 31 through 33, are used for the gap at bearing cage (30).

31. Measure the gap between gear case cover (27) and bearing cage (30). Measure the gap at each bolt. Measure the gap between the bearing cage and the housing from the center of the bolt to the outside diameter of the bearing cage flange.

32. Add the two measurements together. Divide the sum by two to determine the average gap measurement between gear case cover (27) and bearing cage (30).

33. Add 0.41 mm (0.016 inch) to the average gap measurement in order to determine the thickness of the shims required for bearing cage (30).

    Note: Steps 34 through 36, are used for the gap at bearing cage (35).

34. Measure the gap between gear case cover (27) and bearing cage (35). Measure the gap at each bolt. Measure the gap between the bearing cage and the housing from the center of the bolt to the outside diameter of the bearing cage flange.

35. Add the two measurements together. Divide the sum by two to determine the average gap measurement between gear case cover (27) and bearing cage (35).

36. Add 0.46 mm (0.018 inch) to the average gap measurement in order to determine the thickness of the shims required for bearing cage (35).

37. Assemble shim packs (31) (not shown) and shim pack (38) (not shown) in order to match the thickness determined in Step 33 and Step 36.

38. Remove bearing cages (30) and (35).
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    Illustration 15	g01640794

39. Install shim pack (38) (not shown) and bearing cage (35) to gear case cover (27).

40. Install seven bolts (37) to bearing cage (35). Tighten bolts (37) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

41. Remove cover (34).

42. Use tooling (M) in order to ensure that end play is present at gear (46). Add or remove shims that were installed in Step 39 to achieve 0.05 + 0.05 - 0.03 mm (0.002 + 0.002 - 0.001 inch) end play.

43. Remove bearing cage (35).

44. Install O-ring seal (39) (not shown) to bearing cage (35).

45. Install bearing cage (35). Tighten bolts (37) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

46. Install cover (34).
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    Illustration 16	g01061246

47. Install shim pack (31) (not shown) and bearing cage (30) to gear case cover (27).

48. Install eight bolts (29) to bearing cage (30). Tighten bolts (29) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

49. Use tooling (M) in order to ensure that end play is present at gear (48). Add or remove shims that were installed in Step 47 to achieve 0.05 ± 0.03 mm (0.0020 ± 0.0012 inch) end play.
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    Illustration 17	g01094139

50. Install O-ring seal (28) to cover (26).
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    Illustration 18	g01061245

51. Install cover (26) and nine bolts (25) to gear case cover (27).
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    Illustration 19	g01094887

52. Raise the temperature of bearing (24). Install bearing (24) to shaft (18).

53. Lubricate bearing (24) with the lubricant that is being sealed.
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    Illustration 20	g01094888

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    Illustration 21	g01094135

54. Lower the temperature of the two bearing cups. Install one bearing cup to bearing cage (16).

55. Lubricate two bearing cones (23) with the lubricant that is being sealed.

56. Install two bearing cones (23) to bearing cage (16).

57. Install the second bearing cup to bearing cage (16).

58. Install retainer (22) and six bolts (21) to bearing cage (16).

    Note: The part number on retainer (22) should be visible.

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    Illustration 22	g01094890

59. Apply Tooling (L) to the outer edge of lip seal (20) (not shown) prior to installation.

60. Use Tooling (A) in order to install lip seal (20) to bearing cage (16).

    Note: The lip of lip seal (20) must face toward the inside of bearing cage (16).

    Note: Lip seal (20) must contact the counterbore in bearing cage (16).

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    Illustration 23	g01094891

61. Position bearing cage (16), the spacer, and gear (19) in a suitable press. Install shaft (18) through gear (19), the spacer, and bearing cage (16).
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    Illustration 24	g01094132

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    Illustration 25	g01094131

62. Install O-ring seal (17) to bearing cage (16).

63. Install Tooling (C) and a suitable lifting device to bearing cage (16). The weight of bearing cage (16) is approximately 95 kg (210 lb). Install bearing cage assembly (16) to transfer gear case (7).
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    Illustration 26	g01094126

64. Install 11 bolts (15) to bearing cage (16). Tighten bolts (15) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
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    Illustration 27	g01094125

65. Install yoke (13) and O-ring seal (14).
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    Illustration 28	g01094123

66. Install retainer (12) and bolt (11) to yoke (13). Tighten bolt (11) to a torque of 480 ± 52 N·m (355 ± 40 lb ft).
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    Illustration 29	g01094892

67. Lower the temperature of bearing cup (9). Install bearing cup (9) to bearing cage (6).
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    Illustration 30	g01094893

68. Install O-ring seal (10) to bearing cage (6).
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    Illustration 31	g01094894

69. Apply Tooling (L) to the outer edge of lip seal (8) (not shown) prior to installation.

70. Use Tooling (A) in order to install lip seal (8) to bearing cage (6).

    Note: Lip seal (8) must contact the counterbore in bearing cage (6). The lip of seal (8) must face toward the inside of bearing cage (6).

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    Illustration 32	g01094117

71. Turn the transfer gear case. The weight of the transfer gear case is approximately 520 kg (1150 lb).

72. Install bearing cage (6) to the transfer gear case.

73. Install eight bolts (5) to bearing cage (6). Tighten bolts (5) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
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    Illustration 33	g01094116

74. Install yoke (3) and O-ring seal (4).
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    Illustration 34	g01094114

75. Install retainer (2) and bolt (1) to yoke (3). Tighten bolt (1) to a torque of 480 ± 52 N·m (355 ± 40 lb ft).

End By:

1. Connect the output transfer gears to the transmission. Refer to Disassembly and Assembly, "Transmission to Output Transfer Gears - Connect".