R1600H Load Haul Dump Power Train Caterpillar

Disassembly Procedure

Start By:

1. Separate the output transfer gears from the planetary group. Refer to Disassembly and Assembly, "Transmission from Output Transfer Gears - Separate".

Note: Cleanliness is an important factor. Before disassembly, the exterior of the case should be cleaned thoroughly in order to prevent dirt and debris from entering the internal mechanism. During disassembly, all parts should be cleaned thoroughly in cleaning fluid. Then allow the parts to air dry. Wiping cloths or rags should not be used to dry the parts. Lint may be deposited on the parts and may cause later trouble.

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Illustration 1	g00497940

1. Use a hoist to put the transfer gears on wood blocks, as shown. The weight of the transfer gears is 245 kg (540 lb).

2. Remove cover (1) and plate (2) from the back of the bearing cage.

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Illustration 2	g00497946

Note: Keep the shim pack together for assembly purposes.

3. Remove bolts (3) . Use two 3/8 - 16 NC forcing screws in order to loosen bearing cage (4) . Remove the bearing cage and the shims. Keep the shim pack together for assembly purposes. Remove the O-ring seal from the bearing cage.

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Illustration 3	g00497947

4. Remove O-ring seal (6) and bearing cup (5) from bearing cage (4) .

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Illustration 4	g00497950

5. Use a hoist to remove transfer gear (7) and the bearing cones. The combined weight of the transfer gear and the bearing cones is 27 kg (60 lb).

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Illustration 5	g00497952

6. Use Tooling (A) to remove the bearing cone from each side of transfer gear (7) .

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Illustration 6	g00497954

7. Remove bearing cup (8) from the transfer gear case.

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Illustration 7	g00497996
Typical Example

8. Use a hoist to place the transfer gear case in a vertical position, as shown. The weight of the transfer gear case is 193 kg (425 lb).

9. Remove nuts (9) and the washers. Use two 3/8" - 16 NC forcing screws to loosen bearing cage (10) . Remove bearing cage (10) .

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Illustration 8	g00498021
Typical Example

10. Remove O-ring seal (13) , lip type seal (11) , and outer bearing race (12) from bearing cage (10) .

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Illustration 9	g00498024
Typical Example

11. Remove spacer (14) from the output shaft.

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Illustration 10	g00498025

12. Remove the bolt, the retainer, the O-ring seal, and the yoke from the output shaft. Remove the dirt guard from the output shaft.

13. Remove bearing retainer (15) .

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Illustration 11	g00498026

14. Remove lip type seal (16) from bearing retainer (15) .

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Illustration 12	g00498028

15. Install two 3/8" - 16 NC guide bolts through the bearing cage (17) , as shown.

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Illustration 13	g00498030

16. Install a lifting strap and a suitable lifting device to transfer gear (18) , as shown. Use a soft faced hammer to push shaft (20) out of transfer gear (18) and the bearing cage. Remove bearing (19) . Remove output shaft (20) and bearing cage (17) from the opposite side of the transfer gear case.

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Illustration 14	g00498240

17. Remove O-ring seal (21) from bearing cage (17) .

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Illustration 15	g00498260

18. Use a press to push output shaft (20) out of bearing cage (17) .

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Illustration 16	g00498284

19. Use Tooling (B) and a press to push the bearings out of bearing cage (17) .

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Illustration 17	g00498285

20. Remove transfer gear (18) from the transfer gear case.

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Illustration 18	g00498286

21. Remove covers (23) and the gaskets from both sides of the transfer gear case.

22. Remove cover (22) and the gasket from the transfer gear case.

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Illustration 19	g00498287

23. Remove screen tube assembly (25) and screen (24) .