794 AC Off-Highway Truck Machine Systems Caterpillar

Front Wheel, Bearing and Duo-Cone Seal - Install

Usage:

Installation Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	439-3943	Link Bracket As	3
	217-9903⁽¹⁾	Washer	3
	8C-4032⁽²⁾	Nut	3
B	195-3175	Bearing Handler	1
C	422-1785	Lifting Eye Assembly	3
D	8S-0933	Eye Bolt	2
E	473-8690	Instrument Gp	1
F	6V-7030	Micrometer Depth Gauge Gp
G	4C-6582	Duo-Cone Seal Installer	1
J	149-0974	Duo-Cone Seal Installer	1
K	-	Loctite 271	-
L	-	Loctite 242	-
M	7H-1680	Hand Pump Gp	1
N	369-9451	Grease

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⁽¹⁾	Rim Mounting Hardware
⁽²⁾	Rim Mounting Hardware

Note: There are 2 methods for assembling the front wheel. The bearing preload procedure can be performed with or without the service brake installed.

Method 1 - Wheel assembly and Bearing Preload Without Service Brake
1. Use the following steps to assemble the wheel and establish the bearing preload without the service brake installed.
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  Illustration 1 g06160475
2. Install O-ring seal (33) onto retainer (32).
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  Illustration 2 g06160473
  
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  Illustration 3 g06160465
3. Use Tooling (D) and a suitable lifting device to install retainer (32) onto the spindle. The weight of retainer (32) is approximately 53 kg (117 lb).
4. Remove Tooling (D). Install bolts (31). Tighten bolts (31) to a torque of 25 ± 6 N·m (221 ± 53 lb in).
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  Illustration 4 g06160461
5. Raise the temperature of bearing cone (30), rapidly and evenly, to 42° C (75° F) above ambient temperature. Use Tooling (B) and a suitable lifting device to install bearing cone (30). The weight of bearing cone (30) is approximately 67 kg (148 lb).
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  Illustration 5 g06185588
6. Use the following Steps to install bearing cup (24) onto wheel assembly (14).
7. Lower the temperature of bearing cup (24) to a component temperature of −40° C (−40° F) to −57° C (−71° F).
  Note: Minimum cooling temperatures can be obtained using a freezer or dry ice in an alcohol bath. The use of liquid nitrogen is not an acceptable cooling method as liquid nitrogen may cause adverse effects on the bearings metallurgical, fit, and performance characteristics.
  Note: Prior to installation, remove frost from all surfaces of the bearing cup.
8. Install the bearing cup into the mating bore. Apply a load to the bearing cup until the bearing cup is properly seated in the bore.
  Note: Load can be applied using a press or tapping the outer edge around the perimeter of the bearing cup until itthe bearing cup is seated.
  Note: After installation and during warming of the bearing cup, remove the moisture condensation that can accumulate.
9. Once at ambient temperature, wipe with a clean, lint-free, cloth, and apply a corrosion inhibitor.
10. Inspect the bearing cup to ensure that the bearing cup is seated squarely against the shoulder of the mating bore using a feeler gauge. Gaps must not exceed 0.05 mm (0.002 inch).
11. For extra instruction for installing bearing cups, refer to UENR2267Testing and Adjusting, Bearing Cup Cooling and Installation Procedure.
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  Illustration 6 g06185592
12. Use the following Steps to install bearing cup (22) onto wheel assembly (14).
13. Lower the temperature of bearing cup (22) to a component temperature of −40° C (−40° F) to −57° C (−71° F).
  Note: Minimum cooling temperatures can be obtained using a freezer or dry ice in an alcohol bath. The use of liquid nitrogen is not an acceptable cooling method as liquid nitrogen may cause adverse effects on the bearings metallurgical, fit, and performance characteristics.
  Note: Prior to installation, remove frost from all surfaces of the bearing cup.
14. Install the bearing cup into the mating bore. Apply a load to the bearing cup until the bearing cup is properly seated in the bore.
  Note: Load can be applied using a press or tapping the outer edge around the perimeter of the bearing cup until the bearing cup is seated.
  Note: After installation and during warming of the bearing cup, remove the moisture condensation that can accumulate.
15. Once at ambient temperature, wipe with a clean, lint-free, cloth, and apply a corrosion inhibitor.
16. Inspect the bearing cup to ensure that the bearing cup is seated squarely against the shoulder of the mating bore using a feeler gauge. Gaps must not exceed 0.05 mm (0.002 inch).
17. For extra instruction for installing bearing cups, refer to , UENR2267Testing and Adjusting, Bearing Cup Cooling and Installation Procedure.
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  Illustration 7 g06185598
  
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  Illustration 8 g06185601
18. Use Tooling (A) and a suitable lifting device to install wheel assembly (14). The weight of wheel assembly (14) is approximately 1194 kg (2632 lb). Use a suitable lifting device to Install bearing cone (13). The weight of bearing cone (13) is approximately 62 kg (137 lb).
  Note: Install wheel assembly (14) first then install bearing cone (13).
19. Use Tooling (E) to measure the thickness of retainer (11) at the two measurement holes locations on the retainer and calculate the average measurement. Record the result as Dimension (X).
20. Use two people or a suitable lifting device to install retainer (11). The weight of retainer (11) is approximately 30 kg (66 lb). Install all ten bolts (10).
  Note: Do not install shims (12) at this step.
  Note: Apply grease onto bolts (10) prior to installation.
21. While rotating the wheel, tighten all ten bolts (10) in a crisscross pattern to a torque of 339 N·m (250 lb ft) in increments of 68 N·m (50 lb ft).
  Note: Rotate the wheel as bolts (10) are tightened to seat the bearings.
22. Loosen bolts (10) to loosen the bearing cones. Rotate the wheel to verify that the bearing cones are loose.
23. Remove 8 of bolts (10) leaving two of bolts (10) that are equally spaced.
24. While rotating the wheel, tighten the two remaining bolts (10) to a torque of 203 N·m (150 lb ft) in increments of 27 N·m (20 lb ft).
  Note: Rotate the wheel as the two bolts (10) are tightened to seat the bearings.
25. Using Tooling (F), measure the depth from the outer surface of retainer (11) to the end of the spindle through each hole and calculate the average measurement. Record the result as Dimension (Y).
26. Subtract Dimension (Y) from Dimension (X). Record the result as Dimension (Z).
  Note: Dimension (Z) is the shim gap. The shim gap range should be 3.200 to 6.753 mm (0.126 to 0.266 inch).
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  Illustration 9 g06185616
  
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  Illustration 10 g06185598
27. Remove the two bolts (10). Use two people or a suitable lifting device to remove retainer (11). The weight of retainer (11) is approximately 30 kg (66 lb). Use Tooling (A) and a suitable lifting device to remove wheel assembly (14) and bearing assembly (13). The weight of wheel assembly (14) and bearing assembly (13) is approximately 1256 kg (2769 lb).
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  Illustration 11 g06185619
28. Use Tooling (G) and Tooling (J) to install Duo - Cone seals (23).
29. Ensure that Duo-Cone seals (23) are installed correctly. Refer to , UENR3262Disassembly and Assembly, "Seal Installation", Duo-Cone Seals - Install.
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  Illustration 12 g06160459
30. Install O-ring seal (29) onto service brake (26).
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  Illustration 13 g06160455
  
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  Illustration 14 g06160456
31. Use Tooling (C) and a suitable lifting device to install service brake (26) onto the wheel spindle. The weight of service brake assembly (26) is approximately 1581 kg (3486 lb).
  Note: The bolt of Tooling (C) must be cut to a length of 90 mm (3.5 inch)
32. Install 10 nuts (28) and 40 nuts (27).
33. Tighten 10 nuts (28) to a torque of 240 ± 40 N·m (177 ± 30 lb ft). Tighten 40 nuts (27) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).
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  Illustration 15 g06160447
34. Use Tooling (G) and Tooling (J) to install Duo-Cone seals (25).
  Note: The inner Duo - Cone seal can be installed before the service brake is installed for easier access.
  Note: Ensure that Duo-Cone seals (25) are installed correctly. Refer to , UENR3262Disassembly and Assembly, "Seal Installation", Duo-Cone Seals - Install.
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  Illustration 16 g06185903
35. Use Tooling (A) and a suitable lifting device to install wheel assembly (14) . The weight of wheel assembly (14) is approximately 1194 kg (2632 lb). Use a suitable lifting device to Install bearing cone (13). The weight of bearing cone (13) is approximately 62 kg (137 lb).
  Note: Install wheel assembly (14) first then install bearing cone (13).
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  Illustration 17 g06185621
36. Install O-ring seal (15) onto retainer (11).
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  Illustration 18 g06185894
37. Install a number of shims (12) that is equal to Dimension (Z) ± 0.05 mm (± 0.002 inch) that was established at Step 1.z.
  Note: Measure each shim at four equally spaced locations and then calculate the average measurement. The thickness of the shim pack is to be the total of the average shim measurements and equal to Dimension (Z) ± 0.05 mm (± 0.002 inch).
38. Attach Tooling (M) to Port (P) on the brake anchor. Use Tooling (M) to release the parking brake.
  Note: The pressure required to release the parking should be between 4200 kPa (609 psi) and 4600 kPa (667 psi).
39. Use two people or a suitable lifting device to install retainer (11). The weight of retainer (11) is approximately 30 kg (66 lb). Install all ten bolts (10). While rotating the wheel, tighten all ten bolts (10) in a crisscross pattern to a torque of 41 N·m (30 lb ft) in increments of 21 N·m (16 lb ft).
  Note: Rotate the wheel as bolts (10) are tightened to seat the bearings
40. Inspect the gap between the outboard bearing cone and the bearing retainer using a feeler gauge. The gap must not allow for a 0.05 mm (0.002 inch) feeler gauge thickness. Measure the depth from the bearing retainer outer surface to the outer surface of the shim pack through the two measurement holes using Tooling (F). The measurement must not be greater than the average bearing retainer thickness +0.05 mm (+0.002 inch) from Step 1.s
41. While rotating the wheel, tighten all ten bolts (10) in a crisscross pattern to a torque of 800 N·m (590 lb ft) in increments of 136 N·m (100 lb ft).
  Note: Rotate the wheel as bolts (10) are tightened to seat the bearings
42. Release the pressure from Tooling (M) to engage the parking brake. Remove Tooling (M) from Port (P) on the brake anchor.
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  Illustration 19 g06160437
43. Install receptacle (21) onto speed sensor assembly (17). Install bolts (20).
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  Illustration 20 g06160432
44. Install O-ring seal (19) onto speed sensor assembly (17). Connect harness assembly (18).
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  Illustration 21 g06172903
45. Install the lock wire onto bolts (10). Install speed sensor assembly (17) onto retainer (11). Install bolts (16). Tighten bolts (16) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
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  Illustration 22 g06160412
46. Install O-ring seal (9) onto target sensor assembly (8).
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  Illustration 23 g06155560
47. Install target sensor assembly (8) onto cover assembly (2). Tighten target sensor (8) to a torque of 130 ± 20 N·m (96 ± 15 lb ft).
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  Illustration 24 g06155558
48. Install O-ring seals (7) onto cover assembly (2).
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  Illustration 25 g06155550
49. Apply Tooling (K) onto bolts (4). Install bolts (4), plate (5), and cover (6) onto cover assembly (2). Tighten bolts (4) to a torque of 30 ± 7 N·m (266 ± 62 lb in).
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  Illustration 26 g06155556
50. Apply Tooling (N) and install O-ring seal (3).
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  Illustration 27 g03896024
51. Apply Tooling (L) onto bolts (1). Install cover assembly (2) and bolts (1). Tighten bolts (1) to a torque of 100 ± 20 N·m (74 ± 15 lb ft)
52. Refer to Operation and Maintenance Manual, "Front Wheel Oil - Change" for the correct draining and filling procedures.

Method 2 - Wheel assembly and Bearing Preload With Service Brake
1. Use the following steps to assemble the wheel and establish the bearing preload with the service brake installed.
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  Illustration 28 g06160475
2. Install O-ring seal (33) onto retainer (32).
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  Illustration 29 g06160473
  
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  Illustration 30 g06160465
3. Use Tooling (D) and a suitable lifting device to install retainer (32) onto the spindle. The weight of retainer (32) is approximately 53 kg (117 lb).
4. Remove Tooling (D). Install bolts (31). Tighten bolts (31) to a torque of 25 ± 6 N·m (221 ± 53 lb in).
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  Illustration 31 g06160461
5. Raise the temperature of bearing cone (30), rapidly and evenly, to 42° C (75° F) above ambient temperature. Use Tooling (B) and a suitable lifting device to install bearing cone (30). The weight of bearing cone (30) is approximately 67 kg (148 lb).
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  Illustration 32 g06185588
6. Use the following Steps to install bearing cup (24) onto wheel assembly (14).
7. Lower the temperature of bearing cup (24) to a component temperature of −40° C (−40° F) to −57° C (−71° F).
  Note: Minimum cooling temperatures can be obtained using a freezer or dry ice in an alcohol bath. The use of liquid nitrogen is not an acceptable cooling method as liquid nitrogen may cause adverse effects on the bearings metallurgical, fit, and performance characteristics.
  Note: Prior to installation, remove frost from all surfaces of the bearing cup.
8. Install the bearing cup into the mating bore. Apply a load to the bearing cup until the bearing cup is properly seated in the bore.
  Note: Load can be applied using a press or tapping the outer edge around the perimeter of the bearing cup until the bearing cup is seated.
  Note: After installation and during warming of the bearing cup, remove the moisture condensation that can accumulate.
9. Once at ambient temperature, wipe with a clean, lint-free, cloth, and apply a corrosion inhibitor.
10. Inspect the bearing cup to ensure that the bearing cup is seated squarely against the shoulder of the mating bore using a feeler gauge. Gaps must not exceed 0.05 mm (0.002 inch).
11. For extra instruction for installing bearing cups, refer to , UENR2267Testing and Adjusting, Bearing Cup Cooling and Installation Procedure.
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  Illustration 33 g06185592
12. Use the following Steps to install bearing cup (22) onto wheel assembly (14).
13. Lower the temperature of bearing cup (22) to a component temperature of −40° C (−40° F) to −57° C (−71° F).
  Note: Minimum cooling temperatures can be obtained using a freezer or dry ice in an alcohol bath. The use of liquid nitrogen is not an acceptable cooling method as liquid nitrogen may cause adverse effects on the bearings metallurgical, fit, and performance characteristics.
  Note: Prior to installation, remove frost from all surfaces of the bearing cup.
14. Install the bearing cup into the mating bore. Apply a load to the bearing cup until the bearing cup is properly seated in the bore.
  Note: Load can be applied using a press or tapping the outer edge around the perimeter of the bearing cup until the bearing cup is seated.
  Note: After installation and during warming of the bearing cup, remove the moisture condensation that can accumulate.
15. Once at ambient temperature, wipe with a clean, lint-free, cloth, and apply a corrosion inhibitor.
16. Inspect the bearing cup to ensure that the bearing cup is seated squarely against the shoulder of the mating bore using a feeler gauge. Gaps must not exceed 0.05 mm (0.002 inch).
17. For extra instruction for installing bearing cups, refer to , UENR2267Testing and Adjusting, Bearing Cup Cooling and Installation Procedure.
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  Illustration 34 g06160459
18. Install O-ring seal (29) onto service brake (26).
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  Illustration 35 g06160455
  
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  Illustration 36 g06160456
19. Use Tooling (C) and a suitable lifting device to install service brake (26) onto the wheel spindle. The weight of service brake assembly (26) is approximately 1581 kg (3486 lb).
  Note: The bolt of Tooling (C) must be cut to a length of 90 mm (3.5 inch)
20. Install 10 nuts (28) and 40 nuts (27).
21. Tighten 10 nuts (28) to a torque of 240 ± 40 N·m (177 ± 30 lb ft). Tighten 40 nuts (27) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).
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  Illustration 37 g06160447
22. Use Tooling (G) and Tooling (J) to install Duo-Cone seals (25).
  Note: The inner Duo - Cone seal can be installed before the service brake is installed for easier access.
  Note: Ensure that Duo-Cone seals (25) are installed correctly. Refer to , UENR3262Disassembly and Assembly, "Seal Installation", Duo-Cone Seals - Install.
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  Illustration 38 g06185619
23. Use Tooling (G) and Tooling (J) to install Duo - Cone seals (23).
24. Ensure that Duo-Cone seals (23) are installed correctly. Refer to , UENR3262Disassembly and Assembly, "Seal Installation", Duo-Cone Seals - Install.
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  Illustration 39 g06160379
  
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  Illustration 40 g06160491
25. Use Tooling (A) and a suitable lifting device to install wheel assembly (14) . The weight of wheel assembly (14) is approximately 1194 kg (2632 lb). Use a suitable lifting device to Install bearing cone (13). The weight of bearing cone (13) is approximately 62 kg (137 lb).
  Note: Install wheel assembly (14) first then bearing cone (13).
26. Use Tooling (E) to measure the thickness of retainer (11) at the two measurement holes locations on the retainer and calculate the average measurement. Record the result as Dimension (X).
27. Use two people or a suitable lifting device to install retainer (11). The weight of retainer (11) is approximately 30 kg (66 lb). Install all ten bolts (10).
  Note: Do not install shims (12) at this step.
  Note: Apply grease onto bolts (10) prior to installation.
28. Attach Tooling (M) to Port (P) on the brake anchor. Use Tooling (M) to release the parking brake.
  Note: The pressure required to release the parking should be between 4200 kPa (609 psi) and 4600 kPa (667 psi).
29. While rotating the wheel, tighten all ten bolts (10) in a crisscross pattern to a torque of 339 N·m (250 lb ft) in increments of 68 N·m (50 lb ft).
  Note: Rotate the wheel as bolts (10) are tightened to seat the bearings.
30. Loosen bolts (10) to loosen the bearing cones. Rotate the wheel to verify that the bearing cones are loose.
31. Remove 8 of bolts (10) leaving two of bolts (10) that are equally spaced.
32. While rotating the wheel, tighten the two remaining bolts (10) to a torque of 203 N·m (150 lb ft) in increments of 27 N·m (20 lb ft).
  Note: Rotate the wheel as the two bolts (10) are tightened to seat the bearings.
33. Using Tooling (F), measure the depth from the outer surface of retainer (11) to the end of the spindle through each hole and calculate the average measurement. Record the result as Dimension (Y).
34. Subtract Dimension (Y) from Dimension (X). Record the result as Dimension (Z).
  Note: Dimension (Z) is the shim gap. The shim gap range should be 3.200 to 6.753 mm (0.126 to 0.266 inch).
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  Illustration 41 g06186032
35. Remove the two bolts (10) . Use two people or a suitable lifting device to remove retainer (11). The weight of retainer (11) is approximately 30 kg (66 lb).
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  Illustration 42 g06185621
36. Install O-ring seal (15) onto retainer (11).
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  Illustration 43 g06185894
37. Install a number of shims (12) that is equal to Dimension (Z) ± 0.05 mm (± 0.002 inch) that was established at Step 1.ah.
  Note: Measure each shim at four equally spaced locations and then calculate the average measurement. The thickness of the shim pack is to be the total of the average shim measurements and equal to Dimension (Z) ± 0.05 mm (± 0.002 inch).
38. Use two people or a suitable lifting device to install retainer (11). The weight of retainer (11) is approximately 30 kg (66 lb). Install all ten bolts (10). While rotating the wheel, tighten all ten bolts (10) in a crisscross pattern to a torque of 41 N·m (30 lb ft) in increments of 21 N·m (16 lb ft).
  Note: Rotate the wheel as bolts (10) are tightened to seat the bearings.
39. Inspect the gap between the outboard bearing cone and the bearing retainer using a feeler gauge. The gap must not allow for a 0.05 mm (0.002 inch) feeler gauge thickness. Measure the depth from the bearing retainer outer surface to the outer surface of the shim pack through the two measurement holes using Tooling (F). The measurement must not be greater than the average bearing retainer thickness +0.05 mm (+0.002 inch) from Step 1.z
40. While rotating the wheel, tighten all ten bolts (10) in a crisscross pattern to a torque of 800 N·m (590 lb ft) in increments of 136 N·m (100 lb ft).
  Note: Rotate the wheel as bolts (10) are tightened to seat the bearings.
41. Release the pressure from Tooling (M) to engage the parking brake. Remove Tooling (M) from Port (P) on the brake anchor.
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  Illustration 44 g06160437
42. Install receptacle (21) onto speed sensor assembly (17). Install bolts (20).
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  Illustration 45 g06160432
43. Install O-ring seal (19) onto speed sensor assembly (17). Connect harness assembly (18).
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  Illustration 46 g06172903
44. Install the lock wire onto bolts (10). Install speed sensor assembly (17) onto retainer (11). Install bolts (16). Tighten bolts (16) to a torque of 12 ± 3 N·m (106 ± 27 lb in).
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  Illustration 47 g06160412
45. Install O-ring seal (9) onto target sensor assembly (8).
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  Illustration 48 g06155560
46. Install target sensor assembly (8) onto cover assembly (2). Tighten target sensor (8) to a torque of 130 ± 20 N·m (96 ± 15 lb ft).
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  Illustration 49 g06155558
47. Install O-ring seals (7) onto cover assembly (2).
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  Illustration 50 g06155550
48. Apply Tooling (K) onto bolts (4). Install bolts (4), plate (5), and cover (6) onto cover assembly (2). Tighten bolts (4) to a torque of 30 ± 7 N·m (266 ± 62 lb in).
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  Illustration 51 g06155556
49. Apply Tooling (N) and install O-ring seal (3).
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  Illustration 52 g03896024
50. Apply Tooling (L) onto bolts (1). Install cover assembly (2) and bolts (1). Tighten bolts (1) to a torque of 100 ± 20 N·m (74 ± 15 lb ft)
51. Refer to Operation and Maintenance Manual, "Front Wheel Oil - Change" for the correct draining and filling procedures.