R3000H Load Haul Dump Power Train Caterpillar

Final Drive and Brake - Assemble

Usage:

Specifications (Final Drive and Brake)

Show/hide table




Illustration 1	g03842116

Show/hide table

Table 1
Specification for 192-6972 Final Drive and Parking Brake Gp
Item	Qty	Part	Specification Description
1	1	9G-5323 Duo-Cone Seal Gp	Rubber toric rings and all surfaces in contact with seals must be clean and dry at assembly. Apply a thin layer of oil to the contacting surfaces of the metal seals just before installation. Seal rings must be assembled square with the bore. Toric seals must not be bulged or twisted.
Use the following shims as needed, to obtain the required wheel bearing preload. Refer to Disassembly and Assembly, "Final Drive and Brake - Assemble" in order to assemble the final drive and brake.
2	1	8K-0066 Shim Pack	Thickness of shim pack is 2.84 mm (0.112 inch)
	6	-	Thickness of one shim is 0.051 mm (0.002 inch)
	1	-	Thickness of one shim is 0.762 mm (0.030 inch)
	7	-	Thickness of one shim is 0.254 mm (0.010 inch)
3	8	6C-3241 Bolt Bolts (3) are single use only part. Discard bolts (3) whenever loosened.	Apply Loctite 7649 and then apply Loctite 620 to the threads prior to assembly.
			Torque to 135 ± 10 N·m (100 ± 7 lb ft).
4	22	5P-2427 Taperlock Stud	Apply Loctite 263 to the threads prior to assembly.
			Torque to 450 ± 40 N·m (330 ± 30 lb ft)
5	23	8T-9399 Bolt	Apply Loctite 7649 and then apply Loctite 620 to the threads prior to assembly.
			Torque to 475 ± 50 N·m (350 ± 37 lb ft.)
6	10	031-1382 Bolt	Apply Loctite 263 to the threads prior to assembly.
			Final installation torque is 270 ± 25 N·m (200 ± 18 lb ft)
7	3	281-9324 Planetary Gear	Inside diameter of the planetary gear is 112.441 ± 0.010 mm (4.4268 ± 0.0004 inch)
8	22	2J-3507 Full Nut	Apply Bostik Never-Seez Marine Grade to the threads of the studs prior to installation.
			Torque to 1125 ± 100 N·m (830 ± 73 lb ft)
9	3	203-1817 Shaft	Outside diameter of the planetary shaft is 77.577 ± 0.010 mm (3.0542 ± 0.0004 inch)

Specifications (Service and Parking Brake)

Show/hide table




Illustration 2	g03842121

Show/hide table

Table 2
Specification for 386-3413 Service and Parking Brake Gp
Item	Qty	Part	Specification Description
1	60	9S-1366 Bolt	Apply Loctite 271 prior to assembly.
1	60	9S-1366 Bolt	Torque to 135 ± 20 N·m (100 ± 15 lb ft)
2	25	2G-5665 Spring (Inner)	Length under test force 71.42 mm (2.812 inch). Test force 1110 ± 53 N (250 ± 12 lb) Free length after test 89.9 mm (3.54 inch) Outside diameter 24.61 mm (0.969 inch)
3	25	2G-5664 Spring (Outer)	Length under test force 96.82 mm (3.812 inch) est force 3425 ± 170 N (770 ± 38 lb) Free length after test 131.3 mm (5.17 inch) Outside diameter 43.66 mm (1.719 inch)
4	Thickness of nine new discs and ten new plates combined 69.85 ± 1.81 mm (2.75 ± 0.070 inch) The recommended minimum thickness of nine worn discs and ten worn plates combined 65.2 mm (2.56 inch).
5	9	9W-7018 Friction Disc	Thickness of one new disc 5.08 ± 0.13 mm (0.200 ± 0.005 inch) The recommended minimum thickness of a worn friction disc 4.70 mm (0.185 inch)
6	10	7D-7504 Plate	Thickness of one new plate 2.413 ± 0.064 mm (0.0950 ± 0.0025 inch) The recommended minimum thickness of a worn plate 2.29 mm (0.090 inch)
7	8	2D-8155 Taperlock Stud	Apply Loctite 271 prior to assembly.
7	8	2D-8155 Taperlock Stud	Torque to 65 ± 10 N·m (48 ± 7 lb ft)
8	6	6M-8252 Spring	Length under test force 63.5 mm (2.50 inch) Test force 370 ± 20 N (85 ± 5 lb) Free length after test 71.4 mm (2.81 inch) Outside diameter 19.71 mm (0.776 inch)
9	8	2G-5653 Nut	Apply Loctite 271 prior to assembly.
9	8	2G-5653 Nut	Final torque is 120 ± 10 N·m (89 ± 7 lb ft)⁽¹⁾

Show/hide table

⁽¹⁾	Tighten evenly until the housing is fully seated on the anchor.

Assembly Procedure

Show/hide table

Table 3
Required Tools
Tool	Part Number	Part Description	QTY
A	138-7574	Link Bracket	2
B	138-7575	Link Bracket	2
C	319-1115	Spring Compression Tool	1
D	5P-0960	Molybdenum Grease	1
E	-	1/2 inch - 13 NC by 6 inch Guide Bolt	2
F	Loctite 7649	Quick Cure Primer	1
G	Loctite 263	Thread Lock Compound	1
H	197-6033	Disc Aligning Tool	1
J	Loctite 620	Retaining Compound	1
K	8T-9206	Duo-Cone Seal Installer As	1

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.

Show/hide table

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, NENG2500, "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.

Show/hide table




Illustration 3	g03842557

Position anchor (25) in a suitable stand, or support on wood blocks.
Show/hide table

Illustration 4 g03842558
Install the O-ring seals to four plugs (58). Install plugs (58) to anchor (25).
Show/hide table

Illustration 5 g03842559
Install O-ring seal (57) to sleeve (56).
Show/hide table

Illustration 6 g03842561
Install sleeve (56) to anchor (25).
Apply Tooling (F) and then apply Tooling (G) to the threads of bolts (55) prior to installation.
Install eight bolts (55). Tighten bolts (55) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
Show/hide table

Illustration 7 g03842562
Install 25 spring assemblies (54) to anchor (25).
Show/hide table

Illustration 8 g03842563
Install piston (53) to anchor (25).
Install O-ring seal (52) to anchor (25).
Show/hide table

Illustration 9 g03842564
Apply Tooling (F) and then apply Tooling (G) to the threads at the tapered end of taperlock studs (51) prior to installation.
Install taperlock studs (51). Tighten taperlock studs (51) to a torque of 65 ± 10 N·m (48 ± 7 lb ft).
Install seals (49) and (50) to housing (34).
Note: Lubricate the seals with Tooling (D) prior to installation.
Note: Seals (49) and (50) may require stretching to ensure that the seals remain seated in housing (32) during the assembly process.
Note: Ensure that seals (49) and (50) are installed with the flat portion of the seal towards the bottom of the groove in housing (32).
Install Tooling (E) to housing (32).
Note: Tooling (E) must be modified in order to be used as a guide bolt. Position Tooling (E) in a suitable vice. Remove the head of the bolt in order to use Tooling (E) as a guide bolt.
Install three O-ring seals (48) to housing (32).
Show/hide table

Illustration 10 g03842565
Turn housing (32) so that the splined end faces upward.
Apply Tooling (F) and then apply Tooling (G) to the threads at the tapered end of taperlock studs (47) prior to installation.
Install taperlock studs (47). Tighten taperlock studs (47) to a torque of 65 ± 10 N·m (48 ± 7 lb ft).
Install Tooling (A) and a suitable lifting device to housing (32). The weight of housing (32) is approximately 120 kg (265 lb).
Show/hide table

Illustration 11 g03842566
Install four special nuts (45) to anchor (25).
Install housing (32) to anchor (25).
Tighten four special nuts (45) evenly until housing (32) is fully seated on anchor (25).
Remove Tooling (E).
Apply Tooling (F) and then apply Tooling (G) to the threads of bolts (46) prior to installation.
Install 30 bolts (46). Tighten bolts (46) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
Tighten four special nuts (45) to a torque of 120 ± 10 N·m (90 ± 7 lb ft).
Show/hide table

Illustration 12 g03842567
Install seals (43) and (44) to piston (42).
Note: Lubricate the seals with Tooling (D) prior to installation.
Note: Ensure that seals (43) and (44) are installed with the flat portion of the seal towards the bottom of the groove in piston (42).
Show/hide table

Illustration 13 g03842568
Install piston (42) to housing (32).
Note: Ensure correct alignment of the guide pin holes in piston (42) and the anchor.
Show/hide table

Illustration 14 g03842569

Show/hide table

Illustration 15 g03842570

Show/hide table

Illustration 16 g03842571
Install return spring (39) and guide pin (40) to anchor (25).
Install Tooling (C) to anchor (25). Turn Tooling (C) clockwise to compress return spring (39).
Install pin (41) to guide pin (40).
Turn Tooling (C) counterclockwise to release the tension on return spring (39). Remove Tooling (C).
Repeat Step 28 through Step 31 for the five remaining return springs, guide pins and pins.
Show/hide table

Illustration 17 g03842572
Install the O-ring seals to two adaptors (37) and four plugs (38).
Install two adaptors (37), two purge screws (36) and four plugs (38).
Connect an external oil supply to parking brake supply port (P). Disengage the parking brake by applying oil pressure of 4140 kPa (600 psi) to parking brake supply port (P).
Note: Do not exceed 4140 kPa (600 psi) as damage to components may occur.
Show/hide table

Illustration 18 g03842576
Install ten outer plates (34), and nine friction discs (35) in an alternating order. Start with an outer plate and end with an outer plate. Lubricate each plate with clean final drive oil when installing.
Note: When, all the plates are installed, the plates should sit below the level of the splines in housing (32). If not correct, check the pressure in the parking brake supply port.
Show/hide table

Illustration 19 g03842596
Install O-ring seal (33) to spindle (24).
Show/hide table

Illustration 20 g03842616
Install spacer (27) to spindle (24).
Raise the temperature of bearing (26). Install bearing (26) to spindle (24).
Note: Use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cup is seated on spindle (24).
Show/hide table

Illustration 21 g03842617
Install Tooling (E) to housing (32).
Attach Tooling (A) and a suitable lifting device to spindle (24). The weight of spindle (24) is approximately 174 kg (384 lb).
Install four special nuts (31) to spindle (24).
Install spindle (24) to housing (31).
Tighten four special nuts (31) evenly until spindle (24) is fully seated on housing (31).
Note: When tightening the special nuts, check that O-ring seal (33) (not shown) remains seated on spindle (24).
Remove Tooling (E).
Show/hide table

Illustration 22 g03842618
Apply Tooling (F) and then apply Tooling (G) to the threads of bolts (30) prior to installation.
Install 30 bolts (30). Tighten bolts (30) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
Tighten four special nuts (31) to a torque of 120 ± 10 N·m (90 ± 7 lb ft).
Apply Tooling (F) and then apply Tooling (G) to the threads at the tapered end of taperlock studs (29) prior to installation.
Install taperlock studs (29). Tighten taperlock studs (29) to a torque of 450 ± 40 N·m (330 ± 30 lb ft).
Show/hide table

Illustration 23 g03842619
Turn the brake assembly so that anchor (25) faces upward.
Install the O-ring seals to six plugs (28). Install plugs (28) to anchor (25).
Show/hide table

Illustration 24 g03842620
Install Tooling (H) to align the splines of the nine friction discs.
Release the oil pressure in the parking brake supply port.
Remove Tooling (H).
Show/hide table

Illustration 25 g03842621
Install spacer (27) and bearing (26) to spindle (24).
Lubricate bearing (26) with clean final drive oil.
Use Tooling (K) (not shown) to install Duo-Cone seal (23) to anchor (25). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
Show/hide table

Illustration 26 g03842622
Lower the temperature of bearing cup (22). Install bearing cup (22) to wheel (3).
Note: Prior to assembly of the components use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cup is seated in the wheel.
Show/hide table

Illustration 27 g03842623
Use Tooling (K) (not shown) to install Duo-Cone seal (21) to wheel (3). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
Show/hide table

Illustration 28 g03842629
Turn wheel (3) so that the splined end faces downward.
Lower the temperature of bearing cup (20). Install bearing cup (20) to wheel (3).
Note: Prior to assembly of the components use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cup is seated in the wheel.
Show/hide table

Illustration 29 g03842624
Attach Tooling (B) and a suitable lifting device to wheel (3). The weight of wheel (3) is approximately 215 kg (475 lb). Install wheel (3) to the brake assembly.
Note: Ensure the splines of wheel (3) and of the nine friction discs are aligned.
Show/hide table

Illustration 30 g03842625
Lubricate bearing (19) with clean final drive oil.
Install bearing (19) to wheel (3).
Disengage the parking brake by applying oil pressure of 4140 kPa (600 psi) to the parking brake supply port.
Note: Do not exceed 4140 kPa (600 psi) as damage to components may occur.
Show/hide table

Illustration 31 g03842648
Install four retainers (17) to ring gear (15).
Use two people to install ring gear (15) and four retainers (17) to hub (16). The combined weight of ring gear (15) and of four retainers (17) is approximately 35 kg (77 lb).
Install Tooling (A) to the ring gear and hub assembly.
Install six bolts (18) finger tight in order to hold retainers (17) in position.
Attach a suitable lifting device to Tooling (A). The combined weight of ring gear (15), hub (16) and of four retainers (17) is approximately 70 kg (154 lb).
Show/hide table

Illustration 32 g03842626
Install ring gear (15), hub (16) and four retainers (17) as a unit to wheel (3).
Note: The top of spindle (24) should be 1 to 2 mm (0.039 to 0.078 inch) below the face of hub (16).
Remove Tooling (A) and bolts (18)
Apply Tooling (F) and then apply Tooling (J) to the threads of bolts (18) prior to installation.
Install eight bolts (18). Tighten bolts (12) to a torque of 135 ± 10 N·m (100 ± 7 lb ft).
Show/hide table

Illustration 33 g03842627
Install bearing plate (13) without the shims.
Install five bolts (12) evenly spaced, but do not tighten.
Use a depth micrometer to measure the distance from the top of bearing plate (13) to the wheel spindle. Measure through the three evenly spaced small holes in bearing plate (13). Find the average value of the three measurements, to find the zero reading.
Tighten bolts (12) to a torque of 90 ± 14 N·m (66 ± 10 lb ft).
Rotate the wheel assembly two to three complete revolutions.
Loosen bolts (12) until bearing plate (13) is loose.
Rotate the wheel assembly two to three complete revolutions.
Use a depth micrometer to measure the distance from the top of bearing plate (13) to the wheel spindle. Measure through the three holes in bearing plate (13). Find the average value of the three measurements.
Compare the average measurement from Step 83 to the zero reading from Step 78.
If, the difference is 0.05 mm (0.002 inch) or less go Step 87. If the difference is greater than 0.05 mm (0.002 inch), repeat Steps 79 through 84, then go to Step 86.
If, the measurement found at Step 84 is still greater than 0.05 mm (0.002 inch) disassemble the parts to determine the problem. If the measurement is 0.05 mm (0.002 inch) or less, go to Step 87.
Tighten bolts (12) to a torque of 40 ± 7 N·m (30 ± 5 lb ft).
Rotate the wheel assembly two to three complete revolutions.
Tighten bolts (12) to a torque of 40 ± 7 N·m (30 ± 5 lb ft).
Use a depth micrometer to measure the distance from the top of bearing plate (13) to the wheel spindle. Measure through the three holes in the bearing plate (13). Calculate the average value of the three measurements.
Remove bolts (12) and bearing plate (13).
Use an outside micrometer to measure the thickness of bearing plate (13). Make a measurement at each of the three holes that were used for the depth measurement. Find the average value of the three measurements.
Subtract the average thickness of bearing plate (13) found in Step 92 from the value found in Step 90. This difference is the clearance between the end of the spindle and bearing plate (13).
Add 0.10 mm (0.004 inch) to the value found in Step 93 to give the thickness of shims (14) required.
Install required shims (14) (not shown) and bearing plate (13).
Apply Tooling (F) and then apply Tooling (G) to the threads of bolts (12) prior to installation.
Install ten bolts (12). Tighten bolts (12) to a torque of 270 ± 25 N·m (200 ± 20 lb ft)
Release the oil pressure from the parking brake supply port. Disconnect the external oil supply from the parking brake supply port.
Show/hide table

Illustration 34 g03842640
Install O-ring seal (11) to wheel (3).
Show/hide table

Illustration 35 g03842641
Lubricate bearings (8) and (10) with clean final drive oil.
Install spacer (9) and bearings (8) and (10) to planetary gear (7).
Show/hide table

Illustration 36 g03842642

Show/hide table

Illustration 37 g03842643
Apply clean final drive oil to the contact surfaces of the thrust washers. Install two thrust washers (6) and planetary gear assembly (7) to the final drive planetary carrier.
Install the retainer ring to the planetary shaft.
Install planetary shaft (5) to the planetary carrier.
Note: Be sure that the flat on the planetary shaft is facing the outside of the planetary carrier.
Repeat Steps 100 through 104 for the remaining two planetary gears.
Show/hide table

Illustration 38 g03842645
Install O-ring seal (4) to final drive planetary carrier (2).
Show/hide table

Illustration 39 g03842646
Attach Tooling (A) and a suitable lifting device to final drive planetary carrier (2). The weight of final drive planetary carrier (2) is approximately 140 kg (310 lb). Install final drive planetary carrier (2) to wheel (3).
Show/hide table

Illustration 40 g03842647
Apply Tooling (F) and then apply Tooling (J) to the threads of the bolts (1) prior to installation.
Install 23 bolts (1). Tighten bolts (1) to a torque of 475 ± 50 N·m (350 ± 37 lb ft)