Load Haul Dump 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 always.

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Illustration 1	g06011974

1. Lower the temperature of bearing cup (49). Lower the temperature of bearing (50). Install bearing cup (49) and bearing (50) to the transfer gear case.
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   Illustration 2	g06011972

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	g06011970

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	g06011968

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

6. Lubricate two bearings (47) with the lubricant that is being sealed.
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   Illustration 5	g06011963

7. Attach a suitable lifting device and a hoist (not shown) to gear (46). The weight of gear (46) is approximately 39 kg (86 lb). Install gear (46) to the transfer gear case.
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   Illustration 6	g06011935

8. Install speed sensor (45) to transfer gear case (7).
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   Illustration 7	g03331216

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

10. 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 8	g03329662

11. Install eight bolts (44) to gear case cover (27). Tighten eight bolts (44) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).
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    Illustration 9	g03330132

12. Install drain assembly (43) and bolts (42) to transfer gear case (7).
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    Illustration 10	g03330133

13. Lower the temperature of bearing (41). Install bearing (41) to bearing cage (37).

14. Install O-ring seal (40) to bearing cage (37).
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    Illustration 11	g03330135

15. Lower the temperature of bearing cup (32). Install bearing cup (32) to bearing cage (30).
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    Illustration 12	g06011957

16. Install bearing cage (37) and seven bolts (39). Tighten seven bolts (39) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

17. Rotate gear (46) approximately 30° for three or four times.

18. Use Tooling (M) to ensure 1.0 ± 0.34 mm (0.0394 ± 0.0134 inch) end play is present at gear (46).

19. Install O-ring seal (38) to bearing cage (37).
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    Illustration 13	g06019908

20. Install cover (36), four nuts (35), and the washers.

21. Install tube assembly (34) and the bracket. Install bolt (33) and the washer. Tighten bolt (33) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).
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    Illustration 14	g06011955

22. Install bearing cage (30) to gear case cover (27).

    Note: Do not install shims (31) (not shown) now.

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

24. Tighten two bolts (29) 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) evenly to a torque of 41 N·m (360 lb in).

26. Rotate gear (48) approximately 30° for three or four times. Without moving gear (49), loosen bolts (29).

27. Tighten eight bolts (29) evenly until finger tight.

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

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

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

31. Add the two measurements together. Dividing the sum by two gives the average gap measurement between gear case cover (27) and bearing cage (30).

32. Add 0.46 mm (0.018 inch) to the average gap measurement to determine the thickness of the shims required for bearing cage (30).

33. Assemble shim packs (31) (not shown) to match the thickness determined in Step 32.

34. Remove eight bolts (29) and bearing cage (30).
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    Illustration 15	g06011951

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

36. Install eight bolts (29) to bearing cage (30). Tighten eight bolts (29) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

37. Use tooling (M) to ensure that end play is present at gear (48). Add or remove shims that were installed in Step 35 to achieve 0.05 ± 0.03 mm (0.0020 ± 0.0012 inch) end play.
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    Illustration 16	g01094139

38. Install O-ring seal (28) to cover (26).
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    Illustration 17	g01061245

39. Install cover (26) and nine bolts (25) to gear case cover (27). Tighten nine bolts (25) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).
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    Illustration 18	g01094887

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

41. Lubricate bearing (24) with the lubricant that is being sealed.
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    Illustration 19	g01094888

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    Illustration 20	g01094135

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

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

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

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

46. 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 21	g01094890

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

48. Use Tooling (A) to install lip seal (20) to bearing cage (16).

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

    Note: Lip seal (20) must contact the counter-bore in bearing cage (16).

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    Illustration 22	g01094891

49. 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 23	g01094132

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    Illustration 24	g01094131

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

51. 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 25	g01094126

52. Install 11 bolts (15) to bearing cage (16). Tighten bolts (15) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).
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    Illustration 26	g01094125

53. Install yoke (13) and O-ring seal (14).
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    Illustration 27	g01094123

54. Install yoke (13). Apply Loctite 263 to the threads of bolt (11) prior to assembly. Install retainer (12) and bolt (11). Tighten bolt (11) to a torque of 475 ± 60 N·m (350 ± 45 lb ft).
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    Illustration 28	g01094892

55. Lower the temperature of bearing cup (9). Install bearing cup (9) to bearing cage (6).
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    Illustration 29	g01094893

56. Install O-ring seal (10) to bearing cage (6).
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    Illustration 30	g01094894

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

58. Use Tooling (A) to install lip seal (8) to bearing cage (6).

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

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    Illustration 31	g01094117

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

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

61. Install eight bolts (5) to bearing cage (6).
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    Illustration 32	g01094116

62. Install yoke (3) and O-ring seal (4).
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    Illustration 33	g01094114

63. Install yoke (3). Apply Loctite 263 to the threads of bolt (1) prior to assembly. Install retainer (2) and bolt (1). Tighten bolt (1) to a torque of 475 ± 60 N·m (350 ± 45 lb ft).

End By:

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