Procedure to Rework the Axle Housing on R1600G and R1600H Load Haul Dump Machines {3260} Caterpillar

Load Haul Dump

R1600G (S/N: 9PP1-UP; 9YZ1-UP)

R1600H (S/N: 9SD1-224,226-236,239-240)

Introduction

This special instruction covers the procedure to rework the following axle arrangements on the above Load Haul Dump Machines.

• 300-2030 Oscillating Axle Ar

• 386-9386 Fixed Axle Ar

This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock link between the front and rear frames before working on machine.

Reference Section

Reference: Disassembly and Assembly, KENR8508, "R1600G Load Haul Dump Machine Systems".

Reference: Disassembly and Assembly, RENR7843, "R1600G Load Haul Dump Machine Systems".

Reference: Disassembly and Assembly, UENR1457, "R1600H Load Haul Dump Machine Systems".

Reference: Disassembly and Assembly, KENR6828, "R1600G Load Haul Dump Power Train".

Reference: Disassembly and Assembly, RENR7834, "R1600G Load Haul Dump Power Train".

Reference: Disassembly and Assembly, UENR1449, "R1600H Load Haul Dump Power Train".

Required Tools

Required Parts

Procedure

Machine Preparation

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".

5. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

6. Release system pressure. Refer to Disassembly and Assembly, "System Pressure - Release".

Oscillating Axle (Rear) - Disassemble

1. Remove the rear oscillating axle. Refer to Disassembly and Assembly , Oscillating Axle (Rear) - Remove.

2. Remove front and rear trunnion supports. Refer to Disassembly and Assembly , Trunnion Support (Oscillating Axle, Front) - Remove, and Disassembly and Assembly , Trunnion Support (Oscillating Axle, Rear) - Remove.

3. Remove and disassemble the left side and the right side parking brakes. Refer to Disassembly and Assembly , Parking Brake - Remove, and Disassembly and Assembly , Parking Brake - Disassemble.

4. Disassemble the left side and the right side service brakes. Refer to Disassembly and Assembly , Service Brake - Disassemble.

5. Remove the differential and bevel gear. Refer to Disassembly and Assembly , Differential and Bevel Gear - Remove.
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   Illustration 1	g06132866
   View of the left side of the axle assembly (1) Dowel (2) Dowel (3) Bolt (4) Washer (5) Bolt (6) Washer (7) Dowel (8) Bolt

6. Discard four dowels (1), four dowels (2), two bolts (3), two washers (4), 22 bolts (5), 22 washers (6), two dowels (7), and two bolts (8).

   Note: Only two bolts (8) are discarded, two remain.

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   Illustration 2	g06132867
   View of the right side of the axle assembly (9) Dowel (10) Bolt (11) Washer (12) Bolt (13) Washer (14) Dowel

7. Discard four dowels (9), two bolts (10), two washers (11), 22 bolts (12), 22 washers (13), and two dowels (14).

Oscillating Axle (Rear) - Rework

Intermediate and Differential Housing

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Illustration 3	g06131437
(1) Left side axle housing (2) Left side brake piston retainer (3) Intermediate housing (4) Differential housing (5) Right side brake piston retainer (6) Right side axle housing

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Illustration 4	g06131440
Outer facing of the intermediate housing (3) Intermediate housing (4) Differential housing (A) Dowel hole 19.05 mm (0.75 inch) (B) 100 mm (3.94 inch)

1. With two bolts retaining intermediate housing (3) to differential housing (4), drill three holes (A).

   Note: Refer to Illustration 1 to identify the location of the two retaining bolts.

   Note: Intermediate housing (3) must be firmly bolted to differential housing (4).

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   Illustration 5	g06138527
   Outer facing of the intermediate housing (3) Intermediate housing (4) Differential housing (A) Do not drill (C) Do not drill (D) Drill and tap 21 holes (E) 74 mm (2.90 inch) (F) 110 mm (4.35 inch) (G) 115 mm (4.50 inch)

2. Drill 21 holes (D), 18 mm (0.70 inch) in diameter to depth (G). Refer to Illustration 5.

3. Drill 21 holes (D), 21 mm (0.83 inch) in diameter to depth (E). Refer to Illustration 5.

4. Tap 21 holes (D), M20 x 2.5 to depth (F). Refer to Illustration 5.

5. Rotate the differential housing to access the right side.
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   Illustration 6	g06131852
   Right side of the differential housing (4) Differential housing (H) Dowel hole 19.05 mm (0.75 inch) (J) 32 mm (1.26 inch)

6. Drill three holes (H).
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   Illustration 7	g06131860
   Right side of the differential housing (4) Differential housing (H) Do not drill (K) Do not drill (L) Drill and tap M20 x 2.5 with counter-bore (M) 44 mm (1.73 inch) (N) Counter-bore 1 mm (0.040 inch) (P) 21 mm (0.83 inch)

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   Illustration 8	g06131863
   Right side of the differential housing (L) Drill and tap M20 x 2.5 (R) 180.93 mm (7.123 inch) (T) 145.21 mm (5.717 inch) (U) 141.23 mm (5.560 inch) (V) 184.06 mm (7.246 inch)

7. Drill and tap two holes (L). Machine a 1 mm (0.040 inch) counter bore (N) to each hole (L). Refer to Illustration 7 and Illustration 8.

   Note: There are no existing holes at location (L).

8. Drill and tap the remaining 19 holes to M20 x 2.5 TPI. Machine a 1 mm (0.040 inch) counter bore (N) to each of the 19 holes. Refer to Illustration 7.

   Note: Do not drill three holes (H) and four holes (K).

Retainers

Note: The right side retainer on the front fixed axle is identical to the left side retainer on the rear oscillating axle.

Note: The left side retainer on the front fixed axle is identical to the right side retainer on the rear oscillating axle.

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Illustration 9	g06131437
(1) Left side axle housing (2) Left side brake piston retainer (3) Intermediate housing (4) Differential housing (5) Right side brake piston retainer (6) Right side axle housing

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Illustration 10	g06134321
View of a standard and a reworked left side brake piston retainer for the rear oscillating axle View of a standard and a reworked right side brake piston retainer for the front fixed axle (2) Left side brake piston retainer (A) Dowel hole 19.05 mm (0.75 inch) (B) Do not drill

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Illustration 11	g06134790
View of a standard and a reworked right side brake piston retainer for the rear oscillating axle View of a standard and a reworked left side brake piston retainer for the front fixed axle (5) Right side brake piston retainer (A) Dowel hole 19.05 mm (0.75 inch) (B) Do not drill

1. Drill 3 holes (A) in each retainer. Refer to Illustration 10 and Illustration 11.

2. Drill 21 holes from 18 mm (0.71 inch) to 22 mm (0.87 inch) in each retainer.

   Note: Do not drill four holes (B) in either retainer.

3. Rotate the brake piston retainers to access the other side.
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   Illustration 12	g06134322
   View of a standard and a reworked left side brake piston retainer for the rear oscillating axle View of a standard and a reworked right side brake piston retainer for the front fixed axle (2) Left side brake piston retainer (C) Drill 14 mm (0.55 inch) with counter-bore (D) 22 mm (0.87 inch)

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   Illustration 13	g06134791
   View of a standard and a reworked right side brake piston retainer for the rear oscillating axle View of a standard and a reworked left side brake piston retainer for the front fixed axle (5) Right side brake piston retainer (C) Drill 14 mm (0.55 inch) with counter-bore (D) 22 mm (0.87 inch)

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   Illustration 14	g06131888
   Sectional view of the brake piston retainer (C) Drill 14 mm (0.55 inch) with counter-bore (E) Counter-bore 14.5 mm (0.57 inch) (F) 20.5 mm (0.80 inch)

4. Drill two holes (C) and machine counter-bore (E) in each retainer. Refer to Illustration 12 through Illustration 14.

5. Drill two holes (D) in each retainer. Refer to Illustration 12 and Illustration 13.

Axle Housings

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Illustration 15	g06131437
(1) Left side axle housing (2) Left side brake piston retainer (3) Intermediate housing (4) Differential housing (5) Right side brake piston retainer (6) Right side axle housing

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Illustration 16	g06132378
View of the inner facings of the left and right side axle housings (1) Left side axle housing (6) Right side axle housing (A) Dowel hole 19.05 mm (0.75 inch) (B) Do not drill (C) M12 x 1.75 with counter-bore (D) Drill 22 mm (0.87 inch)

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Illustration 17	g06134320
Sectional view of the axle housing (A) Dowel hole 19.05 mm (0.75 inch) (E) 32 mm (1.26 inch)

1. Drill 3 holes (A) in each axle housing. Refer to Illustration 16 and Illustration 17.
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   Illustration 18	g06132382
   Sectional view of the axle housing (C) M12 x 1.75 with counter-bore (F) 18 mm (0.71 inch) (G) 14 mm (0.55 inch) (H) 48 mm (1.89 inch)

2. Drill and tap 2 holes (C) with counter-bore, in each axle housing. Refer to Illustration 16 and Illustration 18.

3. Drill 2 holes (D) in each axle housing. Refer to Illustration 16 .

4. Drill the remaining 19 holes from 18 mm (0.71 inch) to 22 mm (0.87 inch) in each axle housing.

   Note: Do not drill four holes (B) in either axle housing.

Axle Plate

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Illustration 19	g06132383
(1) Axle plate (A) 22 mm (0.87 inch)

1. Drill 3 holes (A) to the left and right side axle plates.

Oscillating Axle (Rear) - Assemble

Refer to the following Illustrations when assembling the axle.

Note: Loctite 5188 must be used where indicated.

Illustration 20	g06132868
Sealing locations (1) 4K-6804 O-Ring Seal (2) 8R-0932 Shim Pack (3) 8T-8883 O-Ring Seal (4) 5H-3252 O-Ring Seal (5) 2R-0239 O-Ring Seal (A) Loctite 5188

Illustration 21	g06132869
Left side axle housing (6) 222-2462 Bolt (7) 226-4192 Hard Washer (8) 170-3396 Bolt

Illustration 22	g06132870
Right side axle housing (7) 226-4192 Hard Washer (9) 170-3394 Bolt (10) 138-3252 Bolt

Illustration 23	g06135268
Left side axle housing assembly (11) 7X-0599 Hard Washer (12) 095-0673 Bolt (13) 357-0339 Dowel (14) Dowel - use existing (15) 6K-8987 Dowel

Illustration 24	g06132876
Right side axle housing assembly (11) 7X-0599 Hard Washer (12) 095-0673 Bolt (13) 357-0339 Dowel

1. Install the differential and bevel gear. Refer to Disassembly and Assembly , Differential and Bevel Gear - Install.

2. Assemble the left side and the right side service brakes. Refer to Disassembly and Assembly , Service Brake - Assemble.

3. Assemble and install the left side and the right side parking brakes. Refer to Disassembly and Assembly , Parking Brake - Assemble and Disassembly and Assembly , Parking Brake - Install.

   Note: Apply Loctite 272 to the threads of bolts (6), bolts (8), bolts (9), and bolts (10) prior to assembly. Tighten to a torque of 520 ± 70 N·m (385 ± 50 lb ft). Refer to Illustration 21 and Illustration 22.

4. Install front and rear trunnion supports. Refer to Disassembly and Assembly , Trunnion Support (Oscillating Axle, Front) - Install, and Disassembly and Assembly , Trunnion Support (Oscillating Axle, Rear) - Install.

5. Install the rear oscillating axle. Refer to Disassembly and Assembly , Oscillating Axle (Rear) - Install.

Fixed Axle (Front) - Disassemble

1. Remove the front axle. Refer to Disassembly and Assembly , Fixed Axle (Front) - Remove.

2. Remove and disassemble the left side and the right side parking brakes. Refer to Disassembly and Assembly , Parking Brake - Remove, and Disassembly and Assembly , Parking Brake - Disassemble.

3. Disassemble the left side and the right side service brakes. Refer to Disassembly and Assembly , Service Brake - Disassemble.

4. Remove the differential and bevel gear. Refer to Disassembly and Assembly , Differential and Bevel Gear - Remove.
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   Illustration 25	g06135272
   View of the left side of the axle assembly (1) Bolt (2) Washer (3) Dowel (4) Bolt (5) Washer (6) Dowel

5. Discard 22 bolts (1), 22 washers (2), two dowels (3), two bolts (4), two washers (5), and four dowels (6).
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   Illustration 26	g06135274
   View of the right side of the axle assembly (7) Bolt (8) Washer (9) Dowel (10) Bolt (11) Washer (12) Dowel (13) Dowel (14) Bolt

6. Discard two bolts (7), two washers (8), two dowels (9), 22 bolts (10), 22 washers (11), four dowels (12), four dowels (13), and one bolt (14).

   Note: Only one bolt (14) is discarded, three remain.

Fixed Axle (Front) - Rework

Intermediate and Differential Housings

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Illustration 27	g06133796
(1) Left side axle housing (2) Left side brake piston retainer (3) Differential housing (4) Intermediate housing (5) Right side brake piston retainer (6) Right side axle housing

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Illustration 28	g06133798
Outer facing of the intermediate housing (3) Differential housing (4) Intermediate housing (A) Dowel hole 19.05 mm (0.75 inch) (B) 100 mm (3.94 inch)

1. With three bolts retaining intermediate housing (4) to differential housing (3), drill three holes (A).

   Note: Refer to Illustration 26 to identify the location of the three retaining bolts.

   Note: Intermediate housing (4) must be firmly bolted to differential housing (3).

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   Illustration 29	g06138877
   Outer facing of the intermediate housing (3) Differential housing (4) Intermediate housing (A) Do not drill (C) Do not drill (D) Drill and tap 20 holes (E) 74 mm (2.90 inch) (F) 110 mm (4.35 inch) (G) 115 mm (4.50 inch)

2. Drill 20 holes (D), 18 mm (0.70 inch) in diameter to depth (G). Refer to Illustration 29.

3. Drill 20 holes (D), 21 mm (0.83 inch) in diameter to depth (E). Refer to Illustration 29.

4. Tap 20 holes (D), M20 x 2.5 to depth (F). Refer to Illustration 29.

5. Rotate the differential housing to access the other side.
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   Illustration 30	g06133805
   Left side of the differential housing (3) Differential housing (H) Dowel hole 19.05 mm (0.75 inch) (J) 32 mm (1.26 inch)

6. Drill three holes (H).
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   Illustration 31	g06133806
   Left side of the differential housing (3) Differential housing (H) Do not drill (K) Do not drill (L) Drill and tap M20 x 2.5 with counter-bore (M) 44 mm (1.73 inch) (N) Counter-bore 1 mm (0.040 inch) (P) 21 mm (0.83 inch)

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   Illustration 32	g06133807
   Left side of the differential housing (3) Differential housing (L) Drill and tap M20 x 2.5 (R) 141.23 mm (5.560 inch) (T) 184.06 mm (7.246 inch)

7. Drill and tap one hole (L). Machine a 1 mm (0.040 inch) counter bore (N) to hole (L). Refer to Illustration 31 and Illustration 32.

   Note: There is no existing hole at location (L).

8. Drill and tap the remaining 19 holes to M20 x 2.5 TPI. Machine a 1 mm (0.040 inch) counter bore (N) to each of the 19 holes. Refer to Illustration 31.

   Note: Do not drill three holes (H) and four holes (K).

Retainers

The right side retainer on the front fixed axle is identical to the left side retainer on the rear oscillating axle.

The left side retainer on the front fixed axle is identical to the right side retainer on the rear oscillating axle.

Refer to "Oscillating Axle (Rear) - Rework", "Retainers" to rework the retainers on the front fixed axle.

Axle Housings

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Illustration 33	g06133796
(1) Left side axle housing (2) Left side brake piston retainer (3) Differential housing (4) Intermediate housing (5) Right side brake piston retainer (6) Right side axle housing

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Illustration 34	g06134792
View of a standard and a reworked left side axle housing (1) Left side axle housing (A) Dowel hole 19.05 mm (0.75 inch) (B) Do not drill (C) M12 x 1.75 with counter-bore (D) Do not drill (E) Drill 22 mm (0.87 inch)

1. Drill three holes (A) to left side axle housing (1).
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   Illustration 35	g06132382
   Sectional view of the axle housing (C) M12 x 1.75 with counter-bore (F) 18 mm (0.71 inch) (G) 14 mm (0.55 inch) (H) 48 mm (1.89 inch)

2. Drill and tap two holes (C) with counter-bore, to left side axle housing (1). Refer to Illustration 34 and Illustration 35.

3. Drill one hole (E) from M12 mm to 22 mm (0.87 inch) in left side axle housing (1). Refer to Illustration 34.

4. Drill the remaining 19 holes from 18 mm (0.70 inch) to 22 mm (0.87 inch) in left side axle housing (1). Refer to Illustration 34.

   Note: Do not drill four holes (B).

   Note: Hole (D) remains the same and is now unused.

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   Illustration 36	g06134795
   View of a standard and a reworked right side axle housing (6) Right side axle housing (A) Dowel hole 19.05 mm (0.75 inch) (B) Do not drill (C) M12 x 1.75 with counter-bore (D) Do not drill (E) Drill 22 mm (0.87 inch)

5. Drill three holes (A) to right side axle housing (6).

6. Drill and tap two holes (C) with counter-bore, to right side axle housing (6). Refer to Illustration 35 and Illustration 36.

7. Drill one hole (E) from M12 mm to 22 mm (0.87 inch) in right side axle housing (6). Refer to Illustration 36.

8. Drill the remaining 19 holes from 18 mm (0.70 inch) to 22 mm (0.87 inch) in right side axle housing (6). Refer to Illustration 36.

   Note: Do not drill four holes (B).

   Note: Hole (D) remains the same and is now unused.

Fixed Axle (Front) - Assemble

Refer to the following Illustrations when assembling the axle.

Note: Loctite 5188 must be used where indicated.

Illustration 37	g06134797
Sealing locations (1) 2R-0239 O-Ring Seal (2) 5H-3252 O-Ring Seal (3) 8T-8883 O-Ring Seal (4) 4K-6804 O-Ring Seal (5) 8R-0932 Shim Pack (A) Loctite 5188

Illustration 38	g06135264
Left side axle housing (6) 170-3394 Bolt (7) 226-4192 Hard Washer

Illustration 39	g06135265
Right side axle housing (7) 226-4192 Hard Washer (8) 222-2462 Bolt

Illustration 40	g06135270
Right side axle housing assembly (9) 095-0673 Bolt (10) 7X-0599 Hard Washer (11) Dowel - use existing (12) 6K-8987 Dowel (13) 357-0339 Dowel

Illustration 41	g06135267
Left side axle housing assembly (9) 095-0673 Bolt (10) 7X-0599 Hard Washer (13) 357-0339 Dowel

1. Install the differential and bevel gear. Refer to Disassembly and Assembly , Differential and Bevel Gear - Install.

2. Assemble the left side and the right side service brakes. Refer to Disassembly and Assembly , Service Brake - Assemble.

3. Assemble and install the left side and the right side parking brakes. Refer to Disassembly and Assembly , Parking Brake - Assemble and Disassembly and Assembly , Parking Brake - Install.

   Note: Apply Loctite 272 to the threads of bolts (6) and bolts (8) prior to assembly. Tighten to a torque of 520 ± 70 N·m (385 ± 50 lb ft). Refer to Illustration 38 and Illustration 39.

4. Install the front axle. Refer to Disassembly and Assembly , Fixed Axle (Front) - Install.