M0091691 (M0083629): 797 Final Drive Axle Installation and Removal Tooling {0374, 0599, 0700, 0722, 0727, 3259, 3282, 4050} Caterpillar

Caterpillar Products Machine Engines

All C175 Series

Introduction

European Union Compliant, CE Marked

Important Safety Information

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Think Safety

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.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate, perform lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as “DANGER”,“WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety Section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. This section provides useful information on individual parts, extra tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.

Safety Section

General Hazard

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Information

Wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment. Make sure that all protective guards and all covers are secured in place on the equipment.

Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only.

Obey all local regulations for the disposal of liquids.

Do not allow unauthorized personnel on the equipment.

Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position. Refer to the Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position.

Crushing Prevention and Cutting Prevention

Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks.

Stay clear of all rotating and moving parts.

Safety Icon Nomenclature

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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To avoid injury do not stand on or between implement and machine while operating lift control.

Personal Protection/Important Information

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Personal Protection/Important Information

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

Contact Information

For product support questions concerning this tool, contact the Dealer Service Tools hotline at:

USA: 800-542-8665, Option 1

International: 1-309-578-7372

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

General Information Section

Introduction

The 797 Final Drive Axle Installation & Removal Tooling is designed to aid in the removal and installation of the final drive axle shafts (P/N’s 185-8902 and 185-8903). The tool is intended to provide additional leverage and alignment capabilities when removing and installing the axle shafts. The tool is not intended to be used as a lifting device.

Note: Refer to the appropriate Disassembly and Assembly Service Manual for extra setup.

The 3 parts shown in this document are used together to assist the service final drive axle shafts.

References

The list of references may change. Always locate and refer to the appropriate Disassembly and Assembly Service manual for the most current information.

Always locate and refer to the appropriate Disassembly and Assembly Service Manual for the most current information on your machine.

Tool Specifications and Nomenclature

487-8639 Plate Assembly

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487-8639 Plate Assembly

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The 487-8639 Plate Assembly is assembled to the final drive cover flange using existing bolts removed from the final drive cover flange. The shown slot allows the tool to be rotated onto the final drive cover flange for positional flexibility. The shown eyelet is used to attach a chain or come along to the additional parts. A suitable chain or come-along should be used with this part to offer best axle alignment.

487-8638 Tool Assembly Installation

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487-8638 Tool Assembly

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The 487-8638 Tool Assembly provides leverage to facilitate axle shaft gear alignment during installation.

524-9350 Adapter Assembly

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188-4534 Adaptor Assembly

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The 524-9350 Adaptor Assembly facilitates removal/installation of the axle shaft alignment by acting as guide. This tool contains a pin that is installed through the hole on both 524-9350 and 487-8638 tube to mate the two parts together. This part should not be used as a lifting device.

Operation Section-Disassembly

1. Center the 487-8639 Plate Assembly in the 12 o’clock position of the final drive cover. Mark the corresponding bolts for removal.

2. Install the 487-8639 Plate Assembly to the final drive using the bolts removed in Step 1.
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   Illustration above shows correct location of 487-8639 Plate Assembly

   Note: The puller plate bracket is slotted to accommodate alignment, ensure the puller winch eye (Feature 1) is aligned vertically at 12 o’clock.

3. Remove the bolts, cover plate, and o-ring seal to expose the final drive axle shaft.

4. Install the 524-9350 Adapter Assembly by threading onto the axle shaft. (Feature 8)

   Note: The Lifting Handle (Feature 7) shall not be used as a lifting point for rigging equipment. It is used to hold 524-9350 and turn the part.

5. Remove the lifting handle and reinsert the hitch pin. Using a lifting strap or chain, strap around the hitch pin.
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6. Pull the axle outward until the axle shaft splines are freed from the differential.
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7. Remove the strap or chain and hitch pin from 524-9350.

8. Install the 487-8368 Tool Assembly into the 524-9350 Adapter Assembly. Reinstall the hitch pin into the Adapter Assembly.
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9. Connect a vertical strap to the axle shaft. The strap should remain slightly loose to allow for positioning as the axle shaft is extracted from the final drive.
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10. Continue to extract the axle shaft from the final drive, while repositioning the vertical lift strap to the center of gravity (CG) of the assembly. Utilize the alignment tube of the 487-8638 Tool Assembly to help manipulate the axle shaft as it is removed.

    Note: Axle must be lifted at the center of gravity (CG) to ensure that load is balanced. Lifting axle shaft outside of CG may cause load to shift. For added protection, additional straps should be used. Place straps outward from strapping installed in Step 10.

Operation Section-Assembly

1. Center the 487-8639 Plate Assembly in the 12 o’clock position of the final drive cover. Mark the corresponding bolts for removal.
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2. Install the puller plate to the final drive using the bolts removed in Step 1.

   Note: The puller plate bracket is slotted to accommodate alignment, ensure the puller winch eye (Feature 1) is aligned vertically at 12 o’clock.

3. Thread the 524-9350 Adapter Assembly onto the axle shaft.

4. Install the 487-8638 Tool Assembly into the 524-9350 Adapter Assembly Secure using the hitch pin (Feature 8).

5. Position a lifting strap at the center of gravity (CG) of the complete assembly.

6. Lift the axle shaft with tooling installed into position and begin to slide into the final drive. Continue installation, repositioning the lifting strap as required.

7. Remove the vertical lifting strap when the axle shaft splines contact the mating splined differential coupler.

8. Connect a chain fail hoist or come-along winch between the winch eye (Feature 4) of the 487-8638 Tool AS and the winch eye (Feature 2) of the 487-8639 Plate Assembly.
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9. While gently raising, lowering, and rotating the 487-9637 Tool Assembly to align the splines, slowly winch the axle shaft into the mating differential coupler.
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10. Remove tooling from axle shaft and final drive.

11. Reinstall o-rings, cover plate, and bolts as instructed in appropriate SIS procedure.

Inspection and Maintenance Section

Inspection

1. Inspect all components prior to each use for nicks, burrs, dents, cracks, bends, or worn parts. If damage is found, discontinue use until inspected by an approved dealership inspector.

2. Inspect all welds, and check for damaged, cracked, or bent components.

3. Inspect all hardware for damaged threads.

4. Do not use unless load identification markings are legible.

5. Do not use if shackle holes and/or bolt holes are elongated.

6. Have tools inspected annually by an approved dealership inspector. Maintain a written record of all inspections

Service Parts

Not Available

Cleaning

Clean the tooling after each use, using a non-solvent cleaner.

Storage

1. Store the tooling in a clean dry location to prevent rust or corrosion. Tooling can be damaged by moisture or high humidity.

2. The tool should be stored in the most stable position.

Tool Disposal

At the end of the operational life of the tool, destroy the tool and dispose of as scrap.