Usage:
Start By:
a. separate track assemblies
Fluid Spillage Containment
Care must be taken to ensure that the fluids are contained during performance of the inspection, the maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and mandates.
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At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the hydraulic system before any of the hydraulic lines or any of the components are disconnected or removed. |
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1. Release the pressure in all of the implement hydraulic circuits (the boom, the stick and the bucket) before any of the hydraulic lines or any of the components are disconnected or removed, as follows:
a. Fully retract the stick cylinder rod.
b. Adjust the position of the bucket so that it will be flat on the ground when the boom is lowered.
c. Lower the boom until the bucket is flat on the ground.
d. Shut off the engine and place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.
e. Move the control levers for the boom, the stick and the swing to all full stroke positions. This will release any pressure that might be present in the pilot system.
f. Return the key to "OFF" position.
g. Slowly loosen the fill plug on the hydraulic tank and release the pressure.
h. Tighten the fill plug on the hydraulic tank. Tighten the fill plug to a torque of 68 ± 7 N*m (50 ± 5 lb ft).
i. The pressure in the hydraulic system has been released and the hydraulic lines and the components can be removed.
2. Remove four bolts (1) and the washers that hold cover assembly (2). Remove cover assembly (2) from the inside rear of the undercarriage frame assembly.
3. When two tube assemblies (3) are disconnected from the travel brake valve and two hose assemblies (4) and (5) are disconnected from the travel motor, oil will flow from the tube assemblies and hose assemblies. Place a suitable drain pan under the tube assemblies and the hose assemblies.
4. Disconnect two tube assemblies (3) from the travel brake valve.
5. Disconnect hose assemblies (4) and (5) from the travel motor. Put plugs in the ends of the tube assemblies and hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system.
6. Remove elbow (6) from the travel motor.
7. Fasten Tooling (A) and a hoist to final drive (7) as shown. Put slight lifting tension on the final drive.
8. Remove two plugs (9) from the forcing bolt holes in the undercarriage frame assembly.
9. Remove 20 bolts (8) and the washers that hold the final drive to the undercarriage frame assembly.
10. Install two suitable size forcing bolts (10) in the forcing bolt holes in the frame. Tighten the two forcing bolts evenly to loosen the final drive from the undercarriage frame assembly.
11. Carefully remove final drive (7) from the undercarriage frame assembly. The combined weight of the final drive and the travel motor is 500 kg (1100 lb).
12. Remove two forcing bolts (10) from the undercarriage frame assembly.
NOTE: The following steps are for the installation of the final drive.
13. Make sure the mating surfaces of the final drive and the undercarriage frame assembly are thoroughly clean and free of dirt and debris.
14. Check the condition of the O-ring seals used in the ends of two tube assemblies (3) and hose assemblies (4) and (5). If any of the O-ring seals are damaged, use new parts for replacement.
15. Fasten Tooling (A) and a hoist final drive (7). Carefully put the final drive in position in the undercarriage frame assembly.
16. Apply 9S-3263 Thread Lock on the threads of 20 bolts (8). Install 20 bolts (8) that hold the final drive to the undercarriage frame assembly. Tighten the bolts evenly.
17. Install two plugs (9) in the forcing bolt holes in the undercarriage frame assembly.
18. Install the O-ring seal on elbow (6). Install the elbow in the travel motor. Tighten the elbow to a torque of 40 ± 5 N*m (30 ± 4 lb ft). Make sure the elbow oriented properly.
19. Connect hose assemblies (4) and (5) to the travel motor.
20. Connect two tube assemblies (3) to the travel brake valve.
NOTE: Refer to the topic "Lubricant Viscosities and Refill Capacities" in the "Operation & Maintenance Manual" for the proper filling procedure and the proper levels for the hydraulic system.
21. Check the oil level in the hydraulic oil tank. If necessary, fill it to the correct level.
22. Start the machine, and check for oil leaks.
23. Install cover assembly (2), the washers and four bolts (1). Tighten four bolts (1) to a torque of 130 ± 10 N*m (95 ± 7 lb ft).
End By:
a. connect track assemblies
Disassemble & Assemble Final Drives
Start By:
a. remove final drives
1. Thoroughly clean the outside of the final drive prior to disassembly.
2. Put an alignment mark across the sections of the final drive for assembly purposes. The parts must be reinstalled in their original locations.
3. Fasten the final drive to Tool (A) as shown. The combined weight of the final drive and the final drive sprocket is 310 kg (685 lb).
4. Remove 20 bolts (1) and the washers that hold the cover in place.
5. Using a soft faced hammer, break the seal between cover (2) and the ring gear.
6. Fasten Tooling (B) and a hoist to cover (2) as shown. Remove the cover. The weight of the cover is 32 kg (70 lb).
7. Remove thrust plate (5) from the cover.
8. Remove 12 socket head bolts (3) and ring gear (4) from the cover.
9. Remove sun gear (6).
10. Remove carrier assembly (7) by lifting it straight up. The weight of the carrier assembly is 14 kg (30 lb).
NOTE: Two spacers (8) are used with carrier assembly (7). One of the spacers fits on the top side of carrier assembly (7). The other spacer (8) is located in the carrier of carrier assembly (15).
11. Remove spacer (8) from carrier assembly (7).
NOTE: Planetary gears (11) have identification marks (L) on them. Note the position of the identification marks in relation to the carrier for assembly purposes.
12. Remove retaining ring (9) with Tool (C).
13. Remove two thrust washers (10) and planetary gear (11) from the carrier.
14. Remove bearing (12) from the planetary gear.
15. Remove the other two planetary gears from the carrier as in Steps 12 through 14.
16. Using a screwdriver, remove retaining ring (13) from the carrier.
17. Remove sun gear (14) from the carrier.
18. Using two persons, remove carrier assembly (15) by pulling it straight up. The weight of the carrier assembly is 25 kg (55 lb).
NOTE: Spacer (16) may remain with carrier assembly (15), or it may remain with carrier assembly (24) (refer to Step 27).
19. Remove the other spacer (8) (not shown) from the top side of carrier assembly (15). Remove spacer (16) from the bottom side of carrier assembly (15).
20. Drive spring pin (17) into planetary shaft (18) with a hammer and a punch.
NOTE: Planetary gears (20) have identification marks (M) on them. Note the position of the identification marks in relation to the carrier for assembly purposes.
21. Remove planetary shaft (18), two thrust washers (19) and planetary gear (20) from the carrier.
22. Remove bearing (21) from the planetary gear.
23. Remove spring pin (17) from planetary shaft (18) with a hammer and a punch.
24. Remove the other two planetary gears from the carrier as in Steps 20 through 23.
25. Using a screwdriver, remove retaining ring (22).
26. Remove sun gear (23) from the carrier.
27. If spacer (16) was not removed in Step 19, remove it from carrier assembly (24) at this time.
28. Slide a piece of steel bar stock in between the planetary gears in carrier assembly (24) as shown. Make sure the bar stock is centered in the carrier assembly.
29. Fasten a lifting sling and a hoist to the steel bar stock as shown. Slowly lift carrier assembly (24) from the final drive. The weight of the carrier assembly is 36 kg (80 lb).
30. Drive spring pin (25) into planetary shaft (26) with a hammer and a punch.
NOTE: Planetary gears (28) have identification marks (N) on them. Note the position of the identification marks in relation to the carrier for assembly purposes.
31. Remove planetary shaft (26), two thrust washers (27) and planetary gear (28) from the carrier.
32. Remove two bearings (29) from the planetary gear.
33. Drive spring pin (25) out of planetary shaft (26) with a hammer and a punch.
34. Remove the other two planetary gears from the carrier as in Steps 30 through 33.
NOTE: It will be necessary to pry ring gear (30) away from main housing (31) in order to install the lifting slings.
35. Fasten lifting slings and a hoist to ring gear (30) as shown. Remove the ring gear from main housing (31). The weight of the ring gear is 48 kg (105 lb).
36. Remove O-ring seal (32) from main housing (31).
37. Remove 16 socket head bolts (33) from gear (34).
38. Using Tooling (D), remove gear (34) from the housing.
39. Remove shim(s) (35) from the housing.
40. Fasten Tooling (E) and a hoist to main housing (31) as shown. Separate the main housing and final drive sprocket from the motor housing. The combined weight of the main housing and the final drive sprocket is approximately 105 kg (232 lb).
41. Remove Duo-Cone seal (36) from the motor housing.
42. Remove Duo-Cone seal (37) from the main housing.
43. Use Tooling (F) to remove bearings (38) and (39) from the main housing.
44. If necessary, remove the sprocket from the main housing. Refer to the topic "Remove & Install Final Drive Sprockets" in this module for details concerning the removal of the sprocket from the main housing.
NOTE: The following steps are for the assembly of the final drives.
45. Make sure all parts of the final drive are thoroughly clean and free of dirt and debris prior to assembly. Check the condition of all O-ring seals used in the final drive. If any of the O-ring seals are damaged, use new parts for replacement. Reassemble the final drive on Tool (A).
46. If the final drive sprocket was removed from the main housing, refer to the topic "Remove & Install Final Drive Sprockets" in this module. This topic will give the necessary details for the installation on the sprocket on the main housing.
47. Apply 5P-3931 Anti-Seize Compound to the surfaces inside the main housing that make contact with bearings (38) and (39). Install bearings (38) and (39) in their original locations in the main housing with a press. Install the bearings until they make contact with the counterbores in the main housing.
48. Use the following procedure to determine the correct bearing preload and the correct thickness of shim(s) (35) used under gear (34):
a. Fasten Tooling (E) and a hoist to main housing (31) as shown. Install the main housing on the motor housing.
b. Using a suitable press and spacer, apply a load of 4000 kg (8820 lb)on bearing (38).
c. Rotate the main housing to seat the bearings.
d. Reduce the load on bearing (38) to 1000 ± 100 kg (2200 ± 220 lb).
e. With the load still on bearing (38), measure the distance between the top face of the motor housing and the inner race of bearing (38) with a depth micrometer. Take this measurement in several locations around the bearing. Find the average of the dimensions measured, and record it. Call this dimension (Y).
f. Using a depth micrometer, measure the step height of gear (34) at several locations around the gear. Find the average of the dimensions measured, and record it. Call it dimension (X).
g. Determine the correct thickness of the shim pack [made up of shims (35)] to be used between the motor housing and gear (34). The shim pack thickness is equal to dimension (Y) - (X) ± 0.05 mm (.002 in).
NOTE: If two shims are required, install the thinner shim next to gear (34) when it is installed.
49. Remove the main housing from the motor housing.
| NOTICE |
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Refer to the topic "Assembly And Installation Of Conventional Duo-Cone Seals" in this module. |
NOTE: The rubber seals and all of the surfaces that make contact with the seals must be clean and dry. After the installation of the rubber seals, put clean SAE 30 oil on the contact surfaces of the metal seals.
50. Install Duo-Cone seal (37) in the main housing with Tool (G).
51. Install Duo-Cone seal (36) in the motor casing with Tool (G).
| NOTICE |
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Do Not scratch or damage the Duo-Cone seals in the main housing or the motor housing during the assembly of these two components. After the installation of the main housing on the motor housing, there will be a small gap between the components. The gap is caused by the Duo-Cone seals and will be eliminated during the installation of gear (34). |
52. Fasten Tooling (E) and a hoist to main housing (31). Put the main housing and final drive sprocket in position on the motor housing. Do Not scratch or damage the Duo-Cone seals in either components during the installation.
53. Apply 5P-3931 Anti-Seize Compound on the four pins in gear (34).
54. Put shim pack (35) determined in Step 48a through 48g and gear (34) in the correct position on the motor housing. If two shims were required, put the thinner shim in contact with the gear (34). Make sure all of the holes in the components are in alignment with each other.
55. Apply 9S-3263 Thread Lock on the threads of 16 socket head bolts (33). Install the socket head bolts to hold gear (34) in place. Tighten the bolts evenly and in diagonally opposite pairs.
56. Install O-ring seal (32) in main housing (31).
57. Thoroughly clean the mating surface of main housing (31) that makes contact with ring gear (30). Apply a bead of 1U-8846 Gasket Maker on the mating surface of ring gear (30).
58. Fasten lifting slings and a hoist to ring gear (30). Put the ring gear in position on the main housing. Make sure the alignment mark on the main housing and the ring gear line up with each other. It may be necessary to use a soft faced hammer to seat the ring gear on the main housing.
59. Assemble carrier assembly (24).
a. Put clean SAE 30 oil on bearings (29).
b. Install two bearings (29) in planetary gear (28).
c. Install a thrust washer (27) on each side of the planetary gear.
d. Install the planetary gear and thrust washers in carrier (24).
e. Make sure identification grooves (N) are facing in the correct direction.
f. Install planetary shaft (26) in carrier (24) and through planetary gear (28).
g. Make sure the spring pin hole in the planetary shaft is in alignment with the spring pin hole in the carrier.
60. Install spring pin (25) in the carrier and into the planetary shaft. Install the spring pin until it is even with the outside surface of the carrier and with the split in the spring pin oriented horizontal to the carrier either to the left or right.
61. To prevent the spring pin from falling out, make a stake mark on each side of the spring pin hole in the carrier. Each stake mark should be approximately 1.5 mm (.10 in) from the outside diameter of the spring pin hole.
62. Install the other two planetary gears in carrier (24) as in Steps 59 through 61.
63. Install carrier assembly (24) in ring gear (30).
a. Slide a piece of steel bar stock in between the planetary gears in carrier assembly (24) as shown.
b. Make sure the bar stock is centered in the carrier assembly. Fasten a lifting sling and a hoist to the steel bar stock as shown.
c. Lower the carrier assembly in position in the ring gear. It may be necessary to move the carrier assembly back and forth to allow all gears to line up and mesh properly.
d. Make sure the carrier assembly is seated properly.
64. Install spacer (16) in carrier assembly (24) as shown.
65. Assemble carrier assembly (15).
a. Install sun gear (23) in carrier (15).
b. Make sure identification grooves (M) are facing in the correct direction as noted during the disassembly of the carrier assembly.
c. Using a screwdriver, install retaining ring (22) that holds the sun gear in the carrier.
d. Put clean SAE 30 oil on bearing (21).
e. Install bearing (21) in planetary gear (20).
f. Install a thrust washer (19) on each side of the planetary gear.
g. Install thrust washers and the planetary gear in carrier (15).
h. Install planetary shaft (18) in carrier (15) and through planetary gear (20). Make sure the spring pin hole in the carrier is in alignment with the spring pin hole in the planetary shaft.
66. Install spring pin (17) in the carrier and into the planetary shaft. Install the spring pin until it is even with the outside surface of the carrier and with the split in the spring pin oriented horizontal to the carrier either to the left or right.
67. To prevent the spring pin from falling out, make a stake mark on each side of the spring pin hole in the carrier. Each stake mark should be approximately 1.5 mm (.10 in) from the outside diameter of the spring pin hole.
68. Install the other two planetary gears in carrier (15) as in Step 64 through 67.
69. Install carrier assembly (15) in carrier assembly (24). Move the carrier back and forth during the installation to ensure all gears engage properly. Make sure the carrier assembly is seated properly.
70. Install spacer (8) in the top side of carrier assembly (15).
| NOTICE |
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Make sure retaining ring (9) is installed with the cross section of the ring as shown in Illustration C28669P2. |
71. Assemble carrier assembly (7).
a. Install sun gear (14) in carrier (7) as shown in Photo C47814P1.
b. Using a screwdriver, install retaining ring (13) that holds the sun gear in the carrier.
c. Put clean SAE 30 oil on bearing (12), and install the bearing in planetary gear (11).
d. Install a thrust washer (10) on each side of the planetary gear.
e. Install the planetary gear and thrust washers on the shaft of carrier (7).
f. Make sure identification marks (L) are facing in the same direction as noted during the disassembly of carrier assembly (7).
g. Using Tool (C), install retaining ring (9) to hold the planetary gear in position. Make sure the retaining ring is installed with the cross section of the ring as shown in Illustration C28669P2.
71. Install the other two planetary gears on carrier assembly (7) as in Step 70.
72. Install spacer (8) in carrier assembly (7).
73. Install carrier assembly (7) in carrier assembly (15). Make sure the carrier assembly is seated properly.
74. Install sun gear (6) in carrier assembly (7).
75. Use a 25.4 mm (1.00 in) thick straight edge and a depth micrometer to measure the distance from the upper surface of sun gear (6) to the machined surface of ring gear (30). Record this dimension. Call it dimension (P).
76. Use a 25.4 mm (1.00 in) thick straight edge and a depth micrometer to measure the distance from the machined surface of cover (2) to the bottom of thrust plate (5) insertion hole. Record this dimension. Call this dimension (Q).
NOTE: Thrust plate (5) is available in several thicknesses.
77. Determine the correct thickness of thrust plate (5). Thrust plate thickness is equal to dimension (Q) - (P) - 1.0 to 2.0 mm (.04 to .08 in).
78. Install the correct thickness thrust plate (5) in cover (2) with a plastic hammer.
79. Put ring gear (4) in position in cover (2). Make sure all of the mounting bolt holes in both components are in alignment with each other.
80. Apply 9S-3263 Thread Lock on the threads of 12 socket head bolts (3) that hold ring gear (4) in place. Install the bolts, and tighten them evenly.
81. Make sure the machined surface of ring gear (30) is thoroughly clean, free of dirt and debris and is dry.
82. Apply a bead of 1U-8846 Gasket Maker around the machined surface of the ring gear.
83. Fasten Tooling (B) and a hoist to cover (2). Put the cover in its original position on the ring gear. It will be necessary to rotate the cover back and forth to engage the planetary gears of carrier assembly (7) with the ring gear in the cover (2).
84. Apply 9S-3263 Thread Lock on the threads of 20 bolts (1) that hold cover (2) in position. Install the bolts and the washers. Tighten the bolts evenly to a torque of 530 ± 70 N*m (390 ± 50 lb ft).
End By:
a. install final drives