797 Off-Highway Truck Power Train Caterpillar

First Reduction and Second Reduction

Assembly of the First Reduction for the Final Drive

Note: The photographs in this story are used for illustration purposes only.

Note: Before assembly, clean all parts and inspect all parts for damage or for wear. Replace all damaged parts and/or worn parts with new parts.

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Illustration 1	g00798813

1. Use a suitable lifting device to position Tooling (AA) in a clear work area. The weight of Tooling (AA) is 227 kg (500 lb).

2. Use a suitable lifting device to position Tooling (AB) onto Tooling (AA). The weight of Tooling (AB) is 215 kg (475 lb).
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   Illustration 2	g00798814

3. Install four bolts (1) which hold Tooling (AA) to Tooling (AB).
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   Illustration 3	g00799871

4. Install four of Tooling (AC) onto Tooling (AB).
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   Illustration 4	g00799872

5. Install Tooling (B) onto carrier (2).
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   Illustration 5	g00799873

   Note: Ensure that carrier (2) is positioned properly onto Tooling (A). If carrier (2) is not properly positioned onto Tooling (A), damage could occur.

6. Attach a suitable lifting device to Tooling (B). Position carrier (2) onto Tooling (A).

7. Position carrier (2) onto Tooling (A). The weight of carrier (2) is 261 kg (575 lb).
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   Illustration 6	g00799874

8. Position gear (7) onto the work bench. The weight of gear (7) is 32 kg (71 lb).
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   Illustration 7	g00798837

9. Install snap ring (11) into gear (7).
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   Illustration 8	g00799875

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   Illustration 9	g00798838

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   Illustration 10	g00803067

10. Check the inside bore of gear (7). Check the inside bore for the larger surface from the ring groove to the outside edge. Position spacer (10) inside gear (7) on top of snap ring (11) on the side with the larger surface.
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    Illustration 11	g00799877

    Note: Bearings (8) are sold as matched sets. Keep the bearing cups and the bearing cones in order for assembly purposes.

11. Lower the temperature of cup (9) to a temperature of −40 °C (−40 °F).
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    Illustration 12	g00799878

12. Position cup (9) onto gear (7).
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    Illustration 13	g00799879

13. Install cup (9) into gear (7). Before gear (7) is turned over gear (7) and cup (9) should return to room temperature.

14. Turn over gear (7).

15. Lower the temperature of cup (9) to a temperature of −40 °C (−40 °F).
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    Illustration 14	g00799878

16. Position cup (9) onto gear (7).

17. Install cup (9) into gear (7).
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    Illustration 15	g00799881

18. Install the correct half of bearing (8) into the correct cup (9) in gear (7).
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    Illustration 16	g00799882

    Note: Bearing (8) will fall out of cup (9) when gear (7) is moved. Hold the bearing securely to prevent the bearing from falling out of the gear.

19. Turn over gear (7).
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    Illustration 17	g00798834

20. Install the other half of bearing (8). Position gear (7) to the side for future assembly.

21. Repeat Step 8 through Step 20 for the remaining three gears (7).
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    Illustration 18	g00798833

22. Attach Tooling (C) to a suitable lifting device.

23. Position Tooling (C) around gear (7). The weight of gear (7) and bearing (8) is approximately 47 kg (104 lb).

    Note: Bearing (8) may fall out of gear (7) when gear (7) is lifted from the work bench. Hold bearing (8) securely to prevent bearing (8) from falling out of gear (7).

24. Position gear (7) into carrier (2) at the rear of Tooling (A).
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    Illustration 19	g00798831

25. Install Tooling (D) into gear (7). Tooling (D) holds gear (7) in position to carrier (2).

26. Repeat Step 23 through Step 25 for one other gear (7).
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    Illustration 20	g00798823

    Note: Adjust the rails of the press bed so that the rails fit between the stops that are welded to the bottom of the fixture.

27. Use a suitable lifting device to install Tooling (A) and carrier (2) into Tooling (E). The weight of Tooling (A) and carrier (2) is approximately 807 kg (1779 lb).

    Note: Before continuing, ensure that carrier (2) is positioned correctly on Tooling (A). If the carrier is not properly located onto Tooling (A), damage to carrier (2) could occur. Refer to Illustrations 3 and 5.

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    Illustration 21	g00799883

28. Position the ram of Tooling (E) over the center of the hole for shaft (6). Remove Tooling (D) from gear (7).
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    Illustration 22	g00798819

29. Position shaft (6) into the hole of gear (7) and carrier (2). Position the hole on shaft (6) in line with alignment hole on carrier (2).
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    Illustration 23	g00799885

    Note: Slowly turn gear (7) as shaft (6) is pressed into position. to avoid damage to carrier (2), do not exceed 400 kN (90000 lb) of pressing force.

30. Use Tooling (E) to slowly press shaft (6) into gear (7) and carrier (2).
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    Illustration 24	g00799892

31. Relieve the pressure from Tooling (E).

32. Repeat Step 28 through Step 31 for the remaining shaft (6).
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    Illustration 25	g00800882

33. Use a suitable lifting device to remove Tooling (A) and carrier (2) from Tooling (E). The weight of Tooling (A) and carrier is approximately 823 kg (1814 lb).

34. Attach a suitable lifting device to Tooling (B).
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    Illustration 26	g00799873

35. Raise carrier (2) from Tooling (A) and turn by 180 degrees. Lower carrier (2) onto Tooling (A). The weight of carrier (2) is approximately 381 kg (840 lb).

36. Repeat Steps 23 through Step 25 for the remaining two gears (7).

37. Use a suitable lifting device to position Tooling (A) and carrier (2) into Tooling (E). The weight of Tooling (A) and carrier (2) is approximately 977 kg (2154 lb).

38. Repeat Step 28 through Step 31 for the remaining two shafts (6).
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    Illustration 27	g00800882

39. Use a suitable lifting device to remove Tooling (A) and carrier (2) from Tooling (E). The weight of Tooling (A) and carrier (2) is approximately 1006 kg (2218 lb).
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    Illustration 28	g00799886

40. Use Tooling (F) to measure the depth of shaft (6) to carrier (2).

41. Position Tooling (F) on carrier (2) and over shaft (6) to obtain a correct measurement.

42. Measure the depth of shaft (6) to carrier (2).

    Note: to calculate the correct thickness of shims, subtract 0.13 ± .03 mm (0.0051 ± 0.0012 inch) from the measurement that was obtained in Step 42.

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    Illustration 29	g00799888

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    Illustration 30	g00799889

43. After the required thickness of shims (5) is calculated use Tooling (G) to measure shims (5). One or more shims (5) may be used to acquire the correct thickness for shims (5).
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    Illustration 31	g00799890

44. Install shim (5) onto shaft (6) in carrier (2).
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    Illustration 32	g00798818

45. Install plate (4) onto carrier (2).
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    Illustration 33	g00798817

46. Apply Tooling (P) to the threads of bolts (3). Install three bolts (3) and the hard washers into shaft (6) (not shown) through plate (4) on carrier (2).

47. Tighten bolts (3) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

48. Repeat Step 40 through Step 47 for the remaining three shafts (6).

49. After carrier (2) is complete position carrier (2) on the side for future installation. The weight of carrier (2) is approximately 563 kg (1241 lb).

Assembly of the Second Reduction for the Final Drive

Note: The photographs in this story are used for illustration purposes only.

Note: Before assembly, clean all parts and inspect all parts for damage or for wear. Replace all damaged parts and/or worn parts with new parts.

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Illustration 34	g00799894

1. Use a suitable lifting device to position Tooling (HA) in a clear work area. The weight of Tooling (HA) is approximately 227 kg (500 lb).

2. Use a suitable lifting device to position Tooling (HB) onto Tooling (HA). The weight of Tooling (HB) is approximately 215 kg (474 lb).
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   Illustration 35	g00799897

3. Install four bolts (12) which hold Tooling (HA) to Tooling (HB).
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   Illustration 36	g00800280

4. Install four of Tooling (HC) into Tooling (HB).
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   Illustration 37	g00800293

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   Illustration 38	g00799893

5. Position carrier (13) onto Tooling (J).

6. Secure a suitable lifting device to Tooling (J). Position carrier (13) onto Tooling (H). The weight of carrier (13) is approximately 757 kg (1669 lb).
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   Illustration 39	g00799255

   Note: Bearings (19) are sold as matched sets. Keep the bearing rollers and the bearing raceways in the correct order for assembly purposes.

7. Use Tooling (K) to put gear (18) on the work bench. The weight of gear (18) is approximately 122 kg (270 lb).
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   Illustration 40	g00800289

8. Install two bearings (19) into gear (18). Insert one bearing (19) from each end of gear (18). Remove the plastic strap from bearing (19) as bearing (19) is being installed. Set gear (18) to the side for future installation.

9. Repeat Step 7 and Step 8 for the remaining three gears (18).
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   Illustration 41	g00800285

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   Illustration 42	g00800290

   Note: Bearings (19) will fall out of gear (18) when gear (18) is raised. Hold bearing (19) securely in gear (18) until gear (18) is installed.

10. Use Tooling (K) to move gear (18) to carrier (13) at the rear of Tooling (H). The weight of gear (18) and bearing (19) is approximately 98 kg (216 lb).
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    Illustration 43	g00800291

11. Install gear (18) into carrier (13).
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    Illustration 44	g00800292

12. Install Tooling (L) into gear (18).

13. Remove Tooling (K) from gear (18).

14. Repeat Step 10 through Step 13 for the other gear (18) in the rear of carrier (13).
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    Illustration 45	g00800296

15. Install Tooling (M) into shaft (14).
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    Illustration 46	g00800782

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    Illustration 47	g00800295

16. Use a suitable lifting device to position Tooling (H) to a position in front of Tooling (E). Prior to the installing of Tooling (H), a shaft (14) (not shown) must be installed in carrier (13). The weight of Tooling (H) and carrier (13) is approximately 1451 kg (3199 lb).

17. Attach a suitable lifting device to Tooling (M) and position shaft (14) above one of the Tooling (L) in the rear of carrier (13). The weight of shaft (14) is approximately 28 kg (62 lb). Remove Tooling (L) from one gear (18) and install shaft (14) in the hole left by Tooling (L). Remove Tooling (M) from shaft (14).
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    Illustration 48	g00800298

    Note: Adjust the rails of the press bed so that the rails fit between the stops that are welded on the bottom of the fixture.

18. Slowly position Tooling (H) and carrier (13) into Tooling (E). The weight of Tooling (H) and carrier (13) is approximately 1451 kg (3199 lb).
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    Illustration 49	g00800299

19. Align the arrow on carrier (13) with the hole on the top of shaft (14).
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    Illustration 50	g00800630

20. Align the ram of Tooling (E) over the center of shaft (14).
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    Illustration 51	g00800631

    Note: Slowly turn gear (18) as shaft (14) is pressed into gear (18). to avoid damage to carrier (13), do not exceed 700 kN (160000 lb) of pressing force.

21. Press shaft (14) into gear (18).
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    Illustration 52	g00800632

22. If the ram of Tooling (E) goes to the end of the stroke, relieve the pressure of Tooling (E). This will retract the ram of Tooling (E). Install Tooling (N) under the ram to press shaft (14) in the rest of the way.
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    Illustration 53	g00800633

23. Relieve pressure from the ram of Tooling (E).

24. Use a suitable lifting device to remove Tooling (H) and carrier (13) from Tooling (E). The weight of Tooling (H) and carrier (13) is approximately 1423 kg (3137 lb).

25. Repeat Step 15 through Step 24 for the remaining shaft (14).
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    Illustration 54	g00800293

26. Attach Tooling (J) to a suitable lifting device. Slowly raise carrier (13) and rotate carrier (13) by 180 degrees. Position carrier (13) onto Tooling (H). The weight of Tooling (H) and carrier (13) is approximately 1451 kg (3199 lb).

27. Repeat Step 10 through step 13 for the other two gears (18).

28. Repeat Step 15 through Step 24 for the remaining two shafts (14).
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    Illustration 55	g00799893

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    Illustration 56	g00800293

29. Use a suitable lifting device to remove Tooling (H) and carrier (13) from Tooling (E). The weight of Tooling (H) and carrier (13) is approximately 1763 kg (3887 lb).

30. Attach a suitable lifting device to Tooling (J) and remove carrier (13) from Tooling (H). The weight of carrier (13) is approximately 1321 kg (2912 lb).

31. Turn over carrier (13) and remove Tooling (J).
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    Illustration 57	g00800634

32. Install Tooling (B) onto carrier (13).

33. Attach a suitable lifting device to Tooling (B). Position carrier (13) on a suitable work bench.
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    Illustration 58	g00800636

34. Use Tooling (F) to measure the depth of shaft (14) to carrier (13).

35. Position Tooling (F) on carrier (13) and over shaft (14) to obtain a correct measurement.

36. Measure the depth of shaft (14) to carrier (13).

    Note: to calculate the correct thickness of shims, subtract 0.13 ± .03 mm (0.0051 ± 0.0012 inch) from the measurement that was obtained in Step 36.

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    Illustration 59	g00800661

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    Illustration 60	g00800662

37. After the required thickness of shim (17) is calculated use Tooling (G) to measure shims (17). One or more shims (17) may be used to acquire the correct thickness for shims (17).
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    Illustration 61	g00800663

38. Install the correct shim (17) onto shaft (14) in carrier (13).
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    Illustration 62	g00800664

39. Install plate (16) onto carrier (13).
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    Illustration 63	g00800665

40. Apply Tooling (P) to the threads of bolts (15). Install four bolts (15) and the hard washers into shaft (14) (not shown) onto carrier (13).

41. Tighten bolts (15) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

42. Repeat Step 35 through Step 41 for the remaining three shafts (14).

43. After carrier (13) is complete position carrier (13) to the side for future assembly. The weight of carrier (13) is approximately 1311 kg (2890 lb).

End By:

1. Install the first reduction and the second reduction of the final drive into a truck. Refer to Disassembly and Assembly, "Final Drive - Install".