CIPI UNDERCARRIAGE Arrangements: 9Q-5262, 191-4041, and 204-9207 Caterpillar

Type "A" Final Drive

Start By:

1. Remove the final drive. Refer to Disassembly and Assembly, "Final Drive - Remove" in this manual.

1. Remove the travel brake valve and travel motor from the final drive. Refer to Disassembly and Assembly, "Final Drive - Remove" in this manual.

2. Thoroughly clean the final drive prior to disassembly.

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Illustration 1	g00844261

3. Fasten the final drive to Tool (A), as shown. The weight of the final drive with the sprocket is approximately 238 kg (525 lb).

4. Put an alignment mark across the sections of the final drive for assembly purposes.

5. Remove 16 socket head bolts (2) that hold cover (1) in position. Use a soft faced hammer, and break the seal between the cover and ring gear (3). Remove cover (1) .

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Illustration 2	g00844268

6. Remove thrust plate (4) from the carrier assembly.

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Illustration 3	g00844275

7. Remove sun gear (5) from the final drive. Remove carrier assembly (6) from the ring gear. Remove the carrier assembly by pulling the carrier assembly straight up.

8. Use the following procedure to disassemble carrier assembly (6) .
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   Illustration 4	g00844278

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   Illustration 5	g00844280

   1. Drive spring pin (7) partially out of the carrier with a hammer and a punch (small diameter). Drive out the spring pin through the center hole in planetary shaft (11). Use locking pliers, and remove the spring pin from the carrier.

   2. Remove planetary shaft (11), two thrust washers (9) and planet gear (8) from the carrier. Remove bearing (10) from the planet gear.

   3. Repeat Steps 8.a and 8.b in order to remove the other planetary gears from the carrier.

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Illustration 6	g00844291

9. Remove sun gear (12) and plate (13) from carrier assembly (14) .

10. Remove carrier assembly (14) from the ring gear by pulling the carrier assembly straight up.

11. Use the following procedure to disassemble carrier assembly (14) .
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    Illustration 7	g00844298

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    Illustration 8	g00844301

    1. Drive spring pin (15) partially out of the carrier with a hammer and a punch (small diameter). Drive out the spring pin through the center hole in planetary shaft (19). Use locking pliers, and remove the spring pin from the carrier.

    2. Remove planetary shaft (19), two thrust washers (17) and planet gear (16) from the carrier. Remove bearing (18) from the planet gear.

    3. Repeat Steps 11.a and 11.b in order to remove the other planetary gears from the carrier.

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Illustration 9	g00844344

12. Fasten Tool (B) and a hoist to ring gear (3), as shown. Remove 16 socket head bolts (20) that hold the ring gear to the sprocket housing. Remove ring gear (3). The weight of the ring gear is 32 kg (71 lb).

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Illustration 10	g00844349

13. Remove O-ring seal (21) from the sprocket housing.

14. Remove sun gear (22) from the carrier assembly.

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Illustration 11	g00844355

15. Turn over the final drive. Remove 12 socket head bolts (23) and three plate (24) .

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Illustration 12	g00844359

16. Turn over the final drive. Remove three socket head bolts (25) and carrier assembly (26) .

17. Use the following procedure to disassemble carrier assembly (26) .
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    Illustration 13	g00844369

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    Illustration 14	g00844373

    1. Drive spring pin (27) partially out of the carrier with a hammer and a punch (small diameter). Drive out the spring pin through the center hole in planetary shaft (30). Use locking pliers, and remove the spring pin from the carrier.

    2. Remove planetary shaft (30), two thrust washers (31) and planet gear (28) from the carrier. Remove two collars (32), bushing (29) and 17 rollers (33) from the planet gear.

    3. Repeat Steps 17.a and 17.b in order to remove the other planetary gears from the carrier.

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Illustration 15	g00844390

18. Remove shims (34) .

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Illustration 16	g00844394

19. Remove bearing (37) from the sprocket housing.

20. Fasten Tool (B) and a hoist to sprocket housing (35), as shown. Put slight lifting tension on the sprocket housing. Use a soft faced hammer, and separate flanged housing (36) from the sprocket housing (35) .

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Illustration 17	g00844399

21. Remove bearing (39) from the flanged housing.

22. Remove Duo-Cone seal (40) from the flanged housing.

23. Remove three locating pins (38) from the flanged housing.

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Illustration 18	g00844405

24. Remove the other half of Duo-Cone seal (40) from the sprocket housing.

25. Remove bearings (41) and (42) from the sprocket housing.

26. If necessary, remove the final drive sprocket from the sprocket housing. For details regarding removal of the sprocket, refer to Disassembly and Assembly, "Final Drive Sprocket - Remove and Install" in this manual.

Type "B" Final Drive

Start By:

1. Remove the final drive. Refer to Disassembly and Assembly, "Final Drive - Remove" in this manual.

1. Thoroughly clean the outside of the travel motor and the final drive prior to disassembly.

2. Put an alignment mark across the sections of the travel motor and the final drive for assembly purposes. The parts must be reinstalled in the original locations of the parts.

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Illustration 19	g00526895

3. Fasten the travel motor and the final drive to Tooling (A) with the travel motor in the up position. Remove drain plugs (1) in order to drain the oil. The capacity of the final drive is 2.5 L (.66 US gal).

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Illustration 20	g00526930

4. Remove the bolts (2) and use the lifting strap in order to remove the travel motor from the final drive.

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Illustration 21	g00527283

5. Use Tooling (B) to compress the brake assembly and remove the retaining ring.

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Illustration 22	g00527299

6. Remove spacer ring (3) and twenty springs (4) .

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Illustration 23	g00527333
Typical example

7. Use suitable tooling in order to apply air pressure in the oil passage in order to partially remove piston (5) .

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Illustration 24	g00527337

8. Remove piston (5) .

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Illustration 25	g00527353

9. Remove shaft link (6) .

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Illustration 26	g00527355

10. Remove brake disks (7) .

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Illustration 27	g00527404

11. Remove supporting ring (8) .

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Illustration 28	g00527398

12. Use Tooling (C) to remove snap ring (9) .

13. Remove seal (10) from spindle (11) .

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Illustration 29	g00527410
Typical example

14. Remove seals (12) from piston (5) .

15. Use lifting straps and Tooling (D) in order to lift the final drive off Tooling (A) .

16. Carefully rotate the final drive so that the planetary cover is up.

17. Fasten the final drive to Tooling (A) .

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Illustration 30	g00527492

18. Remove twelve bolts (13) that secure cover (14) to the final drive. Remove the O-ring seal from the cover.

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Illustration 31	g00527496

19. Remove sun gear shaft (15) from the final drive.

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Illustration 32	g00527500

20. Remove the first stage of planetary gear assembly (16) from the final drive.

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Illustration 33	g00527501

21. Use snap ring pliers to remove snap ring (17) that secures planetary gear (18) to the planetary carrier.

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Illustration 34	g00527505

22. Use Tooling (E) in order to remove planetary gear (18). Remove the disk from planetary carrier (19) .

23. Repeat Step 21 and Step 22.

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Illustration 35	g00527583

24. Use snap ring pliers to remove snap ring (20) from sun gear (21) .

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Illustration 36	g00527597

25. Remove sun gear (21) from planetary carrier (19) .

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Illustration 37	g00527606

26. Remove the second stage of planetary gear assembly (22) from the final drive.

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Illustration 38	g00527613

27. Use snap ring pliers to remove snap ring (23) from planetary gear (24) .

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Illustration 39	g00527622

28. Use Tooling (E) to remove planetary gear (24). Remove the disk from planetary carrier (25) .

29. Repeat Steps 27 and 28 for the other two planetary gears and disks.

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Illustration 40	g00527625

30. Use snap ring pliers to remove snap ring (26) from sun gear (27) .

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Illustration 41	g00527629

31. Remove sun gear (27) from planetary carrier (25) .

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Illustration 42	g00527656

32. Use snap ring pliers to remove snap ring (28) that secures planetary gear (29) to spindle (30) .

33. Use Tooling (E) to remove planetary gear (29) from spindle (30) .

34. Repeat Steps 32 and 33 for the other four planetary gears.

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Illustration 43	g00527840

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Illustration 44	g00528079

35. Remove bolt (31), tab (32) and ball (33) from spindle nut (34).

    Note: Use the access hole in ring gear (35) to access bolt (31). Ring gear (35) can be rotated in order to align the access hole with bolt (31) .

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Illustration 45	g00530820

Note: The procedure for drilling will create a small amount of steel chips. Do not allow the chips to fall into bearing kit (35) .

36. Use a 4.76 mm (.188 inch) drill bit (41) to remove the damaged portion of threads which was caused by ball (33). This will require drilling into spindle (30) to a depth of approximately 1.5 mm (.06 inch).

37. Clear the steel chips from the hole. Do not allow the chips to fall into bearing kit (35) .

38. Repeat Steps 35 through 37 in order to remove the remaining bolt assembly.

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Illustration 46	g00527917

39. Install the reaction shaft from Tooling (F) on spindle (30), as shown.

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Illustration 47	g00527930

40. Install the socket from Tooling (F) over spindle nut (34), as shown.

    Note: The "notches" of the socket from Tooling (F) fit over the "ears" of spindle nut (34) .

41. Use Tooling (F) to remove spindle nut (34). The torque that is required to remove the spindle nut is approximately 1500 N·m (1100 lb ft).

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Illustration 48	g00528669

42. Remove bearing kit (35) from spindle (30) .

    Note: It may be necessary to remove bearing kit (35) by pulling bearing kit (35) with ring gear (36) .

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Illustration 49	g00528772

43. Remove ring gear (36) from spindle (30) .

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Illustration 50	g00528781

44. Remove one half of Duo-cone seal kit (37) from ring gear (36) .

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Illustration 51	g00528793

45. Remove bearing kit (38) from ring gear (36) .

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Illustration 52	g00528800

46. Remove the second half of Duo-cone seal kit (37) from spindle (30) .

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Illustration 53	g00528814
Typical example

47. Use Tooling (G) to shape spindle threads (39), if the threads appear damaged.