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

Type "A" Final Drive

Note: Make sure that all of the parts of the final drive are thoroughly clean and free of dirt and debris prior to assembly.

1. Check the condition of all the O-ring seals that are used in the final drive. If any of the O-ring seals are damaged, use new parts for replacement.

   Note: If the final drive sprocket was removed from the main housing, refer to Disassembly and Assembly, "Final Drive Sprocket - Remove and Install" in this manual for the correct installation procedure.

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Illustration 1	g00844405

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Illustration 2	g00844490

2. Lower the temperature of bearings (41) and (42), and install the bearings in the sprocket housing. Be sure that the bearings are properly seated.

   Note: The rubber seals and all of the surfaces that contact the seals must be clean and dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals. For more information concerning the assembly and installation of Conventional Duo-Cone Seals, refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.

3. Install Duo-Cone seal (40) in the sprocket housing with Tool (C) .

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Illustration 3	g00844399

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Illustration 4	g00844508

4. Install three locating pins in the flanged housing.

5. Install bearing (39) on the flanged housing, as shown.

   Note: The rubber seals and all of the surfaces that contact the seals must be clean and dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals. For more information concerning the assembly and installation of Conventional Duo-Cone Seals, refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.

6. Use Tool (C), and install the other half of Duo-Cone seal (40) in the flanged housing.

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Illustration 5	g00844394

7. Install bearing (37) in the sprocket housing.

8. Fasten Tool (B) and a hoist to sprocket housing (35). Carefully, put the sprocket housing in position over flanged housing (36) .

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Illustration 6	g00844390

Note: Shims (34) are used to determine the force that is required to turn the motor output shaft with the parking brake release port open to the atmosphere. Use the required shim(s) (34) to prevent the motor output shaft from rotating by a maximum force of 213 N·m (157 lb ft) with the parking brake release port open to the atmosphere.

9. Install the correct amount of shims (34) on the flanged housing, as shown.

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Illustration 7	g00844373

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Illustration 8	g00844369

10. Use the following procedure to assemble carrier assembly (26) .

    1. Apply 5N-5561 Silicone Lubricant on 17 rollers (33). Install the rollers in bushing (29). Install a collar (32) on each side of the bushing in order to hold the rollers in position.

    2. Apply clean SAE 30 oil on bearings (29). Install two bearings (29) in planetary gear (28) .

    3. Install thrust washer (31) on each side of planetary gear (28). Install the planetary gear and thrust washers in the carrier. Install planetary shaft (30) in the carrier and through the planetary gear (28). Make sure that the spring pin hole in the planetary shaft is in alignment with the spring pin hole in the carrier.

    4. Install spring pin (27) in the carrier and into the planetary shaft. Install the spring pin to the spring pin's original depth below the outside surface of the carrier and orient the split in the spring pin so that the split faces toward the top or the bottom of the carrier. Make a stake mark on each side of the spring pin hole in the carrier. This will prevent the spring pin from falling out of the spring pin hole. Each stake mark should be approximately 1.5 mm (.06 inch) from the outside diameter of the spring pin hole.

    5. Repeat Steps 10 through 10.d in order to install the other planetary gears in carrier (28) .

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Illustration 9	g00844359

11. Put carrier assembly (26) in position on the flanged housing. Install three socket head bolts (25). Hand tighten the three socket head bolts at this time.

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Illustration 10	g00844355

12. Turn over the final drive. Install three plates (24) and 12 socket head bolts (23). Tighten the 12 socket head bolts to a torque of 415 ± 25 N·m (300 ± 18 lb ft).

13. Turn over the final drive. Tighten three socket head bolts (25) to a torque of 295 ± 20 N·m (220 ± 15 lb ft).

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Illustration 11	g00844349

14. Install O-ring seal (21) in the flanged housing, as shown.

15. Install sun gear (22) in carrier assembly (26) .

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Illustration 12	g00844344

16. Fasten Tool (B) and a hoist to ring gear (3). Put ring gear (3) in the ring gear's original position on the sprocket housing. Install 16 socket head bolts (20). Tighten the 16 socket head bolts to a torque of 125 ± 7 N·m (95 ± 5 lb ft).

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Illustration 13	g00844301

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Illustration 14	g00844298

17. Use the following procedure to assemble carrier assembly (14) .

    1. Apply clean SAE 30 oil on bearing (18). Install the bearing in planetary gear (16) .

    2. Install thrust washer (17) on each side of the planetary gear. Install the planetary gear and thrust washers in the carrier. Install planetary shaft (19) in the carrier and through the planetary gear (16). Make sure that the spring pin hole in the carrier is in alignment with the spring pin hole in the planetary shaft.

    3. Install spring pin (15) in the carrier and into the planetary shaft. Install the spring pin to the spring pin's original depth below the outside surface of the carrier and orient the split in the spring pin so that the split faces toward the top or the bottom of the carrier. Make a stake mark on each side of the spring pin hole in the carrier. This will prevent the spring pin from falling out of the spring pin hole. Each stake mark should be approximately 1.5 mm (.06 inch) from the outside diameter of the spring pin hole.

    4. Repeat Steps 17 through 17.c in order to install the other planetary gears in carrier (16) .

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Illustration 15	g00844291

18. Install carrier assembly (14) in the ring gear, as shown.

19. Install plate (13) and sun gear (12) in carrier assembly (14) .

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Illustration 16	g00844280

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Illustration 17	g00844278

20. Use the following procedure to assemble carrier assembly (6) .

    1. Apply clean SAE 30 oil on bearing (10). Install the bearing in planetary gear (8) .

    2. Install thrust washer (9) on each side of the planetary gear. Install the planetary gear and thrust washers in the carrier. Install planetary shaft (11) in the carrier and through the planetary gear (8). Make sure that the spring pin hole in the carrier is in alignment with the spring pin hole in the planetary shaft.

    3. Install spring pin (7) in the carrier and into the planetary shaft. Install the spring pin to the spring pin's original depth below the outside surface of the carrier and orient the split in the spring pin so that the split faces toward the top or the bottom of the carrier. Make a stake mark on each side of the spring pin hole in the carrier. This will prevent the spring pin from falling out of the spring pin hole. Each stake mark should be approximately 1.5 mm (.06 inch) from the outside diameter of the spring pin hole.

    4. Repeat Steps 20 through 20.c in order to install the other two planetary gears on carrier assembly (16) .

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Illustration 18	g00844275

21. Install carrier assembly (6) in the ring gear.

22. Install sun gear (5) in the carrier assembly.

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Illustration 19	g00844268

23. Install thrust plate (4) in the carrier assembly.

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Illustration 20	g00844261

24. Apply 1U-8846 Gasket Sealant on the machined surfaces of cover (1) and ring gear (3). Put cover (1) in the cover's original position on ring gear (3). Install 16 socket head bolts (2). Tighten the 16 socket head bolts to a torque of 59 ± 5 N·m (43 ± 4 lb ft).

End By: Install the travel brake valve and travel motor from the final drive. Refer to Disassembly and Assembly, "Final Drive - Install" in this manual.

Type "B" Final Drive

Note: Make sure that all of the parts of the final drive and the travel motor are thoroughly clean and free of dirt and debris prior to assembly. Replace all O-ring seals that are used in the final drive with new O-ring seals. Reassemble the final drive and the travel motor on Tooling (A) .

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Illustration 21	g00581889

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Illustration 22	g00528800

1. Use Tooling (E) to install one half of Duo-cone seal kit (37) into spindle (30). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this section.

2. Put a mark (40) on spindle (30). The mark indicates the position of the original balls (33). The mark is used in Step 18.

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Illustration 23	g00581916

3. Use Tooling (G) to check assembled height (X) in at least four places at 90 degree intervals. The difference in height around the ring must not be more than 1.0 mm (.04 inch).

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Illustration 24	g00528793

4. Install bearing kit (38) into ring gear (36) .

   Note: Check the condition of the bearing kit. If the bearing kit is worn or damaged, use a new bearing kit.

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Illustration 25	g00528781

5. Use Tooling (E) to install the second one half of Duo-cone seal kit (37) into ring gear (36). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.

6. Repeat step 3.

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Illustration 26	g00528772

7. Install spindle (30) onto tooling (A) .

   Note: Turn over ring gear (36) very carefully. Make sure that Duo-cone seal kit (37) is not dislodged.

8. Install ring gear (36) onto spindle (30) .

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Illustration 27	g00530753

9. Install bearing kit (35) onto spindle (30) .

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Illustration 28	g00527917

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

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Illustration 29	g00527930

Note: Lubricate the threads of the spindle nut with oil before installation. Use caution. The threads of the spindle nut are easy to cross thread.

11. Install spindle nut (34) onto spindle (30) .

12. Install the socket from Tooling (F) on spindle nut (34) .

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

Note: Rotate the spindle in one direction during the tightening procedure in order to seat the bearings properly.

13. Use Tooling (F) to tighten spindle nut (34) to a torque of 1500 N·m (1100 lb ft).

14. Mark spindle nut (34) per the relationship to spindle (30) .

    Note: Do not confuse this mark with mark (40) for the location of balls (33) .

15. Tighten spindle nut (34) to a torque of 2500 N·m (1840 lb ft).

16. Loosen spindle nut (34) so that the mark on the spindle nut is 5 to 10 degrees from the mark on the spindle.

17. Tighten spindle nut (34) to a torque of 1500 N·m (1100 lb ft).

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Illustration 30	g00530793

18. Measure the distance from the new bolt (31) to mark (40). The distance must be at least 10 mm (.4 inch). If the distance is less than 10 mm (.4 inch), use a new spindle nut (34) .

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Illustration 31	g00581917

19. Use Tooling (H) to peen the threads of spindle (30) .

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Illustration 32	g00528079

20. Install bolt (31), tab (32) and ball (33) into spindle nut (34). Tighten bolt (31) to a torque of 8.5 N·m (6 lb ft).

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

    Note: Bend the long tab on tab (32) over the "ear" of ring gear (35). Bend the short tab of tab (32) over bolt (31) .

21. Repeat step 19 and step 20 in order to install the remaining bolt assembly.

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Illustration 33	g00527656

22. If necessary, heat gears (29) to 135 °C (275 °F). Install gears (29) on spindle (30). Use snap ring pliers to install snap ring (28) that secures planetary gear (29) to spindle (30) .

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Illustration 34	g00527629

23. Install sun gear (27) into planetary carrier (25) .

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Illustration 35	g00527625

24. Use snap ring pliers to install snap ring (26) on sun gear (27) .

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Illustration 36	g00527613

25. If necessary, heat planetary gears (24) to 135 °C (275 °F). Install the disks and planetary gears (24) onto the planetary carrier.

26. Use snap ring pliers to install snap rings (23) onto planetary gears (24) .

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Illustration 37	g00527606

27. Install the second stage of the planetary gear assembly (22) into final drive.

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Illustration 38	g00527597

28. Install sun gear (21) into planetary carrier (19) .

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Illustration 39	g00527501

29. If necessary, heat planetary gears (18) to 135 °C (275 °F). Install three planetary gears (18) on the planetary carrier. Use snap ring pliers to install three snap rings (17) that secure three planetary gears (18) to the planetary carrier.

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Illustration 40	g00527500

30. Install the first stage of planetary gear assembly (16) into the final drive.

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Illustration 41	g00527496

31. Install sun gear shaft (15) into the final drive.

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Illustration 42	g00527492

32. Install a new O-ring seal into cover (14). Install twelve bolts (13) that secure cover (14) to the final drive. Tighten twelve bolts (13) to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

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

34. Carefully rotate the final drive so that the brake is up.

35. Fasten the final drive to tooling (A) .

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Illustration 43	g00527410

36. Install seals (12) into piston (5) .

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Illustration 44	g00527398

37. Install seal (10) into spindle (11) .

38. Use Tooling (C) to install snap ring (9) .

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Illustration 45	g00527404

39. Install supporting ring (8) .

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Illustration 46	g00527355

40. Install brake disks and plates (7) .

    Note: There are six disks and five plates. Start the installation with a disk. Alternate between disks and plates. End the installation with a disk.

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Illustration 47	g00527353

41. Install shaft link (6) .

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Illustration 48	g00527337

Note: Lubricate the seals before installing the piston. Install the piston carefully in order to prevent damage to the seals.

42. Install piston (5) .

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Illustration 49	g00527299

43. Install spacer ring (3) and twenty springs (4) .

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Illustration 50	g00527283

44. Use Tooling (B) to compress the brake assembly. Use Tooling (C) to install the retaining ring.

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Illustration 51	g00530949
Tooling (J) (1) Hydraulic test adapter (2) O-ring seal (3) Nipple assembly (4) Coupler assembly (5) Hose assembly (6) Pressure gauge (7) Hand pump (8) Fitting (9) Valve (10) Tee (11) Nipple assembly

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Illustration 52	g00530964

45. Install Tooling (J) into the oil supply port (42) .

46. Apply 3495 kPa (510 psi) for a minimum of 3 minutes. If the pressure falls, the piston seals must be checked.

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Illustration 53	g00526930

47. Install the travel motor on the final drive. Install two bolts (2) .

48. Fill the final drive with hydraulic oil. The capacity of the final drive is 2.5 L (.66 US gal). Refer to Operation and Maintenance Manual, "Lubricant Viscosities and Refill Capacities" for the correct filling procedure and the correct level for the final drive.

End By: Install the final drive. Refer to Disassembly and Assembly, "Final Drive - Install" in this manual.