CIPI UNDERCARRIAGE Arrangements: 9Q-5195, 9Q-5197, 9Q-5198, 9Q-5232, 9Q-5504, 9Q-5643, 9Q-5651, 9Q-5727, 9Q-5728, 9Q-5729, 9Q-5730, 9Q-5731, 9Q-5747, 9Q-5876, 180-4029, and 213-3892 Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean hydraulic area. Keep cleaned parts covered and protected at all times.

Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the same sealing properties as a new O-ring. Use 1U-6396 O-Ring Assembly Compound during the assembly procedure.

Note: Apply a light film of hydraulic oil to all components before assembly.

1. Install the final drive sprocket if the sprocket was removed from the main housing.

   Reference: Refer to Disassembly and Assembly, "Final Drive Sprocket - Remove and Install" in this manual for the installation of the final drive sprocket.

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Illustration 1	g00708215

2. Apply 5P-3931 Anti-Seize Compound to the outer diameter of the bearings.

3. Install bearings (32) and (33) in the original locations in the main housing (18) with a press.

4. Make sure that bearing (32) and bearing (33) contact the counterbore in the main housing.

5. Use the following procedure to preload the bearings and determine the correct thickness of shims.
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   Illustration 2	g00713058

   1. Fasten Tooling (D) and a hoist to main housing (18). Install the main housing on the motor housing.

   2. Put the main housing and the motor housing in a suitable press.
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   Illustration 3	g00709278
   (a) Bearing surface (b) Housing surface

   3. Use a suitable press and a spacer in order to apply a load of 4000 kg (8820 lb) on the bearings. Rotate the housing in order to seat the bearings.

   4. Reduce the load on the bearings to 1000 ± 100 kg (2200 ± 220 lb).

   5. Use a depth micrometer in order to measure the step length between the bearing surface and the housing surface. Take measurements at several different locations around the housing. Compute the average of the measured dimensions and record the number. Call this dimension (Y) .
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   Illustration 4	g00709276

   6. Use a depth micrometer in order to measure the step length of the coupling gear (26). Take measurements at several different locations around the gear. Compute the average of the measured dimensions and record the number. Call this dimension (X) .

   7. The thickness of the shims is equal to (X - Y) ± 0.05 mm (0.002 inch).

      Note: Use no more than two shims. If two shims are required, install the thinner shim next to the gear.

   8. Remove the main housing from the motor housing.

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Illustration 5	g00713142

6. Use Tooling (C) in order to install Duo-Cone seal (31) in main housing (18) .

   Reference: Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.

   Note: The rubber seals and all surfaces that make contact with the seals must be clean and dry. After installation of the seals, put clean SAE 30 oil on the contact surfaces of the metal seals.

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Illustration 6	g00713147

7. Use Tooling (C) in order to install Duo-Cone seal (29) in motor housing (28) .

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Illustration 7	g00708214

8. Apply 5P-3931 Anti-Seize Compound to the surfaces that contact pins (30).

9. Install alignment pins (30) .

Note: Do not damage the Duo-cone seals in the main housing or in the motor housing during the assembly of the two components. After 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. This gap will be eliminated during installation of gear (26).

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Illustration 8	g00713058

10. Fasten Tooling (D) and a hoist to main housing (18). Install the main housing on the motor housing.

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Illustration 9	g00708211

11. Install shims (27) that were determined in Step 5.g in the main housing.

    Note: If two shims are required, install the thinner shim next to the gear.

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Illustration 10	g00708187

12. Install gear (26) .

13. Install bolts (25) in gear (26). Install the bolts in an even pattern until the gear is seated against the bearing. Tighten the bolts in a crisscross pattern. Tighten the bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

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Illustration 11	g00708186

14. Install O-ring seal (24) to main housing (18) .

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Illustration 12	g00708175

15. Assemble carrier assembly (15), as follows.
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    Illustration 13	g00708220

    1. Install two bearings (22) in planetary gear (23) .

    2. Install two thrust washers (21) and planetary gear (23) in the carrier assembly.

    3. Use a deburring tool in order to remove the metal burr from the openings in the carrier. Install planetary shaft (19) in the carrier assembly.

    4. Drive spring pin (20) into planetary shaft (19) with a hammer and a punch.
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    Illustration 14	g00513451

    5. Orient the split in spring pin (20) vertically to the carrier. Align the split in the spring pin to the top or to the bottom. Make a stake mark on each side of the spring pin hole in the carrier. Each stake mark should be approximately 1.5 mm (0.06 inch) from the outside diameter of the spring pin hole.

16. Repeat Steps 15.a through 25.e in order to install the other two planetary gears in the carrier.

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Illustration 15	g00708172

17. Install a lifting sling through the middle of carrier assembly (15). Fasten a 12.7 mm (0.50 inch) shackle to the lifting sling. Fasten a hoist to the lifting sling.

18. Install carrier assembly (15) on the final drive. The weight of the carrier assembly is 42 kg (93 lb).

19. Remove the shackle, the lifting sling, and the hoist.

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Illustration 16	g00713148

20. Apply 1U-8846 Sealant to the mating surface of ring gear (17b) .

21. Install ring gear (17a) on ring gear (17b) .

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Illustration 17	g00708184

22. Fasten lifting slings and a hoist to ring gears (17), as shown. Install the ring gears to main housing (18). The weight of the ring gears is 48 kg (106 lb).

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Illustration 18	g00708325

23. Install spacer (16) in the carrier assembly.

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Illustration 19	g00708162

24. Install sun gear (14) in carrier assembly (15) .

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Illustration 20	g00708095

25. Assemble carrier assembly (7), as follows.
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    Illustration 21	g00708218

    1. Install bearing (12) in planetary gear (13) .

    2. Install two thrust washers (11) and planetary gear (13) in the carrier assembly.

    3. Install planetary shaft (9) in the carrier assembly.

    4. Drive spring pin (10) into planetary shaft (9) with a hammer and a punch.
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    Illustration 22	g00513451

    5. Orient the split in spring pin (10) vertically to the carrier. Align the split in the spring pin to the top or to the bottom. Make a stake mark on each side of the spring pin hole in the carrier. Each stake mark should be approximately 1.5 mm (0.06 inch) from the outside diameter of the spring pin hole.

26. Repeat Steps 25.a through 25.d in order to install the other two planetary gears in the carrier assembly.

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Illustration 23	g00708092

27. Install carrier assembly (7) in the ring gear. The weight of the carrier assembly is 23 kg (51 lb).

28. Install sun gear (8) in carrier assembly (7) .

29. Install spacer (6) in carrier assembly (7) .

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Illustration 24	g00708235

30. Install new O-ring seals (5) on plugs (4) that were in the cover.

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Illustration 25	g00708091

31. Install two plugs (4) in cover (2). Tighten the plugs to a torque of 80 ± 10 N·m (60 ± 7 lb ft).

32. Install thrust plate (3) in cover (2) .

33. Apply 1U-8846 Sealant to the mating surface of the ring gear.

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Illustration 26	g00708090

34. Fasten Tooling (B) and a hoist to cover (2), as shown. Install the cover. The weight of the cover is 27 kg (60 lb).

35. Remove Tooling (B). Install the setscrews in cover (2) .

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Illustration 27	g00708089

36. Install bolts (1) and the washers that hold the cover in position. Tighten the bolts in a crisscross pattern. Tighten the bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

37. Remove the final drive from Tooling (A). The combined weight of the final drive and final drive sprocket is 272 kg (600 lb).

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