D5M Track-Type TractorPower Train Caterpillar

Assembly Procedure

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Illustration 1	g00560718

1. Install bearing cones (1) and bearing cups (2) in cage (3) .

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Illustration 2	g00560719

2. Put the original amount of shims (5), cage (3), and retainer (6) into position on the case assembly. Install bolts (4) .

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Illustration 3	g00560746

3. Put gear (8) into position on shaft (9) and install bolts (7) .

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Illustration 4	g00560747

4. Put bearing (10) into position on shaft (9). Install snap ring (11) on the shaft by using Tooling (A) .

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Illustration 5	g00560748

5. Fasten a hoist to shaft (9) and put the shaft into position in the case assembly. Remove the hoist from the shaft. Install the shaft fully.

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Illustration 6	g00560749

6. Put the tab and washer (12) into position on shaft (9) .

7. Put 5P-3931 Anti-Seize Compound on the threads and face of nut (13). Install the nut on shaft (9). Use Tooling (B) and tighten the nut to a torque of 612 ± 68 N·m (450.0 ± 50 lb ft).

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Illustration 7	g00560750

8. If bearing cups (14) and (15) were removed, lower the temperature of the bearing cups. Install the bearing cups in the case assembly.

9. The bearing cups must be seated in the case assembly.

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Illustration 8	g00560751

Note: If the bearing cones were removed from gear (18), new bearing cones must be installed.

10. Heat bearing cones (16) and (17) to a maximum temperature of 135° C (275° F). Install the bearing cones on gear (18). The bearing cones must be seated on the gear.

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Illustration 9	g00560755

11. Put pinion (21) into position in gear (20) .

12. Heat bearing cone (19) to a maximum temperature of 135° C (275° F) and install the bearing cone on pinion (21). The bearing cone must be seated on the pinion.

13. Install the retainer and bolt in order to hold the bearing on the pinion until the bearing has cooled.

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Illustration 10	g00560756

14. Heat bearing cone (22) to a maximum temperature of 135° C (275° F) and install the bearing cone on pinion (21). The bearing cone must be seated on the pinion.

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Illustration 11	g00560757

Note: Gear (18) and gear (20) must be installed in the case assembly at the same time.

15. Install gear (18) and gear (20) in the case assembly.

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Illustration 12	g00560759

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Illustration 13	g00560760

16. If dowels (24) were removed, install the dowels in cover (25) .

17. If bearing cup (23) was removed, install the bearing cup. Dimension (X) should equal 4.37 mm (0.1720 inch).

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Illustration 14	g00560762

18. Put cover (25) into position and install bolts (27) .

19. Remove the bolt and retainer (26) .

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Illustration 15	g00560786

20. Put shims (29) with a total thickness of 4.37 mm (0.1720 inch) and cover (28) into position on the cover. Install the bolts that hold the shims and the cover in place.

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Illustration 16	g00560789

21. Install Tooling (C), as shown.

22. Install Tooling (D) so that the point of the dial indicator is against the inside race of the bearing cone.

23. Use Tooling (C) in order to push the gear and the pinion downward. Hold the gear and the pinion in position by using Tooling (C). Use a ratchet wrench in order to rotate the gear and the pinion. Rotate the gear and the pinion at least three times. Observe the dial indicator as the needle moves. Stop rotating the gear and the pinion at the point of maximum needle movement.

24. Zero the dial indicator. Mark the bearing race at the location of maximum needle movement.

25. Pull the gear and the pinion upward by using Tooling (C). Rotate the gear and the pinion at least three times. Stop the gear and the pinion at the same point of maximum needle movement. Record the measurement on the dial indicator. This reading is the actual bearing clearance.

26. Repeat Steps 23 through 25. The readings should be equal if you have correctly completed the procedure.

27. Remove cover (28). Remove enough shims in order to obtain a bearing clearance (end play) of 0.05 mm (0.0020 inch) to 0.15 mm (0.0060 inch).

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Illustration 17	g00560793

28. If bearing (31) was removed, install the bearing in cage (32) by using Tooling (E) .

29. If bearing cup (30) was removed, lower the temperature of the bearing cup. Install the bearing cup in cage (32) .

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Illustration 18	g00560796

30. Put 7M-7260 Liquid Gasket on the seal bore in cage (32) and allow the liquid gasket dry. Do not put liquid gasket material on the case of seal (33). Install lip seal (33) with the lip of the seal toward the bearing, as shown.

31. Install O-ring seal (34) on cage (32) .

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Illustration 19	g00560799

32. Put retainer (26) into position. Install the bolt that holds the retainer in place.

33. Put cage (32) into position without the shims. Install two bolts (35) opposite each other.

34. Tighten bolts (35) to a torque of 2.3 N·m (20 lb in).

35. Rotate the gear at least five times. Tighten the bolts to a torque of 4.5 N·m (40.0 lb in).

36. Again rotate the gear at least five times. Tighten the bolts again to a torque of 4.5 N·m (40.0 lb in).

37. Measure the gap between cage (32) and the cover at the top location of bolts (35) by using a feeler gauge. Average the two measurements.

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Illustration 20	g00560801

38. Remove bolts (35) and cage (32) from the cover.

39. The measurement that was recorded in Step 37 will equal the amount of shims (36) that are required plus 0.18 mm (0.0070 inch).

40. Put cage (32) into position on the shims and install bolts (35). Tighten the bolts to a torque of 135 ± 15 N·m (100 ± 11 lb ft).

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Illustration 21	g00560803

41. Use Tooling (D) and Tooling (F) in order to check the end play of the gear by using the following procedure:

    1. Push the gear downward and hold the gear by using Tooling (F). Rotate the gear by using a ratchet wrench at least five times. Stop rotating the gear at the point of maximum needle movement.

    2. Zero the dial indicator. Mark the location of maximum needle movement.

    3. Pull the gear upward by using Tooling (F). Rotate the gear at least five times. Stop rotating the gear at the same point of maximum needle movement. Record the measurement. This measurement is the actual end play of the gear.

42. Repeat Steps 41.a through 41.c. The readings should be equal. The end play of the gear must be 0.05 mm (0.0020 inch) to 0.15 mm (0.0060 inch).

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Illustration 22	g00560827

43. Fabricate plate (37) by using a piece of mild steel. Use these dimensions of 6.35 mm (0.250 inch) by 38.1 mm (1.50 inch) by 127 mm (5.0 inch).

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Illustration 23	g00560829

44. Install plate (37) in order to hold the gear and the pinion while the backlash is being checked, as shown.

45. Put Tooling (D) into position with the point of the dial indicator against gear (8) .

46. Use Tooling (D) in order to measure the backlash of gear (8) in three locations that are evenly spaced. The difference between the three measurements should not be more than 0.08 mm (.0030 inch).

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Illustration 24	g00560831

47. Add or subtract shims (38) in order to obtain a backlash of 0.20 mm (.0080 inch) to 0.30 mm (.0120 inch). Remove plate (37) after the backlash has been adjusted.

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Illustration 25	g00560834

48. Install O-ring seal (40) on carrier (39) .

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Illustration 26	g00560836

49. Put carrier (39) into position and install the bolts that hold the carrier in place.

50. Install yoke (41) .

51. Install bracket assemblies (42) and (43) .

52. Install the two magnetic sensors (not shown) on the bevel gear case. Maintain a 0.89 mm (.0350 inch) gap between the magnetic sensor and the gear tooth.

End By: Connect the transmission and bevel gears. Refer to Disassembly and Assembly, "Transmission and Bevel Gears - Connect" for the machine that is being serviced.