545 Wheel Skidder Power Train 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 and this may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

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Illustration 1	g00599578

1. Heat the bevel gear to 135 °C (275 °F) for a maximum of four hours. Install the bevel gear on differential carrier (2) and align the bolt holes.

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Illustration 2	g00599488

2. Install bolts (20) in order to secure the bevel gear.

3. Allow the bevel gear to cool to room temperature before tightening bolts (20) . Tighten bolts (20) to a torque of 300 ± 40 N·m (220 ± 30 lb ft). Make sure that the bevel gear is seated properly on the differential carrier.

   Note: Do not use a substitute for the bolts that retain the bevel gear.

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Illustration 3	g00602702

4. Press bearing cone (22) on differential case (2) . Make sure that the bearing cone is fully seated.

   Note: If you heat the bearing cones, allow the assembled parts to reach a uniform temperature. Then use a driver or a press in order to seat the bearing cones. The limit for heating the bearing cones is a maximum of 135°C (275°F) for a maximum of four hours. Lubricate the bearing cones with SAE 30W gear oil after the bearing cones have cooled in order to prevent rust on the bearing cones.

5. Install thrust washer (24) in the differential housing. Refer to illustration 1. Apply 4C-9507 Retaining Compound to differential case (2) that will be in contact with thrust washer (24) . Apply 4C-9507 Retaining Compound to the threads and the screw head of flat head screws (23) in order to bond the screw heads to thrust washer (24) . Tighten the screws to a torque of 12 ± 3 N·m (9 ± 2 lb ft). Torque the screws in a pattern of opposing sides.

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Illustration 4	g00599434

6. Assemble sleeve bearing (18) , spider gear (17) , and washer (16) on spider (19) . Coat all components with SAE 30W gear oil during assembly.

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Illustration 5	g00599430

7. Install spider assembly (15) in differential case (2) .

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Illustration 6	g00599413

8. Place bevel gear (14) on spider assembly (15) .

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Illustration 7	g00599379

9. Install Tooling (B) on the differential housing, as shown.

10. Attach a hoist and a suitable lifting sling to Tooling (B) , as shown. Weight of the assembly is approximately 68 kg (150 lb).

11. Place the assembly on differential housing (2) , as shown. Make sure that you align the scribe marks on the housing when you assemble the two sections of the housing.

12. Install bolts (13) in differential housing (2) .

13. Tighten bolts (13) to a torque of 300 ± 40 N·m (220 ± 30 lb ft).

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Illustration 8	g00602729

14. Turn over the differential assembly in order to position the assembly, as shown.

15. Install splined bevel gear (12) .

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Illustration 9	g00602730

16. Inspect the clutch pack for the locking differential. Refer to Table 3.
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    Table 2

    Specifications for Clutch Pack
    	Front Axle	Rear Axle
    Number of thin discs with external teeth	7	9
    Number of friction discs with internal teeth	6	8
    Thickness of new clutch pack	27.9 mm (1.0984 inch)	36.68 mm (1.4441 inch)
    Minimum allowable thickness of used clutch pack	23.85 mm (0.939 inch)	31.28 mm (1.2315 inch)

    Note: Before inspection, all discs should be thoroughly cleaned in cleaning fluid. Allow the discs to air dry. Do not reuse any discs with the following conditions: signs of overheating, missing friction material, oil grooves less than 0.25 mm (0.01 inch) and excessive spline wear.

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Illustration 10	g00599366

17. Install discs (11) in differential case (2) . Begin with the one thick disc with external teeth. Install one of the thin discs with external teeth. Install one of the friction discs with internal teeth. Install the remaining discs and the remaining friction discs in alternating order until the proper number of discs are installed.

    Note: Thoroughly coat all discs with SAE 30W gear oil during assembly.

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Illustration 11	g00599337

18. Install four springs (10) in differential case (2) .

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Illustration 12	g00599601

19. Install thrust washer (9) on cover assembly (4) . Apply 4C-9507 Retaining Compound to differential case (2) that will be in contact with thrust washer (24) . Apply 4C-9507 Retaining Compound to the threads and the screw head of flat head screws (23) in order to bond the screw heads to thrust washer (24) . Tighten the screws to a torque of 12 ± 3 N·m (9 ± 2 lb ft). Torque the screws in a pattern of opposing sides.

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Illustration 13	g00599212

20. Install cover (4) on thrust ring (7) .

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Illustration 14	g00599203

21. Install plate (6) on cover assembly (4) .

22. Install four flat head screws (5) in thrust ring (7) . Tighten flat head screws (5) to a torque of 28 ± 7 N·m (20 ± 5 lb ft).

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Illustration 15	g00599121

23. Position cover assembly (4) on differential case (2) . Align the tabs on plate (6) with the slots in differential case (2) . Make sure that the scribe mark on cover assembly (4) aligns with the scribe mark on differential case (2) .

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Illustration 16	g00599106

24. Apply 9S-3263 Thread Lock Compound to the threads of bolts (3) . Install bolts (3) in differential case (2) . Tighten bolts (3) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

25. Install the bearing cone on cover assembly (4) . Make sure that the bearing cone is fully seated.

    Note: If you heat the bearing cones, allow the assembled parts to reach a uniform temperature. Then use a driver or a press in order to seat the bearing cones. The limit for heating the bearing cones is a maximum of 135°C (275°F) for a maximum of four hours. Lubricate the bearing cones with SAE 30W gear oil after the bearing cones have cooled in order to prevent rust on the bearing cones.

End By: Install the differential and bevel gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Install" for the machine that is being serviced.