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 which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

Note: The axle housing assemblies that are used in the fixed axle and in the oscillating axle are similar. Therefore, both axle assemblies can be assembled in the same manner.

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Illustration 1	g00604761

1. Use the proper equipment to handle bearing cone (19). Heat bearing cone (19) to a maximum temperature of 135 °C (275 °F).

2. Install bearing cone (19) on the axle shaft. Make sure that the bearing cone is seated against the shoulder.

   Note: Allow the bearing cone and the axle shaft to reach a uniform temperature.

3. Use a suitable driver or a press to reset the bearing cone. This will ensure that the bearing cone is seated properly.

4. Apply a thin coat of clean SAE 30 oil on bearing cone (19) .

5. Use Tooling (G) to install Duo-Cone seal (20) in the axle shaft. Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" for the proper procedure.

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Illustration 2	g00593620

6. Use the proper equipment to handle bearing cup (18). Lower the temperature of bearing cup (18) .

7. Install bearing cup (18) in the end of axle housing (1). Make sure that the bearing cup is seated with the mating surface.

   Note: Allow the bearing cup and the axle housing to reach a uniform temperature.

8. Use a suitable driver or a press to reset bearing cup (18). This will ensure that bearing cup (18) is seated properly.

9. Use Tooling (G) to install Duo-Cone seal (17) in the end of axle housing (1). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".

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Illustration 3	g00593618

10. Use the proper equipment to handle inner bearing cup (14). Lower the temperature of inner bearing cup (14) .

11. Install inner bearing cup (14) in the opposite end of axle housing (1). Make sure that the bearing cup is seated on the mating surface.

    Note: Allow the inner bearing cup and the axle housing to reach a uniform temperature.

12. Use a suitable driver or a press to reset inner bearing cup (14). This will ensure that inner bearing cup (14) is seated properly.

Note: The following steps are for the installation of the ring gear.

Note: Dowels (15) are used to locate ring gear (16) .

13. Locate the position of the ring gear in relation to the axle housing. Align the holes in order to install the dowels. Put alignment marks on ring gear (16) and on axle housing (1) in order to ensure correct installation.

14. Lower the temperature of ring gear (16) to −70°C (−94°F). Install ring gear (16) in axle housing (1) .

15. Install dowels (15). Peen axle housing (1) near the dowels in order to retain the dowels.

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Illustration 4	g00593614

16. Install Tooling (A) and a suitable lifting device to axle housing (1) .

17. Install axle housing (1) on the axle shaft. The weight of axle housing (1) is approximately 205 kg (450 lb).

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Illustration 5	g00604933

18. Use the proper equipment to handle bearing cone (21). Heat bearing cone (21) to a maximum temperature of 135°C (275°F).

19. Install bearing cone (21) on the axle shaft so that there is slight end play. When bearing cone (21) is cool, apply clean SAE 30 oil to the bearing cone.

    Note: The adjusting nut must be installed so that the part number is facing away from bearing cone (21) .

20. Apply clean SAE 30 oil on bearing nut (13). Install bearing nut (13) on the axle shaft. Tighten the nut until a small amount of end play remains.

21. The seal drag torque is the torque that is needed to rotate the axle housing. Use the following procedure to measure the seal drag torque:
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    Illustration 6	g00604990

    1. Install Tooling (F) on the axle housing.

    2. Place a torque wrench on the bolt at the center of the bar, as shown.

    3. Use the torque wrench to rotate the housing.

    4. Record the reading on the torque wrench.

22. Use the following procedure to tighten bearing nut (13) :
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    Illustration 7	g00593613

    1. Rotate the axle housing.

    2. Use Tooling (E) to tighten bearing nut (13) .
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    Illustration 8	g00604990

    3. Install Tooling (F) on the axle housing.

    4. Place a torque wrench on the bolt at the center of the bar, as shown.

    5. The torque wrench reading is equal to the seal drag torque plus the axle bearing preload rolling torque. Use the seal drag torque that was recorded in Step 21.d.

       Note: The preload rolling torque for new bearings is 1.0 to 1.8 N·m (8.85 to 15.93 lb in). The preload rolling torque for used bearings is 0.5 ± 0.9 N·m (4.43 ± 7.96 lb in).

23. Make sure that the axle shaft has zero end play.

24. If the axle bearing preload rolling torque exceeds the specification, back off bearing nut (13) by 1/8 turn and reseat bearing cone (21) against bearing nut (13). Perform Steps 22.a through 22.e again.

25. Use the following procedure to assemble the planetary carrier:
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    Illustration 9	g00605061

    1. Install retaining ring (4) in planetary carrier (6) .
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    Illustration 10	g00593611

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    Illustration 11	g00593610

    2. Apply a thin coat of clean SAE 30 oil on all parts of planetary carrier (6) .

    3. Install bearing (11) in planetary gear (8) .

    4. Install thrust washers (10) and planetary gear (8) in planetary carrier (6) .

    5. Install planetary shaft (7) in planetary carrier (6). Make sure that the spring pin hole in the shaft is aligned with the spring pin hole in the carrier.

    6. Install spring pin (9) through planetary carrier (6) and in planetary shaft (7) .

    7. Use a hammer and a punch to install spring pin (12) through planetary carrier (6) and in spring pin (9) .

    8. Repeat Steps 25.b through 25.g for the installation of the other two planetary gears.

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Illustration 12	g01032210

26. Install Tooling (D) and a suitable lifting device in planetary carrier (6) .

27. Carefully install planetary carrier (6) in axle housing (1). The weight of planetary carrier (6) is approximately 80 kg (175 lb).

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Illustration 13	g00593607

28. Use pliers to install retaining ring (4) on axle shaft (5) .

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Illustration 14	g00593606

29. Install Tooling (A) and a suitable lifting device on axle housing (1) .

30. Carefully remove axle housing (1) from Tooling (C). The weight of axle housing (1) is approximately 500 kg (1100 lb).

31. Apply 6V-6640 RTV Silicone Sealant on the mating surfaces of the axle housing and of the differential housing.

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Illustration 15	g00555676

32. Install Tooling (A) and a suitable lifting device to the opposite end of axle housing (1) .

33. Carefully install axle housing (1) to differential housing (3) .

34. Install bolts (2) and the washers. Tighten bolts (2) to a torque of 300 ± 40 N·m (220 ± 30 lb ft).

End By: Install the axle to the machine. Refer to Disassembly and Assembly, "Fixed Axle (Rear) - Install" or Disassembly and Assembly, "Oscillating Axle (Front) - Install" for the machine that is being serviced.