2009/09/28 Caterpillar

Underground Articulated Truck:

AD30 (S/N: CXR1-UP)

AD30 (S/N: DXR1-UP)

Service Magazine, SEPD0984, 23rd March 2009, "Torque Converter Updrive Gears - Assemble". Disregard this article. See the article that follows.Disassembly and Assembly, RENR6911, "AD30 Underground Articulated Truck", "Power Train". This module is part of Service Manual, RENR8521 Volume 1.

A portion of the existing information is incorrect. Replace the information with the following information.

Table 1

Required Tools
Tool	Part Number	Part Description		Qty
A	2P-8312	Retaining Ring Pliers		1
B	169-5464	Quick Cure Primer		1
C	155-0695	Thread Lock Compound		1
D	1P-0520	Driver Group		1
E	8S-2328	Dial Indicator Group		1

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Illustration 1	g01077113
View of the torque converter updrive sections

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Illustration 2	g01077116

1. Install retaining ring (47) to the bore of idler gear (42) .

2. Install spacer (46) to idler gear (42) .

3. Lower the temperature of bearing cups (43) and (49). Use Tooling (D) to install bearing cups (43) and (49) to the idler gear.

   Note: Prior to assembly of the components use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cups are seated correctly.

4. Install the following components to idler gear (42) ; bearing cone (44), spacer (45) and bearing cone (48) .

   Note: Lubricate the bearing cones with the lubricant that is being sealed.

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Illustration 3	g01077425

5. Place the updrive housing on wood blocks or a suitable support stand so that the torque converter side is downward.

6. Install idler gear (42) .

   Note: Idler gear (42) must be installed through the pump drive end of the updrive housing.

7. Install the two O-ring seals to idler gear shaft (38). Install idler gear shaft (38) .

8. Install two bolts (37) .

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Illustration 4	g01074365

9. Lower the temperature of bearing cups (35) and (40) .

10. Use Tooling (D) to install bearing cup (35) to adapter (34) .

11. Use Tooling (D) to install bearing cup (40) to the updrive housing.

    Note: Prior to assembly of the components use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cups (35) and (40) are seated correctly.

12. Raise the temperature of bearing cones (36) and (41). Install bearing cones (36) and (41) to gear (39) .

    Note: Lubricate the bearing cones with the lubricant that is being sealed.

13. Install the two O-ring seals to adapter (34). Install adapter (34) .

14. Apply Tooling (B) and then apply Tooling (C) to the threads of ten bolts (33) prior to installation.

15. Install ten bolts (33) .

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Illustration 5	g01075842

16. Lower the temperature of the bearing cups for bearing cage (29). Use Tooling (D) to install the bearing cups for bearing cage (29) .

    Note: Prior to assembly of the components use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cups are seated correctly.

17. Raise the temperature of the bearing cones for pump drive gear (32). Install the bearing cones on pump drive gear (32) .

Note: Lubricate the bearing cones with the lubricant that is being sealed.

18. Install pump drive gear (32) to bearing cage (29) .

19. Use Tooling (A) to install snap ring (31) and the washer.

20. Apply Tooling (B) and then apply Tooling (C) to the threads of four bolts (30) prior to installation.

21. Install the following components; bearing cage (29), pump drive gear (32) and four bolts (30) .

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Illustration 6	g01078145

22. Install the two O-ring seals in the torque converter, as shown.

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Illustration 7	g01075832

23. Attach a suitable lifting device to the updrive housing. The weight of the updrive housing is approximately 200 kg (441 lb).

24. Install the updrive housing to the torque converter.

25. Apply Tooling (B) and then apply Tooling (C) to the thread of eight bolts (28) prior to installation.

26. Install eight bolts (28). Tighten eight bolts (28) to a torque of 60 ± 5 N·m (44 ± 4 lb ft).

27. Install the following components to the torque converter output shaft; transfer gear (27) and retainer (26) .

28. Apply Tooling (B) and Tooling (C) to the threads of bolt (25). Install bolt (25). Tighten bolt (25) to a torque of 115 ± 5 N·m (85 ± 4 lb ft).

29. Install the O-ring seal to cover (23) .

30. Install cover (23) and nine bolts (24). Tighten nine bolts (24) to a torque of 60 ± 5 N·m (44 ± 4 lb ft).

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Illustration 8	g01075423

31. Lower the temperature of bearing cups (21) and (18) .

32. Use Tooling (D) to install bearing cup (21) to the updrive housing.

33. Use Tooling (D) to install bearing cup (18) to bearing cage (17) .

    Note: Prior to assembly of the components use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cups (21) and (18) are seated correctly.

34. Raise the temperature of bearing cones (19) and (22). Install bearing cones (19) and (22) to transfer gear (20) .

Note: Lubricate the bearing cones with the lubricant that is being sealed.

35. Install transfer gear (20) .

36. Install a full shim pack and bearing cage (17) .

    Note: Do not install the O-ring seals or cup plug (16) at this time.

37. Install six bolts (15). Tighten six bolts (15) to a torque of 50 ± 5 N·m (37 ± 4 lb ft).

38. Rotate transfer gear (20) at least three revolutions to seat the bearings.

39. Tighten six bolts (15) to a torque of 60 ± 5 N·m (44 ± 4 lb ft).

40. Use Tooling (E) to measure the end play of transfer gear (20). Add or subtract from the shim pack to obtain an end play measurement of 0.15 ± 0.05 mm (0.006 ± 0.002 inch).

41. When the correct shim thickness has been obtained remove bearing cage (17) .

42. Install the two O-ring seals to bearing cage (17) .

    Note: Lubricate the O-ring seals with the lubricant that is being sealed.

43. Install cup plug (16) to bearing cage (17). Install bearing cage (17) to the updrive housing.

44. Apply Tooling (B) and Tooling (C) to the threads of six bolts (15). Install six bolts (15). Tighten six bolts (15) to a torque of 60 ± 5 N·m (44 ± 4 lb ft).

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Illustration 9	g01074364

45. Lower the temperature of bearing cups (10) and (13) .

46. Use Tooling (D) to install bearing cup (13) to the updrive housing.

47. Use Tooling (D) to install bearing cup (10) to bearing cage (3) .

Note: Prior to assembly of the components use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cups are seated correctly.

48. Raise the temperature of bearing cones (11) and (12). Install bearing cones (11) and (12) to transfer gear (9) .

Note: Lubricate the bearing cones with the lubricant that is being sealed.

49. Install transfer gear (9) .

    Note: Do not install the following components at this time; O-ring seals, output shaft (14), spacer (5), retainer (4), yoke (1), retainer ring (7) and lips seal (8) .

50. Using eight bolts (6) install bearing cage (3) with a full shim pack. Tighten eight bolts (6) to a torque of 50 ± 5 N·m (37 ± 4 lb ft).

51. Rotate transfer gear (9) at least three revolutions to seat the bearings.

52. Tighten eight bolts (6) to a torque of 60 ± 5 N·m (44 ± 4 lb ft).

53. Use Tooling (E) to measure the end play of transfer gear (9). Add or subtract from the shim pack to obtain an end play measurement of 0.15 ± 0.05 mm (0.006 ± 0.002 inch).

54. When the correct shim thickness has been obtained remove bearing cage (3) .

55. Install the two O-ring seals to bearing cage (3) .

    Note: Lubricate the O-ring seals with the lubricant that is being sealed.

56. Remove bearing cage (3) and transfer gear (9) .

57. Install output shaft (14) and retaining ring (7) to transfer gear (9) .

58. Install transfer gear (9) and bearing cage (3) .

59. Install the following components; spacer (5), lip seal (8), yoke (1) and retainer (4) .

60. Apply Tooling (B) and Tooling (C) to the thread of bolt (2). Install bolt (2). Tighten bolt (2) to a torque of 115 ± 5 N·m (85 ± 4 lb ft).

61. Apply Tooling (B) and Tooling (C) to the threads of eight bolts (6). Install eight bolts (6). Tighten eight bolts (6) to a torque of 60 ± 5 N·m (44 ± 4 lb ft).