Procedure to Rework the Transmission Input Drive on Certain AD55B and AD60 Underground Articulated Trucks{3063} Caterpillar

Underground Articulated Truck:

AD55B (S/N: JNW1-UP)

AD60 (S/N: KNW1-125)

Introduction

This special instruction covers the procedure to rework the transmission input drive on the above AD55B and AD60 Underground Articulated Trucks. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

ReferenceDisassembly and Assembly, KENR6709, "AD55B Underground Articulated Truck Machine Systems"

ReferenceDisassembly and Assembly, KENR6708, "AD55B Underground Articulated Truck Power Train"

ReferenceDisassembly and Assembly, UENR2741, "AD60 Underground Articulated Truck Machine Systems"

ReferenceDisassembly and Assembly, UENR2734, "AD60 Underground Articulated Truck Power Train"

Parts Required

Machine Preparation

Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.

1. Move the machine to a hard level surface away from operating machines and away from personnel.

2. Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.

3. Stop the engine.

4. Connect the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

5. Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.

Procedure

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Illustration 1	g03745446

1. Separate input drive (2) from transmission (1). Refer to Disassembly and Assembly, "Input Drive from Transmission - Separate".

2. Discard input drive (2), the bolts, the washers, and the O-ring seals.

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Illustration 2	g03745456
(3) 451-2921 Yoke-U Joint (4) 379-1967 Bearing Cover (5) 133-4296 Lip Type Seal (6) 418-7678 Ball Bearing (7) 468-3135 Retainer Bearing (8) 209-1434 Cup Plug (9) 5J-2383 O-Ring Seal (10) 379-1969 Spacer (11) 1B-2790 Bolt

3. Assemble Item (3) through Item (11) .

   Note: Ensure that the sealing lip of 133-4296 Lip Type Seal (5) is facing the inside of 379-1967 Bearing Cover (4) .

   Note: Tighten eight 1B-2790 Bolts (11) in a criss-cross pattern.

   Note: Lubricate 5J-2383 O-Ring Seal (9) with the lubricant being sealed.

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Illustration 3	g03745463
(3) 451-2921 Yoke-U Joint (4) 379-1967 Bearing Cover (12) 379-1965 Front Cover

4. Install the assembled yoke assembly, assembled in Step 3, to 379-1965 Front Cover (12) .

5. Ensure 379-1967 Bearing Cover (4) is not resting on 379-1965 Front Cover (12) and is allowed to rotate with 451-2921 Yoke-U Joint (3) .

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Illustration 4	g03745465
(12) 379-1965 Front Cover (13) 0S-1588 Bolt (14) 9S-8004 O-Ring Plug (15) 214-7568 O-Ring Seal

6. Install Item (13) through Item (15) .

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Illustration 5	g03746065
(16) 6M-5218 O-Ring Seal (17) 9M-7002 O-Ring Seal (18) 2H-3932 O-Ring Seal (19) 9M-4218 O-Ring Seal

7. Install Item (16) through Item (19) .

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Illustration 6	g03746067
(20) 0S-1587 Bolt (21) 5P-8245 Hard Washer

8. Connect the assembled input drive to the transmission using Item (20) and Item (21). Refer to Disassembly and Assembly, "Input Drive to Transmission - Connect".