NEHS0858 - Using the 197-5589 Wheel Stud Remover/Installer {0374, 0599, 0700, 0730, 4210} Caterpillar

Off-Highway Truck/Tractor

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP)

793D (S/N: FDB1-UP)

793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)

793F AC (S/N: EMD2-UP)

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)

Introduction

This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

Some photographs or illustrations in this publication may show details that can be different from your service tool due to updates. Guards and covers might have been removed for illustrative purposes.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product, are therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator is responsible for ensuring that the procedures used are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

Illustration 1	g06358530

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understand the operation lubrication, maintenance, and repair information.

When replacement parts are required for this product, Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.

Whenever a question arises regarding your service tool or this publication, contact the Global Dealer Solutions Network hot line at:

Safety Information

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. The operator should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons

Illustration 2	g06350515

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Safety Signal Words

The following safety signal words can be found throughout this publication. Review the image below to understand the severity of bodily harm that can occur during certain operational steps. Refer to "ANSI Z535.1-2002 - American National Standard For Safety Color Code" and "ANSI Z535.6-2011- American National Standard - Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials"for more information.

Illustration 3	g06358515

Mandatory Action and Personal Protection Identification

The personal protective equipment symbols shown in this section are all not used with this tool. Read and understand the manual fully to know which personal protective equipment should be used during tool operation. Always use the appropriate personal protective equipment when operating the tool.

Illustration 4	g06346292

Product Safety Information

General Safety Hazards

• Read and understand this and all other manuals before installing, operating, repairing, maintaining, or working near the machine.

• Only trained operators should install, adjust, or use this tool. Do not allow unauthorized personnel to operate tool.

• It is your responsibility to make this information available to others that will operate this product.

• The warnings given in this manual are for identified hazards that are foreseeable in the general use of this tool.

• Never use a tool that has been damaged or is malfunctioning.

• Do not modify the tool, safety devices, and accessories. Doing so will increase hazards to the operator and others.

• Perform preventative maintenance on the tool regularly. Keep tool clean of fluids, grease, dust, and debris found around the workspace.

• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment.

• Personal injury can result from slips or falls. Do not leave tools or components laying around the work area and clean up all spilled fluids immediately.

Flying Debris Hazard

• Always wear protective glasses or a face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component.

• Never stand in line with a wheel stud as tension is applied. Keep all body parts (including your head, arms, and hands) away from the wheel stud. You must be aware of this danger always.

High-Pressure Hazard

• Personal injuries can occur as a result of using pressurized air. Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes. Wear protective clothing, protective glasses, and a protective face shield when using pressure air.

• High-pressure hydraulic systems can be dangerous if they are misused. If a tool or component fails, the high-pressure hydraulic system could result in a sudden and explosive force. Therefore, operation of this equipment must not be undertaken by a lone worker, especially outside of normal working hours.

• Be familiar with the technical specifications for this equipment. Do not exceed the maximum stroke or the maximum working pressure for this equipment. The maximum working pressure specified for one piece of equipment may not represent the maximum load that may be placed onto another piece of equipment and/or onto a wheel stud.

• Never leave a pressurized system unattended. If you have to leave the area, make sure that you release the pressure and that the return-to-tank valve on the pump unit is fully open.

• Check hydraulic oil lines, tubes, and hoses carefully. Do not use your bare hand to check for potential leaks. Always use a board or cardboard when checking for a leak. Escaping hydraulic fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

General Description

Hydraulic bolt tensioning is an efficient and accurate means of removing and installing wheel studs. This method is required for the removal and installation of wheel studs on 793 and 797 Off-Highway Truck wheels to prevent damage to the wheel studs or wheel housing.

Illustration 5	g06358530
Do not hammer on a wheel stud. Using a hammer to drive a wheel stud into or out of the wheel housing could result in damage to the wheel stud and/or fractures in the wheel housing flange.

Illustration 6	g06374485
(A) Wheel. (B) Wheel Stud Installer. (C) Stud and Stud Head.

The wheel stud remover/installer and related equipment are simple to use, provided the operating instructions are carefully followed.

Illustration 7	g06358530
Before using the wheel stud remover/installer or the hydraulic pump, it is vital that the operating instructions are read carefully and thoroughly. Particular attention should be given to the Safety Section in this manual.

Specifications

Pressure Load Chart

Illustration 8	g06372212

Parts List

Parts List for Wheel Stud Remover/Installer Set Up For Stud Removal

Illustration 9	g06377007
197–5589 Wheel Stud Remover/Installer set up for stud removal.

Illustration 10	g06376175
Wheel Stud Remover/Installer (Top View).

Parts List for Wheel Stud Remover/Installer Set Up For Stud Installation

Illustration 11	g06377004
197–5589 Wheel Stud Remover/Installer set up for stud installation.

Illustration 12	g06374489
Wheel Stud Remover/Installer (Top View).

₁ Part of 223–2406 Seal Kit.

₂ Part of Puller Bar Group.

Additional Tooling

Extra tooling is needed to perform the wheel stud install process. Read all other manuals regarding the additional tooling before proceeding.

Illustration 13	g06377021

Inspection

If any seals are damaged, and in need of replacing, see the "Replacing the Seals" section in the Maintenance section at the back of the manual.

Wheel Stud Inspection

1. Inspect all components prior to each use for nicks, burrs, dents, cracks, bends, or worn parts. If damage is found, discontinue use until inspected and released for use by an approved inspector at dealership.

2. Inspect all welds and check for damaged, cracked, or bent components.

3. Inspect all hardware for damaged threads and cracked or bent components.

4. Do not use if bolt holes are elongated.

5. Have tools inspected annually by an approved dealership inspector. Maintain a written record of all inspections

Hydraulic System Inspection

Always check the following items before pressurizing a hydraulic system:

• Make sure that the hydraulic hoses are fully connected. Physically pull on the connection to make sure it is secure.

• Make sure that the wheel stud is strong enough for the load being applied to it. The wheel stud remover/installer is powerful and can break a wheel stud if the tensile property is not sufficient.

• Make sure that the threads of the tensioner are screwed onto and fully engaged with the threads of the wheel stud.

• Measure and check the wheel stud protrusion before installing the tensioner.

• Make sure that the tensioner and bridge are seated squarely on the wheel. The threads on the tensioner should fully engage the threads on the wheel stud.

• Never bend hydraulic hoses less than six times their own diameter.

• Do not use kinked hoses.

• Never exceed the maximum stroke.

• Never exceed the maximum pressure.

Note: The maximum working pressure of 44816 kPa (6500 psi), specified for the tool, does not necessarily represent the maximum load 312168 kN (31,330 lb-ft) that may be placed onto a wheel stud.

• Make sure that the pressure regulating valve on the hydraulic pump is set to 44816 kPa (6500 psi).

Wheel Stud Assembly

Illustration 14	g06350515
Before moving forward, make sure to have read and understood the safety section and the personal protective equipment required to prevent injury or death during this procedure.

1. Make sure all the interior surfaces of the wheel stud remover/installer are free from dirt and other foreign particles.

2. Use an oil, preferably hydraulic oil, to lubricate all the interior surfaces, especially the seals and seal contact surfaces.

3. Press insert (17) fully into bridge body (19).

   Note: Make sure that all seals fit smoothly into the seal grooves and are not damaged during installation.

4. Screw end stop (13) into bridge body (19).

5. Reinstall male quick-disconnect coupler assemblies (9) in the side of the wheel stud remover/installer.

Operation

The operating instructions in this manual apply to the removal and installation of M36 x 4 and M24 x 3 wheel studs on a 797 or 793 Off-Highway Truck.

Wheel Stud Removal

1. Make sure that the pump has been regulated to a maximum 44816 kPa (6500 psi) working pressure. Refer to the “Hydraulic Pump” manual for additional information.

2. Assemble the wheel stud remover/installer as shown. Place insert plug (2) onto the tool to remove a wheel stud.

   Note: Spring plunger balls (1) should locate themselves in the machined recess of insert (17) to prevent inset plug (2) from falling out.

3. Connect the hoses to the wheel stud remover/installer quick-disconnect coupler assemblies (9).

4. Fully retract insert (17) to provide space inside the wheel stud remover/installer for the wheel stud.

5. Place the wheel stud remover/installer over the wheel stud to be removed.

   1. Position reaction clamp (5) around the wheel stud head and tool body.

   2. Tighten locking screw (3) to hold the tool in position.
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   Illustration 15	g06350515
   Care should be taken to avoid getting anything trapped between the wheel stud remover/installer, the reaction clamp, and the wheel hub assembly during this process. Failure to do so could result in personal injury.

6. Hold the wheel stud remover/installer in position while slowly applying pressure to the tool.

7. Gradually increase pressure to the wheel stud remover/installer until the wheel stud moves or the tool reaches the maximum working pressure.

   Note: If the maximum working pressure of 44816 kPa (6500 psi) is reached and the stud has not moved, release the pressure and try the removal operation again. Do not exceed the maximum pressure.

8. Once the wheel stud is removed, fully retract the tool and proceed to the next wheel stud, if necessary.

Wheel Stud Installation

1. Make sure that the pump has been regulated to a maximum 44816 kPa (6500 psi) working pressure. Refer to the “Hydraulic Pump” manual for additional information.

2. Assemble the wheel stud remover/installer as shown. Place puller bar (18) and reaction nut (11) onto the tool to install a wheel stud.

   Note: Locking pin (10) should be slightly tight over reaction nut (11) and puller bar (18), and if not, bend the locking pin to prevent it from falling out. See illustration 16.

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   Illustration 16	g06383620

3. Connect the hoses to the wheel stud remover/installer quick-disconnect coupler assemblies (9).

4. Fully extend the tool to make sure that full thread contact is made with the wheel stud.

5. Apply Loctite® LB 8008™or LB 8065™ C5-A® Copper Anti-Seize Compound to the splines of the wheel stud and the bores of the wheel hub.
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   Illustration 17	g06350515
   Care should be taken to avoid getting anything trapped between the wheel stud remover/installer and the wheel hub assembly during this process. Failure to do so could result in personal injury.

6. Hold stud (6) steady in the bolt hole while attaching the wheel stud remover/installer.

   Note: Make sure stud head flat (A) is positioned correctly along wheel flange (B)

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   Illustration 18	g06375005
   Correct position of stud head flats along wheel flange. (A) Wheel. (C) Stud and Stud Head.

7. Use the square drive on top of the puller bar to thread the puller bar onto the wheel stud until reaction nut (11) touches the top of insert (13). Sometimes, the stud head may need to be restrained to prevent it from rotating.

8. Install the wheel stud into the wheel housing flange.

   Note: When the maximum working pressure of 44816 kPa (6500 psi) is reached, stop the pump. Do not over tighten the puller bar.

9. Release the pressure on the wheel stud remover/installer by slightly extending the tool.

10. Unscrew the wheel stud remover/installer from the wheel stud.

11. Proceed to the next wheel stud, if necessary.

Troubleshooting

Maintenance

The 197-5589 Wheel Stud Removal/Installer is durable with high-quality, reliable seals. Therefore, the only maintenance that is typically required is to occasionally replace a hydraulic fitting or a seal.

Be sure to read all other manuals that come with the other tools. Heed all warnings and safety practices that go along with the maintenance, cleaning, storage, and disposal.

Disassembly of the Wheel Stud Remover/Installer

1. Remove female quick-disconnect coupler assemblies (9, Illustration 20) from the side of the wheel stud remover/installer.

2. Remove locking pin (10) from reaction nut (11) and puller bar (18).

3. Remove reaction nut (11) and puller bar (18).

4. Remove end stop (13), using the two holes provided.

5. Push insert (17) out of the wheel stud removal/installer.

Replacing the Seals

End stop (13) and insert (17) must be removed from the wheel stud remover/installer to remove and replace all seals.

Illustration 19	g06358530
Take appropriate precautions when replacing the seals, to avoid damaging the wheel stud remover/installer or the new seals.

• Remove all dust, dirt, and foreign particles.

• Lubricate all components before assembly.

• Avoid sharp edges (cover threaded areas). Do not use sharp edged tools.

Note: Refer to Illustration 20 to determine the location and position of the chamfer of each seal.

1. Install bearing strip (16) into the machined groove of bridge body (19).

2. Install inner seal (15) into bridge body (19).

   1. Slightly fold inner seal assembly (15) and position it in the seal groove of bridge body (19).

   2. Release the fold on the inner seal.

   3. Remove any kinks from the inner seal.

3. Install two outer seals (14) into insert (17).

   1. Stretch a rubber O-ring over the boss and into a groove of the insert.

   2. Install part of the outer seal into the groove.

   3. Stretch the seal over the boss and into the groove.

   4. Make sure that the outer seal does not twist as the seal is being installed.

4. Install seals (12), (14), and (15) into end stop (13).

Illustration 20	g06377011

Testing has shown the seals in the wheel stud remover/installer should perform satisfactorily for at least 1000 cycles when the wheel stud remover/installer is properly used, stored, and maintained.

Cleaning

Clean tooling after each use, using a non-solvent based cleaner.

Storage

Apply a light coating of oil or rust inhibitor to all surfaces to protect the 197-5589 Wheel Stud Remover/Installer from weathering and/or rusting.

Cover the internal threads on the puller bars with 183-8447 Rust Preventative (Aerosol).

Always store the wheel stud remover/installer in an upright position.

Note: Do not store this tool lying down on its side, because the weight of the wheel stud remover/installer will flatten the seals inside the tool causing possible internal leakage.

Keep the dust caps on the quick-disconnect fittings when the wheel stud remover/installer is not being used.

Tool Disposal

At end of operational life of tooling, destroy tooling and dispose of as scrap.

References

1. ANSI Z535.1-2002 - American National Standard For Safety Color Code

2. ANSI Z535.6-2011- American National Standard - Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials

3. Manufacturer Operating Manual for the Hydraulic Pump.