525C, 535C and 545C Wheel Skidders 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.

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Illustration 1	g01274270

1. Raise the temperature of bearing cone (20). Use the proper equipment to handle bearing cone (20).

2. Install bearing cone (20) on the axle shaft. Make sure that bearing cone (20) is seated against the shoulder of the axle shaft.

   Note: Allow bearing cone (20) and the axle shaft to reach a uniform temperature.

3. Use a suitable driver to reset bearing cone (20). This will ensure that bearing cone (20) is seated properly.

4. Apply a thin coat of clean SAE 30 oil on bearing cone (20).

5. Use Tooling (H) to install Duo-Cone seal (21) in the axle shaft. Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
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   Illustration 2	g01274269

6. Lower the temperature of bearing cup (19). Use the proper equipment to handle bearing cup (19).

7. Install bearing cup (19) in the end of axle housing (1). Make sure that bearing cup (19) is seated with the mating surface.

   Note: Allow bearing cup (19) and axle housing (1) to reach a uniform temperature.

8. Use a suitable driver or a press to reset bearing cup (19). This will ensure that bearing cup (19) is seated properly.

9. Use Tooling (H) to install Duo-Cone seal (18) in the end of axle housing (1). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
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   Illustration 3	g01274267

10. Lower the temperature of bearing cup (15). Use the proper equipment to handle bearing cup (15).

11. Install bearing cup (15) in the opposite end of axle housing (1). Make sure that bearing cup (15) is seated on the mating surface.

    Note: Allow bearing cup (15) and axle housing (1) to reach a uniform temperature.

12. Use a suitable driver or a press to reset bearing cup (15). This will ensure that bearing cup (15) is seated properly.

13. Lower the temperature of ring gear (17). Use the proper equipment to handle ring gear (17).

14. Align the dowel holes in ring gear (17) and axle housing (1).

15. Install ring gear (17) and dowels (16).

16. Peen axle housing (1) near dowels (16) to retain dowels (16).
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    Illustration 4	g01274293

17. Attach Tooling (A) and a suitable lifting device to axle housing (1). The weight of axle housing (1) is approximately 205 kg (450 lb).

18. Use the suitable lifting device to install axle housing (1) on the axle shaft.

19. Raise the temperature of bearing cone (14). Use the proper equipment to handle bearing cone (14).

20. Install bearing cone (14) on the axle shaft so that there is slight end play. When bearing cone (14) is cool, apply clean SAE 30 oil to bearing cone (14).
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    Illustration 5	g01274294

    Note: Adjusting nut (13) must be installed so that the flat side of nut (13) faces the bearing cone (14).

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

    Note: The preload rolling torque for new bearings is 9 - 16 N·m (80 - 142 lb in).

    Note: The preload rolling torque for the used bearings is 0.5 ± 0.9 N·m (4 ± 8 lb in)

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    Illustration 6	g01047406

22. Install Tooling (G) on the axle housing.

    Note: Tooling (G) will be used to measure the seal drag torque that is required to rotate the axle housing.

23. Use Tooling (G) to rotate the axle housing.

24. Record the torque that is required to rotate the axle housing as Torque (X).

25. The torque that is required for bearing nut (13) should be equal to Torque (X) plus the axle bearing preload rolling torque.

    Note: The preload rolling torque for new bearings is 9 - 16 N·m (80 - 142 lb in). The preload rolling torque for used bearings is 0.5 ± 0.9 N·m (4 ± 8 lb in).

26. Use Tooling (G) and Tooling (E) to obtain the correct rolling torque for the axle housing.

    Note: Make sure that the axle shaft has zero end play. If the axle bearing preload rolling torque exceeds the specification, back off bearing nut (13) by 1/8 turn and reseat bearing cone (14) against bearing nut (13). Repeat Steps 22 through 26.

27. Use the following procedure to assemble the planetary carrier:
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    Illustration 7	g00975729

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

    2. Install bearing (12) in planetary gear (11).

    3. Install two thrust washers (10) and planetary gear (11) in planetary carrier (6).

       Note: Retaining ring (4) (not shown) must be installed in the planetary carrier assembly before the final planetary gear is installed in planetary carrier (6).

    4. Install planetary shaft (9) in planetary carrier (6). Make sure that the spring pin hole in planetary shaft (9) is aligned with the spring pin hole in planetary carrier (6).

    5. Install spring pin (8) through planetary carrier (6) and in planetary shaft (9).

    6. Use a suitable hammer and a punch to install spring pin (7) through planetary carrier (6) and in spring pin (8).

    7. Repeat Steps 27.a through 27.f for the installation of the other two planetary gears.
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    Illustration 8	g00975728

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    Illustration 9	g00975727

28. Attach Tooling (D) and a suitable lifting device to planetary carrier (6). The weight of planetary carrier (6) is approximately 80 kg (175 lb).

29. Expand retaining ring (4) and use the suitable lifting device to carefully position planetary carrier (6) in the axle housing and over axle shaft (5). Make sure that retaining ring (4) is properly seated on axle shaft (5).
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    Illustration 10	g00975725

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    Illustration 11	g00975723
    Fixed Axle

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    Illustration 12	g01277407
    Oscillating Axle

30. Apply Tooling (J) on the mating surfaces of axle housing (1) and differential housing (3).

31. Use Tooling (A) and a suitable lifting device to remove axle housing (1) from Tooling (C) and position axle housing (1) on differential housing (3). The weight of axle housing (1) is approximately 500 kg (1100 lb).

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

End By:

1. If necessary, install the axle support. Refer to Disassembly and Assembly, "Front Axle Support - Install".

2. Install the axle. Refer to Disassembly and Assembly, "Fixed Axle (Rear) - Install" or Disassembly and Assembly, "Oscillating Axle (Front) - Install".