725, 730 and 730 EJECTOR Articulated Trucks Power Train Caterpillar

Output Transfer Gears - Assemble

Usage:

725 AFX

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0520	Driver Group	1
A	9S-8880	Ring	1
B	1P-0520	Driver Group	1
C	138-7575	Link Brackets	2
D	138-7573	Link Brackets	2
E	1U-6396	O-Ring Assembly Compound	1
F	1U-8846	Gasket Sealant	1
G	-	Loctite 5127	-

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Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.

Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Note: Cleanliness is an important factor. Thoroughly clean all parts in cleaning fluid before assembly. 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: O-ring seals, gaskets, and seals should always be replaced. A used O-ring seal may not have the same sealing properties as a new O-ring seal. Use Tooling (E) during the assembly procedure.

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Illustration 1	g03471280

Install shaft (163) and plug (162) into carrier (136) .

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Illustration 2	g03471257

Install bearing (159) and thrust discs (158) into gears (157) .

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Illustration 3	g03471242

Install two bearings (154) and thrust discs (153) into gears (152) .

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Illustration 4	g03471341

Use the following procedure to install the gears into carrier (136) . Refer to Illustration 4 for the correct sequence. During installation, the centerline of the sun gears must be concentric with the centerline of the carrier.
1. Install sun gear (161) into carrier (136) .
1. Install sun gear (160) .
1. Install gear (152) and shaft (151) . Align the hole in the shaft with the hole in the carrier. Install spring pin (150) into carrier (136) and shaft (151) .
1. Install gear (157) and shaft (156) . Align the hole in the shaft with the hole in the carrier. Install spring pin (155) into carrier (136) and shaft (156) .

Repeat Step 4.c through Step 4.d for the remaining gears.

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Illustration 8	g03471441

Raise the temperature of bearing (149) to 135 °C (275 °F). Install bearing (149) onto carrier (136) . Use Tooling (A) , if necessary.

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Illustration 9	g03471217

Install rings (146) . Apply Tooling (F) or Tooling (G) to the mating face of plate (148) and carrier (136) . Install plate (148) , and install bolts (147) into carrier (136) .

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Illustration 10	g03471184

Install spacer (145) into carrier (136) .

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Illustration 11	g03471178

Install O-ring seal (144) into carrier (136) . Install hub (141) and thrust disc (142) . Start with a disc and alternate until discs and friction discs (143) have been installed into carrier (136) .

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Illustration 12	g03471158

Install ring seal (140) and ring seal (139) onto piston (138) .

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Illustration 13	g03471141

Install piston (138) .

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Illustration 14	g00781645

Raise the temperature of bearing (137) to 135 °C (275 °F). Install bearing (137) onto housing (135) . Use Tooling (B) , if necessary.

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Illustration 15	g00781647

Apply Tooling (F) to the face of carrier (136) . Position the housing onto carrier (136) and install bolts (134) and the washers into housing (135) .

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Illustration 16	g00778726

Lower the temperature of bearing cup (133) . Install bearing cup (133) into the case. Use Tooling (B) , if necessary.

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Illustration 17	g00781649

Attach Tooling (C) to the planetary transfer gear (132) . Attach a suitable lifting device to Tooling (C) . Carefully install planetary transfer gear (132) into case (14) . The weight of planetary transfer gear (132) is approximately 61 kg (135 lb).

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Illustration 18	g00781652

Install O-ring seal (130) and O-ring seals (131) . Lower the temperature of bearing cup (129) . Install bearing cup (129) . Use Tooling (B) , if necessary.

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Illustration 19	g00778723

Install cage (126) into case (14) before installing bolts (124) and installing bolts (125) . Install plug (127) and the O-ring seal and install O-ring seal (128) .

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Illustration 20	g00781654

Use Tooling (B) to install lip seal (123) into retainer (121) .

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Illustration 21	g00781658

Install O-ring seal (122) into retainer (121) .

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Illustration 22	g00778718

Install retainer (121) onto case (14) before installing bolts (119) and installing bolts (120) .

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Illustration 23	g00778716

Install O-ring seal (118) into yoke (117) .

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Illustration 24	g00778715

Install yoke (117) , retainer (116) , and bolt (115) into case (14) . Tighten bolt (115) to 270 ± 40 N·m (200 ± 30 lb ft).

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Illustration 25	g00778714

Install O-ring seal (114) , O-ring seal (113) , backup ring (112) , O-ring seal (111) , and backup ring (110) onto cartridge (109) .

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Illustration 26	g00778713

Install orifice (108) (not shown) and cartridge (109) into solenoid and relief valve (89) .

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Illustration 27	g00778711

Install O-ring seal (107) and backup ring (106) . Install O-ring seal (105) onto relief valve (99) .

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Illustration 28	g00778710

Install O-ring seal (104) onto valve (98) . Install backup rings (101) and O-ring seal (103) . Install backup rings (100) and O-ring seal (102) .

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Illustration 29	g00778703

Install coil assembly (95) . Install plugs (96) and (97) and the O-ring seals. Install valve (98) . Install relief valve (99) into solenoid and relief valve (89) .

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Illustration 30	g00778695

Install tee fitting (91) and the O-ring seal. Install nipples (92) and the O-ring seals and install caps (90) . Install O-ring seals (93) and O-ring seal (94) onto solenoid and relief valve (89) .

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Illustration 31	g00778693

Position solenoid and relief valve (89) onto case (14) in order to install bolts (88) and the washers.

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Illustration 32	g00781693

Lower the temperature of bearing cup (86) . Install bearing cup (86) into cage (84) . Use Tooling (B) , if necessary.

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Illustration 33	g00781699

Install cage (84) into case (14) and install bolts (82) . Hand tighten the bolts only. Do not install the shims or the O-ring seals at this time.

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Illustration 34	g00781705

Use Tooling (B) to install lip seal (59) into retainer (81) . Install seal (59) until the seal is flush with the face of retainer (81) .

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Illustration 35	g00781713

Position retainer (81) onto case (14) in order to install bolts (80) .

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Illustration 36	g00781718

Lower the temperature of bearing race (78) . Install bearing race (78) into case (14) . Use Tooling (B) , if necessary.

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Illustration 37	g00781729

Install shaft (77) . Install retainer (79) into case (14) .

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Illustration 38	g00781740

Raise the temperature of bearing (76) to 135 °C (275 °F). Install bearing (76) onto gear (73) . Use Tooling (B) , if necessary.

Repeat Step 36 in order to install the bearing onto the other side of gear (73) .

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Illustration 39	g00781746

Raise the temperature of bearing (75) to 135 °C (275 °F). Install bearing (75) onto gear (71) . Use Tooling (B) , if necessary.

Repeat Step 38 in order to install the bearing onto the other side of gear (71) .

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Illustration 40	g00778678

Install retaining ring (74) into gear (71) .

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Illustration 41	g00778673

Install gear (71) and gear (73) . Install seal (72) into case (14) .

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Illustration 42	g00781771

Lower the temperature of bearing cup (70) and bearing race (68) . Install bearing race (68) and bearing cup (70) . Use Tooling (B) , if necessary. Install elbow (69) into cage (64) .

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Illustration 43	g00781772

Lower the temperature of bearing race (65) and bearing race (66) . Install bearing race (65) and bearing race (66) . Use Tooling (B) , if necessary. Install elbow (66) into cage (64) .

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Illustration 44	g00778669

Position cage (64) and install bolts (63) into case (14) . Install shaft (62) .

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Illustration 45	g00781773

Install tube (61) and the elbows and install plate (58) into case (14) . Lower the temperature of bearing cup (60) and install bearing cup (60) into case (14) . Use Tooling (B) , if necessary.

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Illustration 46	g00781776

Raise the temperature of bearing (57) to 135 °C (275 °F). Install bearing (57) onto gear (56) . Use Tooling (B) , if necessary.

Repeat Step 46 in order to install the bearing onto the other side of gear (56) .

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Illustration 47	g00778666

Install gear (56) into case (14) .

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Illustration 48	g00778665

Install shroud (55) , bolts (53) and bolts (54) into case (14) .

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Illustration 49	g00781777

Raise the temperature of bearing (52) to 135 °C (275 °F). Install bearing (52) onto gear (48) . Use Tooling (B) , if necessary.

Repeat Step 50 in order to install the bearing onto the other side of gear (52) .

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Illustration 50	g00778663

Install retaining ring (51) into gear (48) .

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Illustration 51	g00781802

Raise the temperature of bearing (50) to 135 °C (275 °F). Install bearing (50) onto gear (49) . Use Tooling (B) , if necessary.

Repeat Step 53 in order to install the bearing onto the other side of gear (49) .

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Illustration 52	g00778657

Install gear (48) and gear (49) into case (14) .

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Illustration 53	g00778656

Install retainer (47) onto the gear.

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Illustration 54	g00781808

Install tube (43) and the elbows. Install O-ring seal (44) into case (8) . Lower the temperature of bearing race (45) and bearing race (46) . Install bearing race (45) and bearing race (46) into case (8) . Use Tooling (B) , if necessary.

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Illustration 55	g00781825

Lower the temperature of bearing (42) . Install bearing (42) into retainer (38) . Use Tooling (B) , if necessary.

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Illustration 56	g00781848

Use Tooling (B) in order to install seal (41) into retainer (38) . Install seal (41) until the seal is flush with the face of retainer (38) .

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Illustration 57	g00778649

Install O-ring seal (39) and O-ring seal (40) into retainer (38) .

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Illustration 58	g00781871

Position retainer (38) into case (8) . Install bolts (36) and install bolts (37) in order to secure retainer (38) into case (8) .

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Illustration 59	g00781884

Lower the temperature of bearing cup (34) . Install bearing cup (34) into cage (32) . Use Tooling (B) , if necessary.

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Illustration 60	g00781899

Install cage (32) into case (8) and install bolts (30) . Hand tighten the bolts only. Do not install the shims or the O-ring seals at this time.

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Illustration 61	g00781920

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Illustration 62	g00781922

Apply Tooling (F) to the face of case (14) . Install Tooling (D) to case (8) . Attach a suitable lifting device to Tooling (D) . Carefully install case (8) and install bolts (29) into case (14) . The weight of case (8) is approximately 50 kg (110 lb).

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Illustration 63	g00778635

Install O-ring seal (25) and O-ring seal (26) onto cover (24) . Install tube (27) and nut (28) .

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Illustration 64	g00778632

Install cover (24) onto case (8) . Install bolts (22) and install bolts (23) into cover (8) .

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Illustration 65	g00781942

Install seal (21) onto yoke (19) . Raise the temperature of bearing race (20) . Install bearing race (20) onto yoke (19) .

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Illustration 66	g00778627

Install yoke (19) into case (8) .

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Illustration 67	g00781972

Install bolt (18) through case (14) into the yoke. Tighten bolt (18) to 270 ± 40 N·m (200 ± 30 lb ft).

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Illustration 68	g00781975

Install cover (17) and install bolts (16) onto case (14) .

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Illustration 69	g00778624

Install seal (15) into yoke (13) .

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Illustration 70	g00778623

Install yoke (13) into case (14) . Install flanges (11) and cover (12) into case (14) and install bolts (10) .

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Illustration 71	g00781983

Install bolt (9) through cover (8) into the yoke. Tighten the bolt to 270 ± 40 N·m (200 ± 30 lb ft).

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Illustration 72	g00782006

Install flanges (6) and cover (7) and install bolts (5) . Install plug (4) and the O-ring seal. Install cover (3) and the O-ring seal and install bolts (2) into cover (8) .

The following steps are used to determine the bearing preload for the rear output shaft.
1. Install new bolts (82) without the washers into cage (84) . Refer to Illustration 73 for the correct location. Tighten bolts (82) to 8 ± 2 N·m (70.8 ± 17.7 lb in). Rotate the gear three times. Tighten bolts (82) again to 8 ± 2 N·m (70.8 ± 17.7 lb in). Rotate the gear three times. Repeat this process until bolts (82) do not move.
1. Completely loosen bolts (82) . Rotate the gear three times. Tighten bolts (82) evenly to 6 N·m (53 lb in). Tighten bolts (82) in an alternating sequence. Rotate the gear three times. Repeat this process until the bolts do not move.
1. Use a depth micrometer to measure the distance from the bearing cage flange to the face of the case. Measure the distance through the threaded holes. Record the average measurement (Y) . Remove bolts (82) . Remove cage (84) .
1. Use a micrometer to measure the flange thickness of cage (84) at each side of the threaded holes. Record the average measurement (X) .
1. Subtract measurement (X) from measurement (Y) and call this measurement (Z) . The result is the average gap.
1. Add 0.087 mm (0.0034 inch) to measurement (Z) . This new measurement is the required shim pack thickness.

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Illustration 76	g00782072

Install correct shim pack (87) onto case (14) .

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Illustration 77	g00782133

Install O-ring seals (85) onto cage (84) .

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Illustration 78	g00782140

Install cage (84) onto case (14) . Install new bolts (82) and install bolts (83) onto case (14) . The gear must rotate freely.

The following steps are used to determine the bearing preload for the front output shaft.
1. Install new bolts (30) without the washers into cage (32) . Refer to Illustration 79 for the correct location. Tighten bolts (30) to 8 ± 2 N·m (70.8 ± 17.7 lb in). Rotate the gear three times. Tighten bolts (30) again to 8 ± 2 N·m (70.8 ± 17.7 lb in). Rotate the gear three times. Repeat this process until bolts (30) do not move.
1. Completely loosen bolts (30) . Rotate the gear three times. Tighten bolts (30) evenly to 6 N·m (53.1 lb in). Tighten bolts (39) in an alternating sequence. Rotate the gear three times. Repeat this process until the bolts do not move.
1. Use a depth micrometer to measure the distance from the bearing cage flange to the face of the case. Measure the distance through the two threaded holes on each side of the cage. Record the average measurement (Y) . Remove bolts (30) . Remove cage (32) .
1. Use a micrometer to measure the flange thickness of cage (32) at each side of the threaded holes. Record the average measurement (X) .
1. Subtractmeasurement (X) from measurement (Y) and call this measurement (Z) . The result is the average gap.
1. Add 0.087 mm (0.0034 inch) to measurement (Z) . This new measurement is the required shim pack thickness.

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Illustration 82	g00782150

Install correct shim pack (35) onto cover (8) .

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Illustration 83	g00778642

Install O-ring seals (33) onto cage (32) .

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Illustration 84	g00782152

Install cage (32) onto cover (8) . Install new bolts (30) and install bolts (31) onto cover (8) . The gear must rotate freely.

End By: Install the output transfer gears. Refer to Disassembly and Assembly, "Output Transfer Gears - Install" for the machine that is being serviced.