TH62, TH63, TH82, TH83 and TH103 Telehandlers Power Train Caterpillar

Installation Procedure

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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.

1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.
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   Illustration 1	g00801408
   Typical Example

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   Illustration 2	g00801400
   Typical Example

2. Reduce the temperature of cup (1) for the inner bearing and cup (2) for the outer bearing. Then use a suitable driver to install the cups into the carrier.
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   Illustration 3	g00801301

3. Install shim (3) onto the shaft of pinion (4). Ensure that the shim is properly seated. The chamfer on the shim should face the head of the pinion. Also, ensure that the shim is the correct thickness. Refer to Systems Operation, Testing and adjusting, SENR1234, "Differential Pinion Bearing - Adjust" for information on adjusting the pinion depth.
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   Illustration 4	g00801415
   Typical Example

4. Use a suitable press to install cone (5) for the inner bearing onto pinion (4).
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   Illustration 5	g00801422

5. Install one of two washers (6) onto the pinion. Install a new sleeve (7) and install the second washer.
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   Illustration 6	g00802351

6. Install pinion (4) into the carrier.
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   Illustration 7	g00801444
   Typical Example

7. Install cone (8) for the outer bearing onto the pinion. Use a suitable driver in order to properly seat the cone.
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   Illustration 8	g00801467
   Typical Example

8. Install a new seal (9) and use a suitable driver to properly seat the seal.
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   Illustration 9	g00802356
   Typical Example

9. Install yoke (10). Install O-ring seal (11), washer (12) and new nut (13).

10. Tighten the nut until resistance is felt. Seat the bearings by striking both ends of the pinion with a soft mallet while tightening the nut until the rolling resistance begins to increase.
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    Illustration 10	g00801638
    Typical Example

11. Use Tool (A) to check the rolling resistance. Tighten the nut on the pinion assembly until the torque that is required to turn the pinion assembly is between 2.8 N·m (24.5 lb in) and 3.0 N·m (26.5 lb in). Do not overtighten the nut. Refer to Testing and Adjusting, SENR1234, "Differential Pinion Bearing - Adjust".
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    Illustration 11	g00802355

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    Illustration 12	g00802359

12. Install cups (14) onto the bearings that are located on differential (17). Use a suitable strap and a suitable hoist to position the differential. The weight of the differential is 33 kg (72.75 lb). Keep the differential supported until the differential is properly secured in the following steps of this procedure.

13. Install two retainer brackets (16). Install four bolts (20) and tighten the bolts to a torque of 413 N·m (305 lb ft). Ensure that the same retainer bracket is installed in the original position.

    Note: If retainer brackets (16) have been removed with nut (15), retainer (18), and bolt (19) in place, the parts can be installed as an assembly. These parts should only be installed as an assembly provided that you have not removed the bevel gear set and the bearings on the differential. If the bevel gear set and the bearings on the differential have been removed, perform Step 14 and Step 15.

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    Illustration 13	g00802391

14. Install nut (15) at each end of the differential and tighten the nuts until resistance is felt. Check the total rolling torque of the bevel gear set and then adjust nut (15) for the differential backlash. Refer to Testing and Adjusting, SENR1234, "Differential Backlash and Bearings - Adjust".

15. Install bolt (19) and retainer (18) onto the retainer brackets. Tighten the bolt to a torque of 13 N·m (9.6 lb ft).
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    Illustration 14	g00802434

16. Apply 1U-8846 Gasket Sealant to the mating surfaces of the housing and the carrier.
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    Illustration 15	g00802365

17. Use suitable straps and a suitable hoist to install carrier (21). The weight of the carrier is 103 kg (227 lb). Ensure that the carrier is installed in the original position. Also ensure that the locating pins on the carrier and on the housing are properly seated.

18. Install twelve bolts (22) and tighten the bolts to a torque of 215 N·m (158.5 lb ft).

End By:

1. Install the steering cylinder. Refer to Disassembly and Assembly, RENR3437, "Steering Cylinder - Install".

2. Install the shaft assemblies into the housing for the axle. Refer to Disassembly and Assembly, "Axle Shaft - Install".

3. Install the rear axle. Refer to Disassembly and Assembly, "Rear Axle (Oscillating) - Install".