AD30 Underground Articulated Truck Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

Show/hide table

Illustration 1	g01061668

1. Lower the temperature of bearing cups (44) and (45).

2. Install the bearing cups to the transfer case.
   Show/hide table

   Illustration 2	g01061260

3. Raise the temperature of two bearing cones (46). Install bearing cones (46) to gear (43).
   Show/hide table

   Illustration 3	g01061676

4. Attach a suitable lifting device to gear (43). The weight of gear (43) is approximately 29 kg (64 lb).

5. Install gear (43).
   Show/hide table

   Illustration 4	g01061680

6. Raise the temperature of bearing cones (42).

7. Install the bearing cones on gear (41).
   Show/hide table

   Illustration 5	g01061697

8. Attach a suitable lifting device to gear (41). The weight of gear (41) is approximately 39 kg (86 lb).

9. Install gear (41).
   Show/hide table

   Illustration 6	g01061252

   Show/hide table

   Illustration 7	g01117990

10. Apply Tooling (M) to the threads of speed sensors (39) and (40). Install speed sensors (39) and (40).

11. Set the clearance (X) between the sensors and the gear to 0.71 mm (0.028 inch). Tighten the lock nut on each sensor to a torque of 25 ± 5 N·m (18 ± 4 lb ft).
    Show/hide table

    Illustration 8	g01061698

12. Apply Tooling (K) using a 3 ± 0.5 mm (0.12 ± 0.012 inch) continuous bead to the mating surface of the transfer case.

13. Install Tooling (C) and a suitable lifting device to gear case cover (38). The weight of gear case cover (38) is approximately 45 kg (100 lb).

14. Install gear case cover (38).
    Show/hide table

    Illustration 9	g01061242

15. Install eight bolts (37) that hold the cover to the transfer case. Tighten eight bolts (37) to a torque of 135 ± 20 N·m (100.0 ± 15.0 lb ft).
    Show/hide table

    Illustration 10	g01061241

16. Install drain assembly (36) and bolts (35).
    Show/hide table

    Illustration 11	g01062025

17. Lower the temperature of the bearing cup . Install the bearing cup to bearing cage (32).
    Show/hide table

    Illustration 12	g01062028

18. Install O-ring seal (33) on the bearing cage (32). Install cover (30).

19. Install the nuts that hold the cover in place.
    Show/hide table

    Illustration 13	g01062027

20. Lower the temperature of the bearing cup. Install the bearing cup to bearing cage (28).
    Show/hide table

    Illustration 14	g01062378

21. Install bearing cage (32) and bearing cage (28) in the transfer case. DO NOT install the O-ring seal or the shims at this time. Install two bolts and the washers at a 180° interval in each bearing cage (28) and (32), and tighten the bolts to a torque of 20.3 N·m (180 lb in).

22. Rotate gears (41) and (43) about 30° for three or four times. Tighten the bolts in each bearing cage (28) and (32) to a torque of 40.7 N·m (360 lb in).

23. Rotate gears (41) and (43) about 30° for three or four times. Without moving the gears, back off the bolts in each bearing cage (28) and (32). Tighten the bolts again until the bolts are finger tight. Tighten the bolts to a torque of 20.3 N·m (180 lb in).

24. Rotate gears (41) and (43) about 30° for three or four times. Tighten the bolts in each bearing cage (28) and (32) to a torque of 20.3 N·m (180 lb in). Continue to tighten the bolts in each bearing cage (28) and (32) until the bolts do not move at a torque of 20.3 N·m (180 lb in).

25. Measure the gaps between the housing and bearing cages (28) and (32). Take two measurements for each bearing cage, and measure the gaps at each bolt. Measure the gap between the bearing cage and the housing from the center of the bolt to the outside diameter of the flange.

26. Add the two measurements for each bearing cage. Divide the sum for each bearing cage by two to give the average gap for each bearing cage.

    Note: Step 27 is used for the gap at bearing cage (28).

27. Add 0.41 mm (0.016 inch) to the average gap measurement in order to determine the thickness of the shims.

    Note: Step 28 is used for the gap at bearing cage (32).

28. Add 0.46 mm (0.018 inch) to the average gap measurement in order to determine the thickness of the shims.

29. Assemble the correct shim pack in order to match the thickness in Step 27 or Step 28. Use a micrometer, and verify that the shim pack thickness is the same as in Step 27 or Step 28.

30. Remove bearing cages (28) and (32). Install the shim packs, the O-ring seals, and the bearing cages. Install the bolts in bearing cages (28) and (32). Tighten the bolts to a torque of 135 ± 20 N·m (100.0 ± 15.0 lb ft).
    Show/hide table

    Illustration 15	g01062384

31. Install O-ring seal (26) to cover (25).
    Show/hide table

    Illustration 16	g01060512

32. Install cover (25) and nine bolts (24).
    Show/hide table

    Illustration 17	g01062385

33. Raise the temperature of bearing (23). Install the bearing on the shaft.
    Show/hide table

    Illustration 18	g01062386

    Show/hide table

    Illustration 19	g01060510

34. Lower the temperature of two bearing cups (22). Install the bearing cups and the bearing cones in bearing cage (17).

35. Install retainer (21) and six bolts (20). The part number on the retainer should be visible.
    Show/hide table

    Illustration 20	g01062388

36. Use Tooling (A) to install the lip seal in bearing cage (17).

    Note: The seal must contact the counterbore in the bearing cage. The lip of the seal must face toward the inside of the bearing cage.

    Show/hide table

    Illustration 21	g00678346

37. Place the bearing cage, the spacer, and the gear in a suitable press. Install the shaft assembly through the gear, the spacer, and the bearing cage with the press.
    Show/hide table

    Illustration 22	g01060501

    Show/hide table

    Illustration 23	g01060491

38. Install Tooling (C) and a suitable lifting device to bearing cage assembly (17). The weight of bearing cage assembly (17) is approximately 95 kg (210 lb).

39. Install O-ring seal (18). Lightly lubricate the bore with the lubricant that is being sealed.

40. Install bearing cage assembly (17) to the transfer case.
    Show/hide table

    Illustration 24	g01060476

41. Install bolts (16). Tighten bolts (16) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
    Show/hide table

    Illustration 25	g01060144

42. Install yoke (15) and O-ring seal (14).
    Show/hide table

    Illustration 26	g01060143

43. Install bolt (12) and retainer (13). Tighten bolt (12) to a torque of 480 ± 52 N·m (355 ± 40 lb ft).

44. Turn the transfer case. The weight of the transfer case is approximately 520 kg (1150 lb).
    Show/hide table

    Illustration 27	g01062389

45. Lower the temperature of the bearing cup. Install the bearing cup to bearing cage (9).
    Show/hide table

    Illustration 28	g01062390

46. Install O-ring seal (11) to bearing cage (9).
    Show/hide table

    Illustration 29	g00514020

47. Use Tooling (A) to install the lip seal in the bearing cage. The seal must contact the counterbore in the bearing cage. The lip of the seal must face toward the inside of the bearing cage.

48. Apply Tooling (L) to the lip of the seal and on the O-ring seal.
    Show/hide table

    Illustration 30	g01060139

49. Install bearing cage (9) to the transfer case.

50. Install bolts (8). Tighten bolts (8) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
    Show/hide table

    Illustration 31	g01060138

51. Install yoke (7) and O-ring seal (6).
    Show/hide table

    Illustration 32	g01060137

52. Install retainer (5) and bolt (4). Tighten bolt (4) to a torque of 480 ± 52 N·m (355 ± 40 lb ft).
    Show/hide table

    Illustration 33	g00673112

53. Install O-ring seal (3).
    Show/hide table

    Illustration 34	g01060134

54. Install adapter (1) and four bolts (2).

End By:

1. Connect the output transfer gears. Refer to Disassembly and Assembly, "Transmission to Output Transfer Gears - Connect".