127-8458 Final Drive Disassembly and Assembly Bench {0374, 0599, 0722, 0727} Caterpillar

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Introduction

Important Safety Information

Illustration 1	g02139237
Think Safety

European Union Compliant, CE marked

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. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

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

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

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.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

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 must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

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.

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

Literature Information

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

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

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

Illustration 2	g02166423
Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Crushing hazard (foot)

Crushing hazard (hand)

Pinch point

Fire hazard

Electrical Shock - Hazard

Fire hazard

Safety Section

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause 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. Always use a board or cardboard when checking for a leak.

General Information

Introduction

The 127-8458 Final Drive Disassembly and Assembly Bench was designed for use in the repair and service of the final drives used in 5110, 5130, 5230 Mining Excavators and Tracked Forest Machines. The proper use of the bench, required adapters, and tooling are outlined in this manual.

Installing bearing locknuts used on Series 5000 Excavator and Track and Forest Machine Final Drive Assemblies requires application of considerable torque. The largest torque needed to establish bearing preload requires up to 23120 N·m (17052.4 lb ft). The 127-8458 Final Drive Disassembly and Assembly Bench is specifically designed to tighten the spindle bearing locknut to the high torque levels required.

Although the bench was originally designed for the Series 5000 Mining Excavators with additional tooling, final drive units from other machines can be serviced.

5110, 5139, 5230 Mining Excavators

322B, 325B, 330B, 541TFB Forest Machines

621F, 627F, 621G, 627G, 631G, 637G, 651E, 657E Wheel Tractor Scrapers equipped with power augers

RM300, RM500 Road Reclaimers

References

Disassembly and Assembly, RENR2908, "541 Feller Buncher Machine System Disassembly and Assembly"

Disassembly and Assembly, KENR3135, "Service Manual RM 500 Final Drive Disassembly and Assembly"

Service Manual, KENR3145, "Service Manual RM 300 Final Drive Disassembly and Assembly"

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

Nomenclature

The 127-8458 Final Drive Disassembly and Assembly Bench consists of two table-like benches. The upper bench includes a pair of hydraulic cylinders attached to a turntable assembly. The cylinders can be configured to stroke clockwise or counterclockwise. The cylinders work together to produce the resulting torque. A hex shaped shaft, mounted through the turntable, applies torque to a spanner-style socket. The socket then transfers torque to the bearing locknut.

The lower bench is used as a disassembly and assembly work table and also as a base to hold the final drive during the tightening procedure. The lower bench is sized to accept the 5230 Mining Excavator final drive bolt-hole pattern. Spanner sockets and adapter rings are available for the final drive units on:

• 5110, 5130 Mining Excavators

• RM300, RM500 Road Reclaimers

• 322B, 325B, 330B, or 541TFB Forest Machines

• 621F, 627F, 621G, 627G, 631G, 637G, 651E, and 657E Wheel Tractor Scrapers equipped with power augers

The two benches can be separated and the spacing between them adjusted to accommodate different-sized drive assemblies. The final drive bench requires a 3S-6624 Electric Hydraulic Pump (115 V) or 8S-8033 Electric Hydraulic Pump (230 V) to supply the required hydraulic power. The hex shaft torque setting is varied by adjusting a pressure reducing valve connected to the double acting hydraulic cylinders. The adjusted pressure is shown on a pressure gauge located on the valve manifolds. The pressure indicates the hydraulic cylinders common inlet port pressure.

Top View

Illustration 3	g02828338
Counterclockwise Rotation Shown

Note: If the bench is used to tighten a locknut in a clockwise direction, hydraulic cylinders (5) can be repositioned. Remove hinge point lockpins (3a) and rotate cylinder rod brackets (6) 180 degrees. Remove anchor point lockpins (3b) and reposition the hydraulic cylinders so cylinder rod brackets will rotate (push) the turntable in a clockwise direction. Reinstall all four lockpins. Hydraulic cylinders must be anchored to the original upper bench brackets. The bench will be set up and will operate in the same manner as in a counterclockwise direction.

Side View

Illustration 4	g02828341
Counterclockwise Rotation Shown

Valve Assembly

Illustration 5	g02828356

Specifications

Additional Tooling

Operation Section

Setup

1. The 127-8458 Final Drive Disassembly and Assembly Bench weighs approximately 1361 kg (3000.5 lb). Place the bench in a location that is accessible by an overhead hoist with adequate capacity. The bench does not need to be secured to the floor. All torque (force) is contained between the upper and lower benches.

2. Lifting points are provided on the four sides of upper bench (9). Attach the overhead hoist and support the weight of the upper bench. Separate the upper and lower benches by removing lockpins (8) on each of the four legs. Use the overhead hoist to lift off the upper bench of the lower bench. Set the upper bench aside until needed.

   Note: Three lockpin holes in each leg of the lower bench allow adjustment of the upper bench in relation to the final drive unit when tightening the locknut.

3. If necessary, refer to Table 5 in this manual and install the correct adapter ring on lower bench (7), using all bolt holes provided. Tighten all fasteners to standard torque specifications.

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NOTICE
Torque is transmitted through the adapter ring during tightening. Use high strength fasteners in each bolt hole and torque to standard specifications to secure adapter rings to the bench. Failure to properly secure adapter rings can result in damage to the adapter ring and lower bench.

4. Use the overhead hoist to place the final drive unit on the lower bench and secure it using all bolt holes provided. Tighten all fasteners to standard torque specifications.

5. Refer to the appropriate service manual for the correct final drive disassembly procedure.

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NOTICE
The final drive disassembly and assembly procedure calls for drilling the locknut, and splitting, for removal. This is due to the high torque and the use of thread sealant between the spindle and the locknut. The bench may be capable of removing the locknut without drilling, but is not recommended. Damage may occur to the spindle threads during removal of extremely tight locknuts.

6. Once the final drive is repaired and before assembly, trial fit the locknut onto the spindle. Make sure that the threads are clean. The locknut must fully engage all the threads.

7. Note the direction the locknut is threaded to tighten, clockwise or counterclockwise. This information will be used to configure the rotation of the turntable in Step 3 of the ""Operation Section" " Section.

8. Follow the service manual assembly procedure up to the point of tightening the locknut.

9. Refer to Table 5 in this manual and place correct spanner socket (12) onto the locknut.

   Note: 127-8468 Reaction Bar is used with spanner sockets available for this bench.

10. Place reaction bar (11) onto spanner socket (12) with the hex hole facing up. Align the reaction bar as close to center as possible.

11. Use the overhead hoist to lift upper bench (9) over the final drive unit and engage the legs into the receiving sockets of lower bench (7) .

12. Lower the upper bench until lockpins (8) can be installed through the lockpin holes to obtain a 25 to 101 mm (1.0 to 4.0 inch) clearance between the bottom of the upper bench hub and the final drive unit.

    Note: The 25 to 101 mm (1.0 to 4.0 inch) clearance between the upper bench hub and the final drive unit allows visual clearance for torque shaft alignment and inspection.

13. Insert 128-4075 Hex Shaft (10) into turntable assembly (4) and lower until engaging the hex portion of reaction bar (11). Movement of the reaction bar, or rotation of the turntable, may be needed for shaft alignment.

Operation

1. Connect 3S-6624 Hydraulic Pump (115 V) or 8S-8033 Hydraulic Pump (230 V) to pressure reducing valve manifold (2) at hydraulic fittings (17) .

   Note: For more information, refer to the applicable hydraulic pump tool operating manual.

2. Remove hinge point lockpins (3) from the hinge point between cylinder rod bracket (6) and turntable (4). This allows cylinder rods to extend without engaging the turntable.

3. If it is necessary to change the direction of turntable rotation to match the direction of locknut tightening, noted in Step 7 of the Section ""Setup" ", do the following:

   1. Rotate each hydraulic cylinder rod 180 degrees so cylinder rod brackets (6) face the opposite direction.

   2. Remove anchor point lockpins (3b) and move the hydraulic cylinders to the opposite side of turntable (4), so cylinder rod brackets (6) realign with the turntable.

   3. Reinstall anchor point lockpins (3b) to anchor each hydraulic cylinder (5) to the original bracket on upper bench (9) .

Note: To allow the cylinder rods to extend without engaging the turntable, do not install hinge point lockpins into cylinder rod brackets and turntable.

4. Turn on the adjusting knob pressure reducing valve (15) completely out, counterclockwise.

5. Start the power supply hydraulic pump.

   Note: The adjustment relief valve, located on the power supply pump, should not be adjusted. The normal 68900 kPa (9993.3 psi) adjustment is acceptable.

6. Refer to NEEG2689 torque/pressure chart (1) for pressure settings and torque conversion formula. Calculate the pressure required for correct final drive locknut torque.
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   Table 7

   Torque Specification Units x Conversion Factor = Bench Relief Valve Setting (Required Pressure).
   Example 1:
   	10,900 lb ft x .138 = 10370 kPa (1504.1 psi)
   Example 2:
   	23,120 N·m x .102 = 16258 kPa (2358.0 psi)

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Illustration 6	g02828377

7. Move the directional valve on the hydraulic pump to the extend position.

8. Turn pressure reducing valve (15) adjustment knob inward, clockwise. The hydraulic cylinder rods should start moving out. Allow the rods to move out until the hydraulic cylinders are fully extended.

   Note: If the hydraulic cylinder rods do not extend when the pressure reducing valve is turned clockwise, the directional valve on the hydraulic pump is not correctly positioned. Rotate the pressure reducing valve adjustment knob fully outward, counterclockwise and relieve all hydraulic pressure Move the directional valve on the pump to the opposite position and repeat Step 8.

9. With hydraulic cylinders (5) fully extended, adjust pressure reducing valve (15) until pressure gauge (14) reaches the pressure setting calculated in Step 6.

10. Once the correct pressure is set, reposition the directional control lever on the hydraulic pump to fully extract the hydraulic cylinders.

    Note: Once the correct pressure setting is obtained with pressure reducing valve, all hydraulic cylinder movement will be controlled by the directional valve on the power supply hydraulic pump.

11. Reconnect cylinder rod brackets (6) to turntable (4) by installing hinge point lockpins (3a) through the brackets and the closest turntable holes.

    Note: The cylinder rod brackets may not fully engage the turntable at this time. When the hydraulic cylinders extend, the brackets will rotate inward and fully engage the turntable.

12. Use the directional control valve on the power supply hydraulic pump to extend hydraulic cylinders (5) and rotate turntable (4). The hydraulic cylinders will stop extending when the torque/pressure rating has been reached or will fully extend before reaching the required torque/pressure setting.

13. If the hydraulic cylinders fully extend before reaching the specified torque/pressure reading, do the following:

    1. Move the direction control lever on the power supply hydraulic pump to the neutral position.

    2. Remove hinge point lockpins (3a) and use the directional control lever to retract hydraulic cylinders (5), leaving turntable (4) in the advanced position.

    3. Reconnect cylinder rod brackets (6) and turntable (4) by installing hinge point lockpins (3a) through brackets and the closest turntable holes.

       Note: The cylinder rod brackets may not fully engage the turntable at this time. When the hydraulic cylinders extend, the brackets will rotate in and fully engage the turntable.

14. Repeat Steps 11 and 12 until hydraulic cylinders (5) stop extending and the specified torque/pressure has been obtained.

    Note: Make sure that the hydraulic cylinders are not fully extended when checking for final torque/pressure.

15. Move the directional control valve on the poser supply hydraulic pump to the neutral position.

16. Remove hinge point lockpins (3a), and use the directional control valve on the power supply hydraulic pump to fully retract hydraulic cylinders (5) .

17. Remove hex shaft (10), and disconnect the power supply hydraulic pump hoses from hydraulic fittings (17) .

18. Attach the overhead hoist to upper bench (9) lift points, and support the weight of the upper bench. Remove lockpins (8) on each of the four legs, and lift the upper bench from the lower bench (7) and set aside.

19. The remainder of the final drive assembly can now be performed using the lower bench as a holding fixture.

Maintenance Section

Inspection/Cleaning

1. Inspect all components of the bench before each daily use. Replace all damage or worn parts before use.

2. Make sure that all informational and warning films are clean and readable. Replace damaged films.

3. Keep the bench and additional tooling clean and free of dirt, oil, and debris. Clean the bench using a non-solvent based cleaning solution.

4. Store the assembled bench, upper and lower bench together, in a clean, dry indoor location.

5. Store additional tooling in a clean, dry indoor location.

Service Parts

Top View

Illustration 7	g02828379
Counterclockwise Rotation Shown

Side View

Illustration 8	g02828380
Counterclockwise Rotation Shown

Valve Assembly

Illustration 9	g02828381

Hydraulic Schematic

Illustration 10	g02828396
(1) Hydraulic Valve Body (2) Hydraulic Cylinders (3) Hydraulic Fittings (4) Pressure Gauge (5) Pressure Reducing Valve - Adjustable: 172 to 20684 kPa (25.0 to 3000.0 psi) (6) Cylinder Retract Pressure Relief Valve - Set to 6895 kPa (1000.0 psi) (7) Cylinder Extend Pressure Relief Valve - Set to 20684 kPa (3000.0 psi) (8) Internal Check Valve