785D OEM Off-Highway Truck Power Train Caterpillar

Assembly Procedure

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Illustration 1	g06290731

1. Use Tooling (B) to Install bearing (16) into gear (15). The weight of gear (15) and bearing (16) is approximately 32 kg (70 lb). Remove Tooling (B).

   Note: The rollers and the race of bearing (16) are matched sets. Do not mix the parts during the assembly procedure.

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   Illustration 2	g06290730

2. Install Tooling (B) onto gear (15) and bearing (16) to retain the bearing rollers.
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   Illustration 3	g06290762

3. Use Tooling (A) and a suitable lifting device to position planetary carrier (17) over gear (15) and bearing (16). The weight of planetary carrier (17) is approximately 499 kg (1100 lb).
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   Illustration 4	g06290766

4. Install gear (15) and bearing (16) into the planetary carrier. Remove Tooling (B). Align gear (15) and bearing (16) with the bore that is in the planetary carrier.

   Note: Do not allow the bearing rollers to fall from the gear.

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   Illustration 5	g06290771

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   Illustration 6	g06290825

5. Use a suitable press to install shaft (14). Rotate gear (15) while shaft (14) is pressed into the planetary carrier.

   Note: Support the planetary carrier in the locations that are indicated prior to the installation of shaft (14). Failure to properly support the planetary carrier can result in damage to carrier assembly.

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   Illustration 7	g06290833

6. Use Tooling (C) to measure the distance from the top of planetary carrier (17) to the top of shaft (14). Record the measurement as Dimension (X).
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   Illustration 8	g06290846

7. Install shims (13) that is equal to Dimension (X) within 0.000 to 0.050 mm (0.0000 to 0.0020 inch).

8. Install plate (12). Apply Tooling (D) onto bolts (11). Install bolts (11). Tighten bolts (11) to a torque of 255 ± 15 N·m (188 ± 11 lb ft).

9. Repeat Step 1 through 8 for the remaining gears.
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   Illustration 9	g06290718

10. Install retaining ring (10) into gear (7).
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    Illustration 10	g06290717

11. Lower the temperature of bearing cup (9). Install bearing cup (9). Allow bearing cup (9) to warm to room temperature. Ensure that bearing cup (9) is seated into gear (7). Install bearing cone (8). Repeat this procedure for bearing cup (9) and bearing cone (8) on the opposite side of gear (7).

    Note: The bearing cone and the bearing cup are a matched set. Do not mix the parts during the assembly procedure.

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    Illustration 11	g06290852

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    Illustration 12	g06290858

12. Install gear (7). Align gear (7) with the bore that is in the planetary carrier. Use a suitable press to install shaft (6). Rotate gear (7) while shaft (6) is pressed into the planetary carrier.

    Note: Support the planetary carrier in the locations that are indicated prior to the installation of shaft (6). Failure to properly support the planetary carrier can result in damage to the carrier assembly.

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    Illustration 13	g06290866

13. Use Tooling (C) to measure the distance from the top of the planetary carrier to the top of shaft (6). Record the measurement as Dimension (Y).
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    Illustration 14	g06290703

14. Install shims (5) that is equal to Dimension (Y) within 0.000 to 0.050 mm (0.0000 to 0.0020 inch).

15. Install plate (4). Apply Tooling (D) onto bolts (3). Install bolts (3). Tighten bolts (3) to a torque of 135 ± 15 N·m (100 ± 11 lb ft).

16. Repeat Steps 10 through 15 for the remaining planetary gears.
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    Illustration 15	g06290702

17. Install four dowels (2) in the inner carrier assembly.

18. Apply Tooling (E) to thrust washer (1). Install thrust washer (1) in the inner carrier assembly.

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1. Install the final drive.