2012/11/09 Caterpillar

Load Haul Dump:

R2900G (S/N: JLK1149-UP)

Disassembly and Assembly, RENR8558, "R2900G Load Haul Dump Power Train", "Final Drive and Brake - Assemble". This manual is part of Service Manual, RENR8526 Volume 1.

The information in this manual has changed. Replace the information with the following information.

Final Drive and Brake - Assemble

Assembly Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7574	Link Bracket	2
B	138-7575	Link Bracket	2
C	319-1115	Spring Compression Tool	1
D	5P-0960	Molybdenum Grease	1
E	-	1/2 inch - 13 NC by 6 inch Guide Bolt	2
F	-	Loctite 7649	1
G	-	Loctite 271	1
H	197-6033	Disc Aligning Tool	1
J	-	Loctite 620	1
K	8T-9206	Duo-Cone Seal Installer As	1

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.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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Illustration 1	g01089023

1. Position anchor (25) in a suitable stand, or support on wood blocks.

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Illustration 2	g01089022

2. Install the O-ring seals to four plugs (58). Install plugs (58) to anchor (25) .

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Illustration 3	g01089021

3. Install O-ring seal (57) to sleeve (56) .

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Illustration 4	g01089020

4. Install sleeve (56) to anchor (25) .

5. Apply Tooling (F) and then apply Tooling (G) to the threads of bolts (55) prior to installation.

6. Install eight bolts (55). Tighten bolts (55) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

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Illustration 5	g01089019

7. Install 25 spring assemblies (54) to anchor (25) .

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Illustration 6	g01089018

8. Install piston (53) to anchor (25) .

9. Install O-ring seal (52) to anchor (25) .

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Illustration 7	g01091739

10. Apply Tooling (F) and then apply Tooling (G) to the threads at the tapered end of taperlock studs (51) prior to installation.

11. Install taperlock studs (51). Tighten taperlock studs (51) to a torque of 65 ± 10 N·m (48 ± 7 lb ft).

12. Install seals (49) and (50) to housing (32) .

    Note: Lubricate the seals with Tooling (D) prior to installation.

    Note: If necessary, stretch seals (49) and (50) to ensure that the seals remain seated in housing (32) during the assembly process.

    Note: Ensure that seals (49) and (50) are installed with the flat portion of the seal towards the bottom of the groove in housing (32) .

13. Install Tooling (E) to housing (32) .

    Note: Tooling (E) must be modified in order to be used as a guide bolt. Position Tooling (E) in a suitable vice. Remove the head of the bolt in order to use Tooling (E) as a guide bolt.

14. Install three O-ring seals (48) to housing (32) .

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Illustration 8	g01089016

15. Turn housing (32) so that the splined end faces upward.

16. Apply Tooling (F) and then apply Tooling (G) to the threads at the tapered end of taperlock studs (47) prior to installation.

17. Install taperlock studs (47). Tighten taperlock studs (47) to a torque of 65 ± 10 N·m (48 ± 7 lb ft).

18. Install Tooling (A) and a suitable lifting device to housing (32). The weight of housing (32) is approximately 120 kg (265 lb).

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Illustration 9	g01089014

19. Install four special nuts (45) to anchor (25) .

20. Install housing (32) to anchor (25) .

21. Tighten four special nuts (45) evenly until housing (32) is fully seated on anchor (25) .

22. Remove Tooling (E) .

23. Apply Tooling (F) and then apply Tooling (G) to the threads of bolts (46) prior to installation.

24. Install 30 bolts (46). Tighten bolts (46) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

25. Tighten four special nuts (45) to a torque of 120 ± 10 N·m (90 ± 7 lb ft).

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Illustration 10	g01089013

26. Install seals (43) and (44) to piston (42) .

    Note: Lubricate the seals with Tooling (D) prior to installation.

    Note: Ensure that seals (43) and (44) are installed with the flat portion of the seal towards the bottom of the groove in piston (42) .

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Illustration 11	g01089012

27. Install piston (42) to housing (32) .

    Note: Ensure correct alignment of the guide pin holes in piston (42) and the anchor.

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Illustration 12	g01089011

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Illustration 13	g01089008

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Illustration 14	g01089009

28. Install return spring (39) and guide pin (40) to anchor (25) .

29. Install Tooling (C) to anchor (25). Turn Tooling (C) clockwise to compress return spring (39) .

30. Install pin (41) to guide pin (40) .

31. Turn Tooling (C) counterclockwise to release the tension on return spring (39). Remove Tooling (C) .

32. Repeat Step 28 through Step 31 for the five remaining return springs, guide pins and pins.

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Illustration 15	g01089007

33. Install the O-ring seals to two adaptors (37) and four plugs (38) .

34. Install two adaptors (37), two purge screws (36) and four plugs (38) .

35. Connect an external oil supply to parking brake supply port (P). Disengage the parking brake by applying oil pressure of 4140 kPa (600 psi) to parking brake supply port (P) .

    Note: Do not exceed 4140 kPa (600 psi) as damage to components may occur.

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Illustration 16	g01089006

36. Install ten outer plates (34), and nine friction discs (35) in an alternating order. Start with an outer plate and end with an outer plate. Lubricate each plate with clean final drive oil when installing.

    Note: After installation, ensure that all the plates are below the level of the splines in housing (32). If the plates are not seated correctly, check the pressure in the parking brake supply port.

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Illustration 17	g01089005

37. Install O-ring seal (33) to spindle (24) .

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Illustration 18	g03293916

38. Install spacer (27) to spindle (24) .

39. Raise the temperature of bearing (26). Install bearing (26) to spindle (24) .

    Note: Use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cup is seated on spindle (24). Refer to Illustration 18.

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Illustration 19	g01091752

40. Install Tooling (E) to housing (32) .

41. Attach Tooling (A) and a suitable lifting device to spindle (24). The weight of spindle (24) is approximately 174 kg (384 lb).

42. Install four special nuts (31) to spindle (24) .

43. Install spindle (24) to housing (32) .

44. Tighten four special nuts (31) evenly until spindle (24) is fully seated on housing (32) .

    Note: When tightening special nuts (31), check that O-ring seal (33) (not shown) remains seated on spindle (24) .

45. Remove Tooling (E) .

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Illustration 20	g01092895

46. Apply Tooling (F) and then apply Tooling (G) to the threads of bolts (30) prior to installation.

47. Install 30 bolts (30). Tighten bolts (30) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

48. Tighten four special nuts (31) to a torque of 120 ± 10 N·m (90 ± 7 lb ft).

49. Apply Tooling (F) and then apply Tooling (G) to the threads at the tapered end of taperlock studs (29) prior to installation.

50. Install taperlock studs (29). Tighten taperlock studs (29) to a torque of 450 ± 40 N·m (330 ± 30 lb ft).

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Illustration 21	g03293918

51. Turn the brake assembly so that anchor (25) faces upward.

52. Install the O-ring seals to six plugs (28). Install plugs (28) to anchor (25) .

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Illustration 22	g01091809

53. Install Tooling (H) to align the splines of the nine friction discs.

54. Release the oil pressure in the parking brake supply port.

55. Remove Tooling (H) .

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Illustration 23	g03291176

56. Lubricate bearing (26) with clean final drive oil.

57. Use Tooling (K) (not shown) to install Duo-Cone seal (23) to anchor (25). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".

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Illustration 24	g01089783

58. Lower the temperature of bearing cup (22). Install bearing cup (22) to wheel (3) .

    Note: Prior to assembly of the components use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cup is seated in the wheel.

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Illustration 25	g01089782

59. Use Tooling (K) (not shown) to install Duo-Cone seal (21) to wheel (3). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".

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Illustration 26	g01089781

60. Turn wheel (3) so that the splined end faces downward.

61. Lower the temperature of bearing cup (20). Install bearing cup (20) to wheel (3) .

    Note: Prior to assembly of the components use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cup is seated in the wheel.

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Illustration 27	g01089780

62. Attach Tooling (B) and a suitable lifting device to wheel (3). The weight of wheel (3) is approximately 215 kg (475 lb). Install wheel (3) to the brake assembly.

    Note: Ensure the splines of wheel (3) and of the nine friction discs are aligned.

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Illustration 28	g01089777

63. Lubricate bearing (19) with clean final drive oil.

64. Install bearing (19) to wheel (3) .

65. Disengage the parking brake by applying oil pressure of 4140 kPa (600 psi) to the parking brake supply port.

    Note: Do not exceed 4140 kPa (600 psi) as damage to components may occur.

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Illustration 29	g01089766

66. Install four retainers (17) to ring gear (15) .

67. Use two people to install ring gear (15) and four retainers (17) to hub (16). The combined weight of ring gear (15) and of four retainers (17) is approximately 35 kg (77 lb).

68. Install Tooling (A) to the ring gear and hub assembly.

69. Install six bolts (18) finger tight in order to hold retainers (17) in position.

70. Attach a suitable lifting device to Tooling (A). The combined weight of ring gear (15), hub (16) and of four retainers (17) is approximately 70 kg (154 lb).

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Illustration 30	g01092555

71. Install ring gear (15), hub (16) and four retainers (17) as a unit to wheel (3) .

    Note: The top of spindle (24) should be 1 to 2 mm (0.039 to 0.078 inch) below the face of hub (16) .

72. Remove Tooling (A) and bolts (18) .

73. Apply Tooling (F) and then apply Tooling (J) to the threads of bolts (18) prior to installation.

74. Install eight bolts (18). Tighten bolts (18) to a torque of 125 ± 8 N·m (90 ± 6 lb ft).

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Illustration 31	g01089760

75. Install bearing plate (13) without the shims.

76. Install five bolts (12) evenly spaced, but do not tighten.

77. Use a depth micrometer to measure the distance from the top of bearing plate (13) to the wheel spindle. Measure through the three evenly spaced small holes in bearing plate (13). Use the average value of the three measurements as the zero reading.

78. Tighten bolts (12) to a torque of 90 ± 14 N·m (66 ± 10 lb ft).

79. Rotate the wheel assembly one revolution.

80. Loosen bolts (12) until bearing plate (13) is loose.

81. Rotate the wheel assembly one revolution.

82. Use a depth micrometer to measure the distance from the top of bearing plate (13) to the wheel spindle. Measure through the three holes in bearing plate (13). Find the average value of the three measurements.

83. Compare the average measurement from Step 82 to the zero reading from Step 77.

84. Go to Step 86 if the difference is 0.05 mm (0.002 inch) or less. If the difference is greater than 0.05 mm (0.002 inch), repeat Steps 78 through 83, then go to Step 85.

85. Recheck the measurement taken in Step 83. If the measurement is still greater than 0.05 mm (0.002 inch), disassemble the parts to determine the problem. If the measurement is 0.05 mm (0.002 inch) or less, go to Step 86.

86. Tighten bolts (12) to a torque of 40 ± 7 N·m (30 ± 5 lb ft).

87. Rotate the wheel assembly one revolution.

88. Tighten bolts (12) to a torque of 40 ± 7 N·m (30 ± 5 lb ft).

89. Use a depth micrometer to measure the distance from the top of bearing plate (13) to the wheel spindle. Measure through the three holes in the bearing plate (13). Calculate the average value of the three measurements.

90. Remove bolts (12) and bearing plate (13) .

91. Use an outside micrometer to measure the thickness of bearing plate (13). Make a measurement at each of the three holes that were used for the depth measurement. Find the average value of the three measurements.

92. Subtract the average thickness of bearing plate (13) found in Step 91 from the value found in Step 89. This difference is the clearance between the end of the spindle and bearing plate (13) .

93. Add 0.15 mm (0.006 inch) to the value found in Step 92. The new value obtained is the thickness of shims (14) that is required.

94. Install required shims (14) (not shown) and bearing plate (13) .

95. Apply Tooling (F) and then apply Tooling (G) to the threads of bolts (12) prior to installation.

96. Install ten bolts (12). Tighten bolts (12) to a torque of 270 ± 25 N·m (200 ± 20 lb ft).

97. Release the oil pressure from the parking brake supply port. Disconnect the external oil supply from the parking brake supply port.

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Illustration 32	g03259156

98. Install O-ring seal (11) to wheel (3) .

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Illustration 33	g01079541

99. Lubricate bearings (8) and (10) with clean final drive oil.

100. Install spacer (9) and bearings (8) and (10) to planetary gear (7) .

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Illustration 34	g01079929

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Illustration 35	g01079930

101. Apply clean final drive oil to the contact surfaces of the thrust washers. Install two thrust washers (6) and planetary gear assembly (7) to the final drive planetary carrier.

102. Install the retainer ring to the planetary shaft.

103. Install planetary shaft (5) to the planetary carrier.

     Note: Be sure that the flat on the planetary shaft is facing the outside of the planetary carrier.

104. Repeat Steps 99 through 103 for the remaining two planetary gears.

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Illustration 36	g01103426

105. Install O-ring seal (4) to final drive planetary carrier (2) .

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Illustration 37	g01089756

106. Attach Tooling (A) and a suitable lifting device to final drive planetary carrier (2). The weight of final drive planetary carrier (2) is approximately 140 kg (310 lb). Install final drive planetary carrier (2) to wheel (3) .

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Illustration 38	g01089755

107. Apply Tooling (F) and then apply Tooling (G) to the threads of bolts (1) prior to installation.

108. Install 23 bolts (1). Tighten bolts (1) to a torque of 475 ± 50 N·m (350 ± 37 lb ft).

End By:

a. Install the final drive and brake to the axle housing. Refer to Disassembly and Assembly, "Final Drive and Brake - Install"