Procedure to Rework the Final Drive on R3000H Load Haul Dump Machines {4050} Caterpillar

Load Haul Dump

R3000H (S/N: RCM1-146)

Introduction

This special instruction covers the procedure to rework the final drive on the above Load Haul Dump Machines. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this standard machine.

Read the entire Special Instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

Safety Section

Work safely. 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.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine. Before operating the machine, place the steering frame lock in the stored position. Failure to place the steering frame lock into the stored position before operating can result in loss of steering.

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Reference: Disassembly and Assembly, UENR1475, "R3000H Load Haul Dump Power Train"

Parts Required

Part quantities are for one final drive assembly. Ensure that enough parts are ordered for the number of final drives being reworked.

Tools Required

Disassemble Procedure

1. Remove the final drive and brake. Refer to Disassembly and Assembly, "Final Drive and Brake - Remove".

2. Disassemble the final drive. Refer to Disassembly and Assembly, "Final Drive and Brake - Disassemble".
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   Illustration 1	g06023670
   (1) Retaining ring (2) Carrier (3) Retainer (4) Bolt (5) Ring gear (6) Bearing (7) Bearing (8) Bearing (9) Bearing (10) Shim (11) Axle shaft (12) Hub (13) Retainer (14) Bolt (15) Duo cone seal

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   Illustration 2	g06023672
   (2) Carrier (16) Washer (17) Retainer (18) Shaft (19) Bearing (20) Sun gear (21) Spacer (22) Planet gear (23) Washer (24) Bearing

3. Discard Item (1) through Item (24), and the O-ring seals. Refer to Illustration 1 and Illustration 2.

   Note: Step 3 refers to after failure parts to be discarded. Refer to Table 1 to determine before failure parts to discard.

4. Assemble the final drive. Refer to the information that follows.

Specifications

Illustration 3	g03867474

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 always.

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Illustration 4	g06024928
(1) Spindle (2) 9M-5892 O-Ring Seal

1. Install 9M-5892 O-Ring Seal (2) to spindle (1).
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   Illustration 5	g06025428
   (1) Spindle (3) 1P-9593 Bearing Cone (4) Spacer

2. Install spacer (4) to spindle (1).

3. Raise the temperature of 1P-9593 Bearing Cone (3). Install 1P-9593 Bearing Cone (3) to spindle (1).

   Note: Use 0.038 mm (0.0015 inch) shim stock or standard feeler gauge to check that the bearing cup is seated on spindle (1).

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   Illustration 6	g06025438
   (5) Supply port

4. Connect an external oil supply to parking brake supply port (5). Disengage the parking brake by applying oil pressure of 4140 kPa (600 psi) to parking brake supply port (5).

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

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   Illustration 7	g06025432
   (1) Spindle (6) Guide bolt (1/2 inch - 13 UNC x 6 inch) (7) Brake housing (8) Special nut

5. Install two guide bolts (6) to brake housing (7).

6. Using a suitable lifting device install spindle (1). The weight of spindle (1) is approximately 174 kg (384 lb).

7. Install four special nuts (8).

8. Tighten four special nuts (8) evenly until spindle (1) is fully seated on brake housing (7).

   Note: Ensure 9M-5892 O-Ring Seal (2) remains seated on spindle (1).

9. Remove two guide bolts (6).
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   Illustration 8	g06025434
   (1) Spindle (7) Brake housing (8) Special nut (9) 5P-2427 Taperlock Stud (10) Bolt

10. Apply Loctite 7649 and then apply Loctite 263 to the threads of 30 bolts (10) prior to installation.

11. Install 30 bolts (10) and tighten to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

12. Tighten four special nuts (8) to a torque of 120 ± 10 N·m (90 ± 7 lb ft).

13. Apply Loctite 7649 and then apply Loctite 277 to the threads at the tapered end of 22 5P-2427 Taperlock Studs (9) prior to installation.

14. Install 22 5P-2427 Taperlock Studs (9) and tighten to a torque of 450 ± 40 N·m (330 ± 30 lb ft).
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    Illustration 9	g06029600
    Typical example (11) 197-6033 Tool Gp

15. Turn the brake assembly to access the other side.

16. Install 197-6033 Tool Gp (11) to align the splines of the nine friction discs.

17. Release the oil pressure in the parking brake supply port (5). Refer to Illustration 6.

18. Remove 197-6033 Tool Gp (11).
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    Illustration 10	g06025443
    (3) 1P-9593 Bearing Cone (12) 9G-5323 Duo-Cone Seal Gp

19. Install one half of 9G-5323 Duo-Cone Seal Gp (12). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".

20. Lubricate 1P-9593 Bearing Cone (3) with clean final drive oil.
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    Illustration 11	g06027902
    (12) 9G-5323 Duo-Cone Seal Gp (13) 1P-9594 Bearing Cup (14) Wheel

21. Lower the temperature of 1P-9594 Bearing Cup (13). Install 1P-9594 Bearing Cup (13) to wheel (14).

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

22. Install one half of 9G-5323 Duo-Cone Seal Gp (12) to wheel (14). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
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    Illustration 12	g06027904
    (14) Wheel (15) 107-7089 Bearing Cup

23. Turn wheel (14) so that the splined end faces downward.

24. Lower the temperature of 107-7089 Bearing Cup (15). Install 107-7089 Bearing Cup (15) to wheel (14).

    Note: 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 13	g06027906
    (14) Wheel (16) Brake assembly (17) Friction discs

25. Using a suitable lifting device install wheel (14) to brake assembly (16). The weight of wheel (14) is approximately 215 kg (475 lb).

    Note: Ensure that the splines of wheel (14) and the splines of nine friction discs (17) are aligned.

26. Disengage the parking brake by applying oil pressure of 4140 kPa (600 psi) to the parking brake supply port (5). Refer to Illustration 6.

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

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    Illustration 14	g06025440
    (18) 463-9547 Hub (19) 3D-0294 Bearing Cone

27. Raise the temperature of 3D-0294 Bearing Cone (19).

28. Install 3D-0294 Bearing Cone (19) on 463-9547 Hub (18).

29. Lubricate 3D-0294 Bearing Cone (19) with clean final drive oil.
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    Illustration 15	g06028287
    (18) 463-9547 Hub (20) 6C-3241 Bolt (21) 464-1949 Retainer (22) 184-5086 Ring Gear

30. Assemble Item (18) through Item (22).

    Note: Tighten 12 6C-3241 Bolts (20) finger tight.

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    Illustration 16	g06028292
    (1) Spindle (14) Wheel (18) 463-9547 Hub (22) 184-5086 Ring Gear

31. Using a suitable lifting device, install 184-5086 Ring Gear (22) and 463-9547 Hub (18) to wheel (14). The weight of 184-5086 Ring Gear (22) and 463-9547 Hub (18) is approximately 70 kg (154 lb).

    Note: The top of spindle (1) should be 1 mm to 2 mm (0.039 inch to 0.078 inch) below the face of 463-9547 Hub (18).

32. Remove one at a time, 12 6C-3241 Bolts (20). Apply Loctite 7649 and then apply Loctite 263 to the threads and tighten to a torque of 135 ± 10 N·m (100 ± 7 lb ft). Refer to Illustration 15.
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    Illustration 17	g06028294
    (23) 463-6115 Ring (24) 031-3185 Bolt (25) Hole

33. Apply clean final drive oil to the threads of five 031-3185 Bolts (24) prior to installation.

34. Install 463-6115 Ring (23) and five 031-3185 Bolts (24) evenly spaced, do not tighten the bolts.

35. Using a depth micrometer through three holes (25), measure the distance from the top of 463-6115 Ring (23) to the top of the spindle. Calculate the average value of the three measurements.

36. Tighten five 031-3185 Bolts (24) to a torque of 90 ± 14 N·m (66 ± 10 lb ft).

37. Rotate the wheel assembly two to three complete revolutions.

38. Loosen five 031-3185 Bolts (24) until 463-6115 Ring (23) is loose.

39. Rotate the wheel assembly two to three complete revolutions.

40. Using a depth micrometer through three holes (25), measure the distance from the top of 463-6115 Ring (23) to the top of the spindle. Calculate the average value of the three measurements.

41. Compare the average value from Step 35 to the average value from Step 40.

42. If the difference is equal to or less than 0.05 mm (0.002 inch) go to Step 44.

43. If the difference is greater than 0.05 mm (0.002 inch), repeat Step 36 through Step 43.

    Note: If the measurement found at Step 41 is still greater than 0.05 mm (0.002 inch) disassemble the parts to determine the problem.

44. Tighten five 031-3185 Bolts (24) to a torque of 40 ± 7 N·m (30 ± 5 lb ft).

45. Rotate the wheel assembly two to three complete revolutions.

46. Tighten five 031-3185 Bolts (24) to a torque of 40 ± 7 N·m (30 ± 5 lb ft).

47. Using a depth micrometer through three holes (25), measure the distance from the top of 463-6115 Ring (23) to the top of the spindle. Calculate the average value of the three measurements.

48. Remove five 031-3185 Bolts (24) and 463-6115 Ring (23).

49. Apply Loctite 7649 to the five holes where five 031-3185 Bolts (24) were removed.

50. Using an outside micrometer, measure the thickness of 463-6115 Ring (23). Make a measurement at each of the three holes (25) that were used for the depth measurement. Calculate the average value of the three measurements.

51. Subtract the average thickness of 463-6115 Ring (23) found in Step 50 from the value found in Step 47. This difference is the clearance between 463-6115 Ring (23) and the top of the spindle.

52. Add 0.10 mm (0.004 inch) to the value found in Step 51 to give the thickness of shims required.
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    Illustration 18	g06028296
    (23) 463-6115 Ring (24) 031-3185 Bolt (26) 479-4083 Spacer (27) 8K-0066 Shim

53. Install the required thickness of 8K-0066 Shim (27) and 463-6115 Ring (23).

54. Apply Loctite 7649 and then apply Loctite 263 to the threads of ten 031-3185 Bolts (24).

55. Install ten 031-3185 Bolts (24) and tighten to a torque of 270 ± 25 N·m (200 ± 20 lb ft).

56. Install 479-4083 Spacer (26).

57. Release the oil pressure from parking brake supply port (5). Disconnect the external oil supply from the parking brake supply port. Refer to Illustration 6.
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    Illustration 19	g06028298
    (14) Wheel (28) 6F-4855 O-Ring Seal

58. Install 6F-4855 O-Ring Seal (28) to wheel (14).
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    Illustration 20	g06028300
    (29) 8X-4552 Washer (30) 7H-0308 Retaining Ring (31) 203-1817 Shaft (32) 6Y-9885 Roller Bearing As (33) 8X-9563 Spacer (34) 281-9324 Gear (35) 203-1795 Planetary Carrier

59. Assemble Item (29) through Item (35).

    Note: Lubricate six 6Y-9885 Roller Bearing As (32) with clean final drive oil.

    Note: Apply clean final drive oil to the contact surfaces of six 8X-4552 Washers (29).

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    Illustration 21	g06028674
    (31) 203-1817 Shaft

60. Ensure that the flats on three 203-1817 Shafts (31) are facing the outside of the planetary carrier.
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    Illustration 22	g06028680
    (35) 203-1795 Planetary Carrier (36) 2R-0098 O-Ring Seal

61. Install 2R-0098 O-Ring Seal (36) to 203-1795 Planetary Carrier (35).
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    Illustration 23	g06028682
    (14) Wheel (35) 203-1795 Planetary Carrier

62. Using a suitable lifting device install 203-1795 Planetary Carrier (35) to wheel (14). The weight of 203-1795 Planetary Carrier (35) is approximately 140 kg (310 lb).
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    Illustration 24	g06028685
    (35) 203-1795 Planetary Carrier (37) 8T-9399 Bolt (38) 8T-4994 Hard Washer

63. Apply Loctite 7649 and then apply Loctite 277 to the threads of 23 8T-9399 Bolts (37) prior to installation.

64. Install 23 8T-9399 Bolts (37) and tighten to a torque of 475 ± 50 N·m (350 ± 37 lb ft).
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    Illustration 25	g06028687
    (39) 1H-8278 O-Ring Seal (40) 2J-3507 Full Nut (41) 3K-5234 Hard Washer

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    Illustration 26	g06029044
    (42) 2A-1162 Gasket (43) 6D-0692 O-Ring Seal (44) 281-9323 Sun Gear (45) 5B-3265 Gasket (46) 231-4410 Axle Shaft (47) 1T-0479 Retaining Ring

65. Install the final drive and brake to the axle housing using Item (39) through Item (47). Refer to Illustration 25, Illustration 26, and Disassembly and Assembly, "Final Drive and Brake - Install".