986H Wheel Loader Differential and Bevel Gear - Assemble Caterpillar

Specifications

Illustration 1	g03404753

Illustration 2	g03404718

Assembly Procedure

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Illustration 3	g03720075

1. Raise the temperature of bearing cone (45) and install bearing cone (45) to case assembly (38).

   Note: Allow bearing cone (45) and case assembly (38) to reach a uniform temperature.

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   Illustration 4	g03720130

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   Illustration 5	g03719842

2. Apply Tooling (L) to case assembly (38). Install thrust washer (43). Apply Tooling (L) to the threads of bolts (44) and under the heads of bolts (44). Install bolts (44) and tighten in a cross pattern.
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   Illustration 6	g03719809

3. Lubricate the thrust face of gear (42) with clean oil. Install gear (42) in case assembly (38).
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   Illustration 7	g03719783

4. Install sleeve (39), pinion gear (40), and spacer (41) onto the spider and pinion gear assembly (37). Repeat this procedure for the remaining spider and pinion gear assemblies.
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   Illustration 8	g03719686

5. Attach a suitable lifting device to spider and pinion gear assembly (37).

6. Install spider and pinion gear assembly (37) in case assembly (38). The weight of spider and pinion gear assembly (37) is approximately 32 kg (70 lb).
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   Illustration 9	g03719479

7. Install gear (36). Lubricate the thrust face of gear (36) with clean oil.
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   Illustration 10	g03720234

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   Illustration 11	g03719170

8. Apply Tooling (L) to case assembly (32). Install thrust washer (35). Apply Tooling (L) to the threads of bolts (34) and under the heads of bolts (34). Install bolts (34) and tighten in a cross pattern.
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   Illustration 12	g00685294

9. Raise the temperature of bearing cone (33) and install bearing cone (33) on case assembly (32).

   Note: Allow bearing cone (33) and case assembly (32) to reach a uniform temperature.

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   Illustration 13	g00685191

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   Illustration 14	g01151499

10. Install Tooling (B) and a suitable lifting device to case assembly (32).

11. Install case assembly (32) to differential (29). The weight of case assembly (32) is approximately 105 kg (230 lb).

12. Install two bolts (31).
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    Illustration 15	g00685189

13. Reposition differential (29).

14. Install remaining bolts (31). Tighten bolts (31) to a torque of 300 ± 30 N·m (220 ± 22 lb ft).
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    Illustration 16	g01151512

15. Position bevel gear (30) on suitable cribbing.

16. Install Tooling (B) and a suitable lifting device to differential assembly (29). The weight of differential assembly (29) is approximately 59 kg (130 lb). Position suitable cribbing on bevel gear (30). Lower differential assembly (29) onto the suitable cribbing. Remove Tooling (B). Use a suitable pry bar that is positioned between differential assembly (29) and bevel gear (30) in order to remove the suitable cribbing.
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    Illustration 17	g00685148

17. Install bolts (28). Tighten bolts (28) to a torque of 130 ± 30 N·m (95 ± 22 lb ft) plus an additional 120 degrees ± 10 degrees.
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    Illustration 18	g00686566

18. Raise the temperature of bearing cone (13).

19. Install bearing cone (13) on pinion shaft (10).

    Note: Allow bearing cone (13) and pinion shaft (10) to reach a uniform temperature.

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    Illustration 19	g01151484

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    Illustration 20	g01151482

20. Lower the temperature of bearing cups (14) and (15).

21. Install bearing cup (15) in pinion housing (1).

22. Reposition pinion housing (1) and install bearing cup (14).

    Note: Allow bearing cups (14) and (15), and pinion housing (1) to reach a uniform temperature.

23. Use Tooling (H) in order to reset bearing cups (14) and (15).

    Note: Ensure bearing cups (14) and (15) are seated against the shoulders of pinion housing (1).

24. Lubricate bearing cups (14) and (15) with clean oil.
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    Illustration 21	g01151539

25. Lubricate bearing cone (13) with clean oil.

26. Install Tooling (B) and a suitable lifting device to pinion housing (1).

27. Lower pinion housing (1) onto pinion shaft (10). The weight of pinion housing (1) is approximately 81 kg (180 lb).
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    Illustration 22	g00685310

28. Raise the temperature of bearing cone (12) and install bearing cone (12) on pinion shaft (10).

    Note: Do not reset bearing cone (12) at this time. Allow bearing cone (12) to cool. Refer to Steps 29 through 34 for the procedure to set the bearing load.

29. Lubricate bearing cone (12) with clean oil.
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    Illustration 23	g00667186

30. Install washer (11) on pinion shaft (10).
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    Illustration 24	g00685313

    Note: Retaining nut (9) may be reused if the collar was not cracked during removal or during restaking. Otherwise, use a new part for replacement.

31. Install retaining nut (9) on pinion shaft (10).
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    Illustration 25	g01151540

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    Illustration 26	g00686568

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    Illustration 27	g00667185

32. Install yoke (10A) to pinion shaft (10). Install Tooling (K) to yoke (10A).

33. Use a suitable torque wrench in order to rotate pinion shaft (10). Check the rolling torque. The proper rolling torque of new bearings is 1.0 N·m to 1.7 N·m (9 lb in to 15 lb in).

    Note: Reduce the rolling torque to 0.5 N·m to 0.85 N·m (4.5 lb in to 7.5 lb in) for machines with more than 100 hours of operation.

34. Use Tooling (C) to tighten retaining nut (9) until the proper rolling torque is achieved.

    Note: If the rolling torque exceeds the specifications, back off the retaining nut by 45 degrees. Reset the bearing in order to relieve the preload. Repeat steps 33 and 34 until the specified preload is achieved.

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    Illustration 28	g00382081
    Completed Stake (H) The spherical radius of the tool for peening must be 7.50 to 8.00 mm (0.295 to 0.315 inch). (J) The acceptable angle of the tool for peening is 20 ± 10 degrees. (K) The minimum length of the crimp is 4.70 mm (0.185 inch). (L) The minimum depth of the crimp is 2.50 mm (0.098 inch). (M) Top view

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    Illustration 29	g01151544

35. Lock retaining nut (9) by peening the collar in the slot on pinion shaft (10).

    Note: Before the nut is staked, make sure that the pinion shaft has zero end play.

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    Illustration 30	g00667183

36. Use Tooling (H) in order to install lip seal (8) in retainer (6).

    Note: The sealing lip of lip seal (8) must be facing the inside of retainer (6).

37. Install O-ring seal (7). Lubricate the O-ring seal with clean oil.
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    Illustration 31	g01151547

38. Position retainer (6) on pinion housing (1).

39. Install bolts (5). Tighten bolts (5) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
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    Illustration 32	g00685146

40. Attach a suitable lifting device to differential and bevel gear (26) and install differential and bevel gear (26) in carrier (27). The combined weight of differential and bevel gear (26) is approximately 272 kg (600 lb).
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    Illustration 33	g00685145

41. Lubricate bearing cup (25) with clean oil. Install bearing cup (25) in the carrier. Repeat this procedure for the opposite side.
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    Illustration 34	g00685303

42. Install bearing cap (22) and adjusting ring (23). Ensure that adjusting ring (23) can turn freely.

43. Install bolts (24). Tighten bolts (24) to a torque of 25 N·m (18 lb ft).

    Note: Allow adjusting ring (23) to move freely.

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    Illustration 35	g01151553

44. Install bearing cap (18) and adjusting ring (19). Ensure that adjusting ring (19) turns freely.

45. Install bolts (24). Tighten bolts (24) to a torque of 25 N·m (221 lb in). Allow adjusting ring (19) to move freely.

    Note: Adjust the bearing preload and the gear backlash after the pinion housing has been installed.

46. Use a suitable lifting device in order to reposition carrier (27) on Tooling (A). The weight of carrier (27) is approximately 454 kg (1000 lb).
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    Illustration 36	g01151563

    Note: When replacing the pinion housing or carrier housing, install 80 percent of a new shim pack as a starting point for the pinion depth adjustment.

47. Position original shims (3) to carrier (27).
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    Illustration 37	g01151568

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    Illustration 38	g00667181

48. Install Tooling (B) and a suitable lifting device to pinion housing (1). The weight of pinion housing (1) is approximately 132 kg (290 lb).

49. Install O-ring seal (4) to pinion housing (1). Lubricate O-ring seal (4) with clean oil.

50. Install pinion housing (1) to carrier (27).
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    Illustration 39	g01151600

51. Ensure that backlash is present before pinion housing (1) is secured to carrier (27). Install bolts (2). Tighten bolts (2) to a torque of 210 ± 40 N·m (155 ± 30 lb ft) plus an additional 120 degrees ± 10 degrees.

    Note: Steps 52 through 63 are for setting the backlash and the pinion depth.

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    Illustration 40	g01151577

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    Illustration 41	g01151573

52. Move adjusting rings (19) and (23) on carrier (27) to a position that maintains gear backlash and slight bearing end play.
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    Illustration 42	g01151591

53. Install yoke (10A) to pinion shaft (10). Install Tooling (K) to yoke (10A). Use a torque wrench in order to turn pinion shaft (10). Check the overall rolling torque with no load on the carrier bearings. Record the measured torque.

54. Oscillate the bevel gear and advance adjusting ring (19). Continue to advance adjusting ring (19) until there is no backlash. Retract adjusting ring (19) by 1/2 turn.

55. Advance adjusting ring (23) and check the rolling torque on pinion shaft (10). Continue to advance adjusting ring (23) until the rolling torque increases by 20 percent over the rolling torque that was measured in Step 53. The bearings are now in the seated position.

56. Advance adjusting ring (23) by an additional three lugs. Advance adjusting ring (23) to the nearest lock position.
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    Illustration 43	g01151581
    Typical Example

57. Mount Tooling (J) on carrier (27). Measure the backlash at four places on the bevel gear at 90 degree intervals. Compare the lowest reading to the specifications. The proper backlash setting is 0.40 ± 0.12 mm (0.016 ± 0.005 inch).

58. If the backlash is not within the specification, retract one adjusting ring and advance the opposite adjusting ring equally to maintain the bearing preload.

59. When proper backlash is obtained, tighten bearing cap bolts (24) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

60. Use a suitable torque wrench and Tooling (F) in order to measure the overall rolling torque at the pinion shaft. The rolling torque must be 4.5 N·m to 6.7 N·m (40 lb in to 60 lb in).
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    Illustration 44	g00315875

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    Illustration 45	g00315877

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    Illustration 46	g00315878

61. After the backlash adjustment and the preload adjustment have been made, the tooth contact between the pinion shaft and the ring gear must be checked. Use the following procedure:

    1. Put a small amount of Prussian blue, red lead or paint on the teeth of the ring gear.

    2. Rotate the pinion in both directions.

    3. The correct area of tooth contact starts near the inside end of the teeth. The contact area should extend to a maximum of 50 percent of the length of the teeth. See Illustration 44 for the correct area of tooth contact.

62. If the area of tooth contact looks like Illustration 45, use the following procedure:

    1. Remove some of the shims under the pinion housing.

    2. Perform Steps 57 through 59 again.

    3. Perform Step 61 again in order to check the area of tooth contact.

63. If the area of tooth contact looks like Illustration 46, use the following procedure:

    1. Add some shims (8) under the pinion housing.

    2. Perform Steps 57 through 59 again.

    3. Perform Step 61 again in order to check the area of the tooth contact.

       Note: Make sure that the backlash adjustment is correct before you adjust the area of the tooth contact. Several adjustments of the backlash and of the tooth contact may be necessary in order to achieve the correct adjustments.

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    Illustration 47	g00685321

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    Illustration 48	g00685322

64. Install locks (17) and (21). Secure the locks to the bearing caps with new bolts (16) and (20). The torque for bolts (16) is 105 ± 15 N·m (78 ± 11 lb ft).

End By:

1. Install the differential and bevel gear.