2009/06/01 Correction to Disassembly and Assembly , "Differential and Bevel Gear (Front) - Install" {3256, 3258} Caterpillar

Underground Articulated Truck:

AD55B (S/N: JNW1-UP)

Disassembly and Assembly, KENR6708, "AD55B Underground Articulated Truck Power Train", "Differential and Bevel Gear (Front) - Install". This module is part of Service Manual, KENR6715 Volume I.

The information in the above manual has changed for AD55B JNW1-UP. Replace the information with the following information.

Installation Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7576	Link Bracket	1
B	8T-0070	Bolt	2
C	169-5464	Quick Cure Primer	1
D	155-0695	Thread Lock Compound	1

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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Illustration 1	g01118390

1. Install Tooling (A) and a suitable lifting device to differential and bevel gear (17). The weight of differential and bevel gear (17) is approximately 600 kg (1323 lb).

2. Install yoke (18) and O-ring seal (19) .

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Illustration 2	g01118394
Typical example

3. Install differential and bevel gear (17). Install Tooling (B) to hold differential and bevel gear (17) to the front axle housing. Remove Tooling (A) .

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Illustration 3	g01118380

Note: Bolts (16) can not be reused. Always install new bolts.

4. Install 43 bolts (16). Remove Tooling (B) and install the remaining two bolts (16). Tighten 45 bolts (16) to a torque of 210 ± 30 N·m (155 ± 22 lb ft) then turn an additional 120 ± 10 degrees.

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Illustration 4	g01118396

5. Install the O-ring seal to thrust pin (15). Push thrust pin (15) into the front axle housing.

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Illustration 5	g01118397

6. Install cover (14) and four bolts (13). Tighten four bolts (13) enough to remove the end play between thrust pin (15) and cover (14) .

7. Measure the gap between cover (14) and the front axle housing. Record this measurement. Use the measurement to determine the correct thickness of the required shims.

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Illustration 6	g01118398

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Illustration 7	g01118378

8. Install four bolts (13), cover (14) and a thickness of shims that will establish a −0.03 mm (−0.001 inch) preload to a 0.03 mm (0.001 inch) end play in thrust pin (15). Tighten four bolts (13) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

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Illustration 8	g01118377

9. Attach a suitable lifting device to suspension mount (5). The weight of suspension mount (5) is approximately 560 kg (1235 lb).

10. Install suspension mount (5) .

11. Apply Tooling (C) and then apply Tooling (D) to the threads of four bolts (11) .

12. Install four bolts (11) .

13. Apply Tooling (C) and then apply Tooling (D) to the threads of four bolts (12) (not shown).

14. Install four bolts (12) (not shown) to suspension mount (5) .

15. Tighten four bolts (11) and four bolts (12) (not shown) to a torque of 1800 ± 200 N·m (1330 ± 150 lb ft).

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Illustration 9	g01118375

16. Install four locknuts (10). Tighten four locknuts (10) to a torque of 850 ± 100 N·m (625 ± 75 lb ft).

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Illustration 10	g01118374

17. Position the two hoses and install clamp assembly (9) and two bolts (8) to suspension mount (5) .

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Illustration 11	g01118373

18. Install brake cooling manifold (7) and three bolts (6) .

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Illustration 12	g01117992

19. Install clamp (3), two bolts (2) .

20. Connect lubrication hose (4) to both sides of suspension mount (5) .

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Illustration 13	g01117991

21. Position the two clamps. Install two bolts (1) .

End By:

a. Install the axle shafts. Refer to Disassembly and Assembly, "Axle Shaft - Install".

b. Install the front axle housing and differential. Refer to Disassembly and Assembly, "Front Axle Housing and Differential - Install".