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


Correction to Disassembly and Assembly , "Differential and Bevel Gear (Front) - Install" {3256, 3258}
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2009/06/01 [SEPD0994]
POWER TRAIN
DIFFERENTIAL & BEVEL GEAR GP
2009/06/01 The Assembly Process for the Front Axle Mount is Now Improved {3258, 3260}
2009/06/01 Correction to Disassembly and Assembly , "Differential and Bevel Gear (Front) - Install" {3256, 3258}
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.




    Illustration 1g01118390

  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).

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



    Illustration 2g01118394

    Typical example

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



    Illustration 3g01118380

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

  1. 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.



    Illustration 4g01118396

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



    Illustration 5g01118397

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

  1. 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.



    Illustration 6g01118398



    Illustration 7g01118378

  1. 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).



    Illustration 8g01118377

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

  1. Install suspension mount (5) .

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

  1. Install four bolts (11) .

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

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

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



    Illustration 9g01118375

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



    Illustration 10g01118374

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



    Illustration 11g01118373

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



    Illustration 12g01117992

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

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



    Illustration 13g01117991

  1. 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".

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