SUPPLEMENT FOR 206 & 212 WHEEL-TYPE EXCAVATORS Final Drive Caterpillar

Squeeze out the snap ring and pull off the planetary gears.

(S) two-leg puller

Remove angle ring and take roller bearing out of the planetary.

Remove the snap ring and pull off inner carrier from the sun gear shaft.

Remove the snap ring.

Remove the backing plate.

Pull the clutch plate pack for the brakes out of the gear ring.

Version A (Lock Plates)

Tighten slotted nut slightly until lock plates are released.

(S) hook spanner

(S) centering disc

Version B (Circlip)

Working operation is not required.

Version A

Remove both lock plates and remove the slotted nut.

Version B

Squeeze out circlip.

Back off gear ring carrier using pry bars, be careful not to let it drop.

NOTE: Pay attention to the released angle ring and O-ring.

(S) pry bars

In order to make possible the slipping out of the circlip and therefore a separation of gear ring carrier and gear ring, provide the circlip with two bores 2.50 mm.

NOTE: Use a drill.

Compress circlip (snap ring) and separate the gear ring carrier from gear ring.

Fasten the gear ring carrier into a vise an unhook the return springs.

(S) spring hook

Remove wire ring and all return springs.

Pull piston out of the gear ring carrier, using adjusting spanner.

(S) adjusting spanner

Remove both O-rings.

Remove thrust washer.

Pull off hub.

If required, drive the bearing inner races out of the hub.

NOTE: Pay attention to the released tapered roller bearing.

(S) two-leg puller

(S) pressure piece

Destroy and remove shaft seal.

Pull off tapered roller bearing.

(S) grab sleeve

(S) two-leg puller

(S) pressure piece

Carefully split the liner and remove it.

Unlock castle nut, loosen and unhook tie rod.

Loosen hex head screws and remove both king pins.

Fasten a hoist and lift off the steering knuckle housing from the axle.

NOTE: Pay attention to the released tapered roller bearing (below).

Remove the shaft seal and pull liner (brass) out of the housing.

(S) internal puller

(S) support

Pull universal shaft out of the axle.

Squeeze out circlip, tap loose sun gear shaft and drive it out of the double joint.

Remove stub shaft in the same way.

Remove the shaft seal and pull the liner (brass) out of the axle.

(S) internal puller

(S) support

If required, carefully drive out both sealing covers and bearing outer races.

Assemble Final Drive

Install the sleeve (brass) flush-mounted into the axle housing.

(S) driver

(S) handle

Assemble shaft seal, cover the outside edge with sealing compound and install it firmly against shoulder.

NOTE: Cover sealing lip with grease.

(S) driver

(S) handle

nstall both caps, respectively bearing outer aces into the upper and lower bore of the steering knuckle bearing.

NOTE: Cover caps with sealing compound.

Install the snap ring into the groove of the double joint.

Install the sun gear shaft until the circlip is engaged in the sun gear shaft recess.

Install stub shaft (figure 37 + 38) in the same way.

Introduce universal shaft carefully into the axle until the stub shaft splines have been received in the differential (in mesh with gear teeth).

Install sleeve (brass) flush-mounted into the steering knuckle housing.

Cover the outside edge of shaft seal with sealing compound and drive it firmly against shoulder.

NOTE: Cover sealing lip with grease.

(S) driver

(S) handle

Cover both tapered roller bearings with grease and insert them into the bores of the steering knuckle bearing and place sealing caps upon them.

Fasten a hoist and guide the steering knuckle housing over the sun gear shaft and place it against the axle housing.

Cover O-ring with grease and make it adhere in the annular groove of the two king pins.

Fix steering knuckle housing by means of the two king pins.

NOTE: With the upper king pin, insert shim s = 0.80 mm (value found by experience).

Pay attention to the installation position of the king pins.

Fasten both king pins by means of hex head screws.

Torque limit (M16/10.9) 295 N·m

Check rolling resistance 28 - 35 N·m.

In case of deviations from the specified rolling resistance, correct by means of a thicker or a thinner shim.

(S) spanner

Pull wheel studs into the hub.

Install both bearing outer races into the hub until contact is obtained.

(S) wheel stud puller - basic set

(S) insert

Cover the press fit surface for liner with Loctite surface sealing (No. 573).

Heat the liner in hot oil and install it firmly against shoulder, using driver.

(S) driver

Rolling resistance of the wheel bearing.

Determine nominal value 8-12 N·m (figure 50-55).

Heat bearing inner race in hot oil and install it firmly against shoulder.

Place spacer (value of experience s = 14.50 mm) firmly against the bearing inner race.

Guide hub over the collar of the hub carrier and install subsequently heated bearing inner race.

Place gear ring carrier against its shoulder.

Install slotted nut and tighten by continuous rotation of the hub.

Torque limit (M90x1.5) 1000 N·m

Torque limit (M95x1.5) 1500 N·m

(S) hook spanner

Check rolling resistance (T = F × R):

T = rolling resistance in N·m

F = traction force in N

R = radius in mm

Wrap suitable string around the hub and check rolling resistance - nominal value 8 - 12 N·m, corresponds to a traction force.

For run-in bearings:

If the rolling resistance, or traction force has not been obtained, correct by means of a thinner or a thicker spacer (see figure 51).

Loosen afterwards slotted nut again, remove gear ring carrier and pull hub from hub carrier.

Remove bearing inner face.

Insert the heated bearing inner race.

Press shaft seal carefully against shoulder.

NOTE: Cover outer diameter with a spirit and water mixture (1:1).

Fill sealing lip with grease.

(S) driver

(S) handle

Press scraper ring (with small sealing lip toward above) into position until contact with the shaft seal has been obtained.

Place pre-assembled hub against the steering knuckle housing by continuous rotation.

Assemble the spacer (see figure 50-55) determined before, for example 14.50 mm.

Install the heated bearing inner race firmly against shoulder.

Grease O-ring and insert it into the groove of the hub, and on the steering knuckle housing.

Install the new rectangular rings (2 pieces).

NOTE: Oil rectangular rings slightly (use 10W oil).

Insert piston into the gear ring carrier.

NOTE: Pay attention to the location (bores for return springs).

Insert wire ring and return springs into the gear ring carrier.

Fasten the gear ring carrier into a vise and hook return springs into the inserted wire ring.

(S) spring hook

Insert snap ring into the groove of the gear ring carrier, preload and push gear ring carrier in until the snap ring engages in the gear ring groove.

Position the complete gear ring upon the splines of the steering knuckle housing firmly against shoulder.

NOTE: Pay atention to the overlapping of the oil bores (steering knuckle housing/gear ring carrier). Be sure they are aligned.

Position O-ring uniformly, place angle ring upon it and install O-ring carefully against shoulder, using slotted nut.

Afterwards, remove slotted nut and check that the O-ring has not been damaged.

NOTE: Pay attention to the installation position of the angle ring (recessed plane surface towards the O-ring). Cover O-ring and angle ring with grease.

Tighten the slotted nut.

Torque limit (M90x1.5) 1000 to 1500 N·m

Torque limit (M95x1.5) 1500 to 2000 N·m

NOTE: For the locking of the lock plates, there is only a slight backing off of the slotted nut permitted.

(S) hook spanner

(S) centering disc

Make thrust washer adhere with grease.

Version A

Insert both lock plates and fasten them by a slight backing off of the slotted nut.

Version B

Squeeze out circlip.

Engage circlip (baffle ring).

Place inner plate carrier upon the splines of the sun gear shaft firmly against shoulder and fix by means of the snap ring.

Determine the plate end play.

NOTE: In order to be able to determine a correct plate end play, there may be no end play between gear ring and gear ring carrier. This can be obtained by installing a puller set, see illustration.

Determine dimension A, between gear ring face and piston.

For Example: 81.10 mm

Insert backing plate and engage circlip.

Place backing plate against circlip until contact is obtained.

With an inside micrometer, measure dimension B from gear ring face to the inner plane surface of the backing plate.

For Example: 51.90 mm

Charge the brake clutch plate pack assembly with about 200 N (compress) by means of a press and determine dimension C.

For Example: 26.50 mm

Example:

If required, correct by outer plates of different thickness.

Assemble the clutch plate pack for the brake, starting with one outer plate (5 plates), and then one inner plate (4 plates) etc.

Insert backing plate and fix it by means of the snap ring.

Engage first angle ring in the planetary gear, install subsequently the roller bearing and fix it by means of second angle ring.

NOTE: Large butting face of angle rings go toward the bearing.

Guide planetary gears over the shafts of the planetary carrier and place them firmly against shoulder.

NOTE: Large radius of the bearing inner race goes toward the planetary carrier.

Install the planetary gears by means of the snap rings.

Adjust end play of the universal shaft, nominal value 0.30 - 0.60 mm (see figure 83 up to the example).

Determine dimension A from flange facing to contact surface of thrust washer.

For Example: 289.50 mm

Slide the sun gear shaft in until contact is obtained.

Measure dimension B from face/sun gear shaft to flange facing.

For Example: 286.40 mm

Example:

In order to obtain an end play of 0.30 to 0.60 mm, it is therefore necessary to select a thrust washer of s = 2.70 mm.

Cover determined thrust washer, for example s = 2.70 mm, with Loctite and make it adhere in the planetary carrier.

Assemble planetary carrier and place it against the hub until contact is obtained.

NOTE: Grease O-ring slightly.

Fasten planetary carrier by means of two socket head screws.

Torque limit (M10/8.8) 49 N·m

Install the tie rod in, and tighten the castle nut.

Torque limit 220 N·m

Secure castle nut by means of a cotter pin.

Pressure check the brake hydraulics for leakage:

Before starting the check, bleed the air from the brake hydraulic system.

Show/hide table

The brake hydraulic system will have high pressure at the bleed screw when it is opened. Do this operation in a position where the fluid can not make contact with anyone.

After a compressive load of 15 min. with 120 bar (12 000 kPa), a pressure drop of 2% [117.5 bar (11 750 kPa)] is permissible.

See topic Assemble Final Drive, figure 136 on page 44.

Test Medium:

Motor oils SAE-10W, corresponding to MIL - L 2104 1. ATF-Oils type A Suffix A/Dexron II D.

(S) hand pump