2021/05/18 Final Drive - Assemble - Type-Two (RENR8648)

SMCS - 4050 i08480418

Assembly Procedure
Required Tools 

Tool  Part Number  Part Description  Qty 

A  439-3940  Link Bracket  3 
B  439-3939  Link Bracket  2 
8T-9206  Duo-Cone Seal Installer As  1 
D 
169-0503 Installation Kit  1 
E  1U-9895  Crossblock  1 
F  -  Loctite Copper Anti Seize  - 
G  -  Loctite 243  - 
H  -  Loctite RTV Silicone Clear  - 
J  FT-2770  Leak Down Test Tool  1 
K  6V-2012  Depth Micrometer  1 
L  6V-7059  Micrometer  1 

Table 1

1. Make sure that all parts of the final drive are thoroughly clean and free of dirt and debris prior to assembly. Check the condition of all O-ring
seals that are used in the final drive. If any of the seals are damaged, use new parts for replacement.

Illustration 1 g03873123

2. Use Tooling (D) to install Duo-Cone seal (45).

Illustration 2 g03873131

3. Apply Tooling (F) to the surface of dowels (46). Install dowels (46).

4. Raise the temperature of lower bearing cone (47). Install lower bearing cone (47) on motor housing (48).
 Illustration 3 g03873115

5. Lower the temperature of bearing cups (43). Install bearing cups (43) in sprocket housing (41).

Illustration 4 g03873145

6. Use Tooling (D) to install Duo-Cone seal (44).

Illustration 5 g03873151

7. Attach Tooling (B) and a suitable lifting device to sprocket housing (41). The weight of sprocket housing (41) is approximately 110 kg (243 lb).
Install sprocket housing (41).

8. Raise the temperature of upper bearing cone (42). Install upper bearing cone (42).

Illustration 6 g03873237
 Illustration 7 g03873187

9. Use Tooling (E) and a suitable press to apply force to upper bearing cone (42). Apply a force of 4000 kg (8818 lb) to the top of Tooling (E).
Rotate sprocket housing (41) to seat the roller bearings.

10. Reduce the force on top of Tooling (E) to 3000 ± 300 kg (6614 ± 661 lb). Use Tooling (K) to measure Dimension (X). Record Dimension (X).

Illustration 8 g03873199

11. Remove Tooling (E).

12. Use Tooling (K) to measure Dimension (W) on coupling gear (39). Record Dimension (W).

Illustration 9 g03873204
 Illustration 10 g03873207

13. Subtract Dimension (X) from Dimension (W) and record the difference as Dimension (V). The correct shim thickness is Dimension (V). Use
Tooling (L) to measure the correct thickness of shims (40). The tolerance of Dimension (V) is 0 ± 0.05 mm (0.0 ± 0.002 inch).
Note: Use a maximum of two shims (40). If two shims (40) are used to achieve the proper dimension, install the thinner of the two shims toward
coupling gear (39).

14. Install shims (40).

15. Apply Tooling (G) to the threads of bolts (38) and the threads in the housing. Install coupling gear (39) and bolts (38). Tighten bolts (38) to a
torque of 900 ± 100 N·m (665 ± 75 lb ft).

Illustration 11 g03873246

16. Install O-ring seal (37) in sprocket housing (41).

17. Thoroughly clean the mating surface of sprocket housing (41) that makes contact with ring gear (36).

18. Attach Tooling (A) and a suitable lifting device to ring gear (36). Put ring gear (36) in position on sprocket housing (41). The weight of ring gear
(36) is approximately 65 kg (143 lb). Make sure that the alignment marks on sprocket housing (38) and ring gear (36) are lined up with each
other.

Illustration 12 g02152467

19. Install roller bearings (33) in planetary gear assembly (29).

20. Install washer (32) and washer (35), and install planetary gear (34) in planetary gear assembly (29).

21. Install planetary shaft (31) in carrier assembly (29).

22. Drive spring pin (30) into planetary shaft (31).

Illustration 13 g00941047
The stake mark is at position (S).

23. Orient the split in spring pin (30) vertically to the carrier. Align the split in the spring pin to the top or to the bottom. Make a stake mark on each
side of the spring pin hole in the carrier. Each stake mark should be approximately 1.5 mm (0.06 inch) from the outside diameter of the spring
pin hole.

24. Repeat Steps 19 through 23 to install the other two planetary gears in the carrier assembly.

Illustration 14 g02152208

25. Use Tooling (A) and a suitable lifting device to install planetary gear assembly (29). The weight of planetary gear assembly (29) is approximately
38 kg (85 lb).

Illustration 15 g02151782

26. Position sun gear (28) in planetary gear assembly (19) and install retaining ring (23).

27. Install roller bearing (25) in planetary gear (26).

28. Install washer (24) and washer (27), and install planetary gear (26) in planetary gear assembly (19).
29. Install planetary shaft (22) in planetary gear assembly (19).

30. Drive spring pin (21) into planetary shaft (22).

Illustration 16 g00941047
The stake mark is at position (S).

31. Orient the split in spring pin (21) vertically to the carrier. Align the split in the spring pin to the top or to the bottom. Make a stake mark on each
side of the spring pin hole in the carrier. Each stake mark should be approximately 1.5 mm (0.06 inch) from the outside diameter of the spring
pin hole.

32. Repeat Steps 27 through 31 to install the other two planetary gears in the carrier.

Illustration 17 g02151813

33. Install spacer (20).

34. Use Tooling (A) and a suitable lifting device to install planetary gear assembly (19). The weight of planetary gear assembly (19) is approximately
48 kg (105 lb).
 Illustration 18 g02153647
Note: Make sure that the oil passages in the shafts are oriented toward the center of carrier assembly (17).

35. Raise the temperature of carrier assembly (17). Lower the temperature of the shafts. Install the shafts into carrier assembly (17) until the groove
of the shafts is at Dimension (A). Dimension (A) equals 25.00 ± 0.10 mm (0.984 ± 0.004 inch).

36. Make eight stake marks at distance of Dimension (C) from each shaft. Dimension (C) equals 2.0 ± 1.0 mm (0.08 ± 0.04 inch). The width of each
stake mark should be equal to Dimension (B). Dimension (B) equals 4.0 ± 1.0 mm (0.16 ± 0.04 inch).

Illustration 19 g02151809

37. Install sun gear (18) and retaining ring (14).

38. Install washer (16) and roller bearing (15). Install planetary gear (13) and washer (12). Install retaining ring (11).

39. Repeat Step 38 for the other two planetary gears.

 Illustration 20 g02151806

40. Install planetary gear assembly (10), spacer (9), and sun gear (8).

Illustration 21 g00879365

41. Install O-ring seals (7) on plugs (4).

Illustration 22 g00879362

42. Install plugs (4) in cover (2). Tighten plugs (4) to a torque of 80 ± 10 N·m (59 ± 7 lb ft). Install plate (6) in cover (2). Position gear (5) and install
bolts (3).

43. Place a piece of solder in the center of gear (8).

Note: You may need to apply some grease to the solder to keep the solder in position on gear (8).

Illustration 23 g02151790

44. Use Tooling (A) and a suitable lifting device to install cover (2). The weight of cover (2) is approximately 32 kg (70 lb).

45. Install four bolts (1) at 90 degrees from each other.

46. Remove bolts (1).

47. Use Tooling (A) and a suitable lifting device to remove cover (2).

48. Use a micrometer to measure the thickness of the solder. Record this measurement to determine the thickness of the shims for plate (6). Adjust
the shims to obtain a clearance of 1.000 + 1.000 mm (0.0394 + 0.0394 inch) between plate (6) and gear (8).

49. Apply Tooling (H) to the mating surfaces of cover (2) and the housing.

50. Use Tooling (A) and a suitable lifting device to Install cover (2).

51. Install bolts (1). Tighten bolts (1) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).
 Illustration 24 g01304937

52. Remove the plug (not shown) from cover (2). Attach Tooling (J) to cover (2). Reduce the air pressure at the source to 103 kPa (15 psi). Apply air
pressure to Tooling (J). This air will test the Duo-Cone seals.

53. Use the ball valve on Tooling (J) to eliminate the air pressure to the final drive. A pressure of 98 kPa (14.2 psi) must be maintained for 30
seconds.

54. Remove Tooling (J). Install the plug . Torque the plug to 80 ± 10 N·m (59 ± 7 lb ft).

End By:

a. Install the final drive and the travel motor.

(Type 1) Assembly Procedure

Required Tools 
Tool  Part Number  Part Description  Qty 
A  439-3940  Link Brackets  3 
B  154-6183  Forcing Bolts  3 
C  439-3941  Link Brackets  3 
D  -  Loctite C5A Copper Anti-Seize  - 
E  1U-9895  Crossblock  1 
F  6V-2012  Depth Micrometer  1 
G  6V-7059  Micrometer  1 
H  -  Loctite 243  - 
J  6V-2055  Grease  - 
K  -  Loctite RTV Clear Silicone  - 
L  8T-9206  Seal Installer  1 

Table 2

Illustration 25 g02132155

1. Apply Tooling (D) to the surface of dowels (46). Install dowels (46).

2. Raise the temperature of roller bearing (47). Install the roller bearing (47) on motor housing (48).

3. Install Duo-Cone seal (45).

 Illustration 26 g02131888

4. Lower the temperature of bearing races (43). Install bearing races (43) in sprocket housing (41).

5. Install Duo-Cone seal (44).

Illustration 27 g02131887

6. Attach Tooling (C) and a suitable lifting device to sprocket housing (41). The weight of sprocket housing (41) is approximately 107 kg (235 lb).
Install sprocket housing (41).

7. Raise the temperature of roller bearing (42). Install the roller bearing (42).

Illustration 28 g02135728
 Illustration 29 g02134214

8. Use Tooling (E) and a suitable press to apply force to roller bearing (42). Apply a force of 4000 kg (8818 lb) to the top of Tooling (E). Rotate
sprocket housing (41) to seat the roller bearings.

9. Reduce the force on top of Tooling (E) to 3000 ± 300 kg (6614 ± 661 lb). Use Tooling (F) to measure Dimension (X). Record Dimension (X).

Illustration 30 g02134175

10. Use Tooling (F) to measure Dimension (W) on gear (39). Record Dimension (W).

11. Remove Tooling (E).

 Illustration 31 g02131886

Illustration 32 g02131882

12. Subtract Dimension (X) from Dimension (W) and record the difference as Dimension (V). The correct shim thickness is Dimension (V). Use
Tooling (G) to measure the correct thickness of shims (40). The tolerance of Dimension (V) is 0 ± 0.05 mm (0 ± 0.002 inch).
Note: Use a maximum of two shims (40). If two shims (40) are used to achieve the proper dimension, install the thinner of the two shims toward
gear (39).

13. Install shims (40).

14. Apply Tooling (H) to the threads of bolts (38) and the threads in the housing. Install gear (39) and bolts (38). Tighten bolts (38) to a torque of
900 ± 100 N·m (665 ± 75 lb ft).

Illustration 33 g02131881

Illustration 34 g02133219
Note: Make sure that the spring pin hole in planetary shaft (32) is aligned with the spring pin hole in the carrier.

15. Install roller bearings (35), planetary gear (36), washer (37), washer (33), planetary shaft (32), and spring pin (31) into carrier assembly (34).
Install spring pin (31) until spring pin (31) is even with the outside surface of the carrier. Align the split in spring pin (31) to the top or the bottom.

16. Make a stake mark on each side of the spring pin hole in the carrier, as shown. The stake mark will prevent the spring pin from falling out of the
spring pin hole. Make a stake mark at Dimension (Y). Dimension (Y) is 2.25 ± 0.75 mm (0.089 ± 0.030 inch).
 Illustration 35 g02131879

17. Attach Tooling (A) and a suitable lifting device to planetary gear assembly (30). The weight of planetary gear assembly (30) is approximately
57 kg (125 lb). Install planetary gear assembly (30).

18. Install O-ring seal (29).

Illustration 36 g02131878

19. Attach Tooling (A) and a suitable lifting device to ring gear (27). The weight of ring gear (27) is approximately 70 kg (155 lb). Install ring gear
(27) and bolts (28). Tighten bolts (28) to a torque of 520 ± 70 N·m (385 ± 52 lb ft).

20. Install spacer (26).

Illustration 37 g02131877

Illustration 38 g02133219

21. Install roller bearing (22), planetary gear (23), washer (24), washer (20), planetary shaft (18), and spring pin (17) into carrier assembly (21).
Install spring pin (17) until spring pin (17) is even with the outside surface of the carrier. Align the split in spring pin (17) to the top or the bottom.

22. Make a stake mark on each side of the spring pin hole in the carrier, as shown. The stake mark will prevent the spring pin from falling out of the
spring pin hole. Make a stake mark at Dimension (Y). Dimension (Y) is 2.25 ± 0.75 mm (0.089 ± 0.030 inch).
23. Install sun gear (25) and retaining ring (19).

Illustration 39 g02131876

24. Attach Tooling (A) and a suitable lifting device to planetary gear assembly (15). The weight of planetary gear assembly (15) is approximately
32 kg (70 lb). Install planetary gear assembly (15).

25. Install spacer (16).

Illustration 40 g02131875

26. Install sun gear (14) and retaining ring (10).

27. Install washer (12), roller bearing (11), planetary gear (9), washer (8), and retaining ring (7) on carrier assembly (13).

Illustration 41 g02131415

28. Install planetary gear assembly (6), spacer (5), and sun gear (4).
 Illustration 42 g02135393

29. Use the correct plate (3) to achieve Dimension (Z). Dimension (Z) is 1.00 to 2.00 mm (0.039 ± 0.079 inch).

Illustration 43 g02131414

30. Use Tooling (J) to secure plate (3) in cover (2).

Illustration 44 g02131413

31. Apply Tooling (K) to the mating surface of cover (1). Attach Tooling (A) and a suitable lifting device to cover (2). The weight of cover (2) is
approximately 20 kg (45 lb). Install cover (2) and bolts (1). Tighten bolts (1) to a torque of 105 ± 20 N·m (80 ± 15 lb ft).

32. Remove Tooling (A) and the suitable lifting device. Apply Tooling (H) to the threads of the set screws. Install the set screws so that the
setscrews are flush with cover (1).

End By:

a. Install the final drive and the travel motor.

B6H568-UP, DTS1-UP, EAH1-UP, EDX1-UP, EFT1-UP, ERN275-UP, FAR1-UP, FFK1-UP, GGE1-UP, GGH1-UP, GTN188-UP, HHK1-UP, J2F1-UP,
JBT1-UP, JLP299-UP, JTN1-UP, JWR1-UP, KDJ1-UP, LMG1-UP, LRM1-UP, M3M1-UP, M3N1-UP, M4T1-UP, MDS1-UP, MEY179-UP, MKR198-UP,
MPL1-UP, MWP1-UP, MYG1-UP, MYP1-UP, NBD169-UP, NBN1-UP, PGW1-UP, PPN1-UP, PRF1-UP, PTB1-UP, RAS573-UP, RMX1-UP, SWF1-UP,
T2Y226-UP, THJ1-UP, TLY1-UP, W3K1-UP, WDC1-UP, WET1-UP, WRK1-UP, XBH1-UP, YCF1-UP, ZCT1-UP, ZML1-UP

PIP-10800244
2021/06/19
00:52:55-05:00
i03927450
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