992G Wheel Loader AZX00001-UP (MACHINE) POWE...

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Product: WHEEL LOADER

Model: 992G WHEEL LOADER AZX

Configuration: 992G Wheel Loader AZX00001-UP (MACHINE) POWERED BY 3508B Engine

Testing and Adjusting

992G Wheel Loader and 854G
Wheel Dozer Power Train
Media Number -SENR1347-08 Publication Date -01/07/2012 Date Updated -24/07/2012

i02254116

Differential Backlash and Bearings - Adjust

SMCS - 3258-025-BKL

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Illustration 1 g00405449

Differential and Bevel Gear

(1) Adjusting nut lock

(2) Bolts

(3) Adjusting nut

(4) Bolts

(5) Cover

(6) Shims

(7) Pin

(8) Bearing cup

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(9) Bearing cone

(10) Shims

(11) Bevel gear

(12) Housing

(13) Bearing cup

(14) Bearing cone

(15) Retainer

(16) Bolts

(17) Adjusting nut lock

(18) Adjusting nut

(19) Differential case

(20) Bolts

(21) Differential

(22) Bearing cone

(23) Bearing cup

(24) Carrier assembly

(25) Bearing cup

(26) Bearing cone

(27) Washer

(28) Nut

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(29) Bevel pinion

Note: The following procedure controls bearing preload. The

procedure provides the same results for new bearings and for used
bearings.

1. Install bevel gear (11) onto differential case (19) . Torque for
the 36 bolts is 750 ± 90 N·m (550 ± 65 lb ft).

2. Install bearing cone (9) and bearing cone (22) onto differential
group (21) . Make sure that the bearing cone is fully seated.
Lubricate the bearing cone with SAE 50W differential oil.

3. Press bearing cup (13) and bearing cup (25) on pinion housing
(12) . Make sure that the bearing cups are fully seated.

4. Press bearing cone (14) on pinion (29) . Make sure that the
bearing cone is fully seated. Lubricate the bearing cone with SAE
50W differential oil.

5. Install pinion (29) in housing (12) . Press bearing cone (26) onto
the pinion shaft. Allow a small amount of end play to remain.
Lubricate the bearing cone with SAE 50W differential oil.

Note: If you freeze the bearing cups, allow the parts to reach a
uniform temperature. Then use a driver or a press to reset the
bearing cups. The limit for freezing the bearing cups is -29°C (-
20°F). Remove any frost and wipe the bearing cups dry.
Lubricate the bearing cups with SAE 50W differential oil in order
to prevent rust on the bearing cups.

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Note: If you heat the bearing cones, allow the parts to reach a
uniform temperature. Then use a driver or a press to reset the
bearing cones. The limit for heating the bearing cones is a
maximum of 135°C (275°F) for a maximum of four hours.
Lubricate the bearing cones with SAE 50W differential oil after
the bearing cones have cooled in order to prevent rust on the
bearing cones.

6. Secure the assembled pinion housing (12) in a holding fixture.

Install washer (27) and nut (28) .

Table 1

Required Tools

Part Number Description Quantity

1U-6691 Socket Wrench Assembly 1

7. While you rotate pinion shaft (29) , tighten nut (28) in order to
achieve a preload rolling torque of 2.2 to 5.1 N·m (20 to 45 lb
in). This is the torque that is needed in order to rotate pinion
(29) . Make sure that there is zero end play of pinion shaft (29) .

Note: Reduce preload rolling torque to 1.1 to 2.55 N·m (10 to 23

lb in) for used roller bearings with more than 100 hours of
operation.

8. If the preload rolling torque for the pinion exceeds the

specifications, back off nut (28) by 1/8 turn and reseat bearing
cone (26) and washer (27) against nut (28) . Perform Step 7
again.

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Illustration 2 g00103469

Stake Nut and Tooling

9. When the torque for rotating pinion (29) is correct, stake nut
(28) by peening the collar into the slot in the pinion shaft.
Proper peening requires the use of a punch with a spherical
nose. The punch should have a nose that is (C) diameter. The
punch should be held at an angle (B) . The desired result is a
stake of minimum length (D) and minimum depth (E) . See
Illustration 2 for a view of a completed staked nut.

List of dimensions for a staked nut

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Dimension (B) ... 10 to 30°

Dimension (C) ... 7.5 to 8.0 mm (0.30 to 0.32 inch)
Dimension (D) ... 4.7 mm (0.19 inch)
Dimension (E) ... 2.5 mm (0.10 inch)

Note: The nut may be reused if the collar is not cracked during
removal or during restaking.

10. Secure carrier assembly (24) in a holding fixture.

11. Install the pinion subassembly in carrier assembly (24) with 80

percent of a new shim pack (10) . Make sure that the axle
centerline is vertical and that the teeth of bevel gear (11) are
facing upward, as shown.

12. Tighten bolts (2) and (16) in each bearing cap to a torque of 25
N·m (18 lb ft).

13. Move adjusting nut (3) and adjusting nut (18) to a position that
maintains the gear backlash and a slight bearing end play, but
not a tight gear mesh.

14. Reposition the differential assembly so that the pinion shaft is

vertical and the gear end is downward.

15. Measure the torque for rotating pinion (29) and record the
measured torque.

16. Move adjusting nut (3) to the zero backlash position. Back off
adjusting nut (3) by one-half turn.

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17. Move adjusting nut (18) while you rotate bevel gear (11) .
Monitor the torque that is required to rotate pinion (29) .

18. Continue to move adjusting nut (18) until a torque is registered

over the torque that was measured in Step 15. This is the
seated position.

19. Move adjusting nut (18) while rotating the bevel gear set until
the overall rolling torque is 4 N·m to 15 N·m (35 lb in to 130 lb
in).

20. Measure the backlash between bevel gear (11) and pinion gear
(29) . Measure the backlash at three equally spaced positions
around the bevel gear. The backlash must be 0.40 ± 0.12 mm
(0.016 ± 0.005 inch).

21. If the backlash does not meet the specification at any one of the
three positions, back off one adjusting nut and move the other
adjusting nut forward by the same amount. This will maintain
the bearing preload.

22. Measure the torque for rotating pinion (29) . The torque must be
4 N·m to 15 N·m (35 lb in to 130 lb in).

23. When proper backlash has been obtained tighten bolts (2) and
(16) in each bearing cap to a torque of 1800 ± 200 N·m (1330
± 150 lb ft).

24. Install adjusting nut locks (1) and (17) .

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Tooth Contact Pattern Adjustment (Pinion and

Bevel Gear)

Illustration 3 g00103470

1. After the backlash adjustment and the preload adjustment have

been made, check the tooth contact between pinion (29) and
bevel gear (11) by using the following procedure:

a. Put a small amount of Prussian blue, of red lead, or of paint

on the teeth of bevel gear (11) .

b. Turn pinion (29) in both directions.

c. The end of the correct area of tooth contact is near the

inside end of the teeth of the bevel gear (11) . The contact

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area should extend halfway across the length of the teeth.

See Illustration 3 for the correct area of tooth contact.

Illustration 4 g00103471

2. If the area of tooth contact looks like Illustration 4, use the

following procedure:

a. Remove some of the shims (10) .

b. Perform Step 14 through Step 24 again.

c. Perform Step 2 and Step 3 again in order to check the area

of tooth contact.

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Illustration 5 g00103472

3. If the area of tooth contact looks like Illustration 5, use the

following procedure:

a. Add some of the shims (10) .

b. Perform Step 14 through Step 24 again.

c. Perform Step 2 and Step 3 again in order to check the area

of tooth contact.

Note: Always make sure that the backlash adjustment is

correct before an adjustment is made to the area of tooth
contact. Several adjustments to the backlash and to the
tooth contact may be necessary in order to achieve the
correct adjustments.

4. Install pin (7) and cover (5) without shims (6) . Tighten bolts (4)
enough in order to remove any clearance between the pin and
the cover.

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5. Measure the distance between the face of the cover (5) and the
face of the axle housing. Install the shims (6) so that the pin is
under a preload of -0.03 mm (-.001 inch) or an end play of 0.03
mm (.001 inch).

6. Install retainer (15) .

Copyright 1993 - 2014 Caterpillar Inc. Mon Jul 21 10:11:50 UTC+0630 2014

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