PULLEY-CRANKSHAFT 1189155 - Caterpillar

This is a 10.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".
Refer to the Service Manual if/as necessary.
Refer to Media Number UENR5021, Disassembly and Assembly, 415F2, 416F2, 420F2 IT, 420F2 ST, 430F2 IT and 430F2 ST Backhoe Loaders Power Train, sections:
- Axle Housing, Axle Shaft, and Wheel Flange ? Remove
- Axle Housing, Axle Shaft, and Wheel Flange - Install
- Axle Housing (Service Brakes, Differential and Bevel Gear) - Disassemble - ZF Axle
- Axle Housing (Service Brakes, Differential and Bevel Gear) - Assemble - ZF Axle
Refer to Media Number UENR5023, Testing and Adjusting, 415F2, 416F2, 420F2 IT, 420F2 ST, 430F2 IT and 430F2 ST Backhoe Loaders Axles, Differential and Brakes, sections:
- Service Brake Control ? Adjust
- Brake System Air ? Purge
Refer to Media Number SEBU9212, Operation and Maintenance Manual, 416F2, 420F2 and 430F2 Backhoe Loaders, section:
- Differential Oil (Rear) ? Change
Rework Procedure:
1. Use a grinder to smooth out the grooves and marks on the housing. Refer to Image1.2.1.
Image1.2.1
2. Refer to Image1.3.1 for a view of the assemble parts.
Legend:
(1) 482-6791 Axle Housing
(2) 490-0022 Back-up Ring
(3) 110-4755 Grooved Ring
(4) 482-6784 Piston
(5) 482-6741 Cup Spring
(6) 482-6780 Ring (PREVIOUS) 490-0029 Ring (NEW)
(7) 490-0401 Retaining Ring
(8) 482-6796 Washer
(9) 482-6740 Slotted Pins
(10) 482-6742 Cup Spring
(11) 482-6797 Washer
(12) 490-0021 Back-Up Ring
(13) 482-6728 Grooved Ring
Image1.3.1
3. Insert back-up ring (2) and grooved ring (3), back-up ring (12) and grooved ring (13), into the annular groove (arrow) of axle housing (1). Refer to Image1.4.1.
IMPORTANT - Pay attention to the installation position of the sealing elements.
Image1.4.1
4. Install flush-mount slotted pins (9) (front face) into piston (4). Refer to Image1.5.1.
Image1.5.1
5. Locate cup spring (10), paying attention to the correct installation position, and washer (11) into axle housing (1). Refer to Image1.6.1.
Image1.6.1
6. Oil grooved rings and sealing surfaces of axle housing and piston. Mount pre-assembled piston (1). Refer to Image1.7.1. Push the piston to contact position using a two-armed puller and a pressure plate. Refer to Image1.7.1.
Note: Pay attention to the slotted pins placed in the piston. Ensure that position of located slotted pins does not change. The pressure plate may only touch the piston front face.
Image1.7.1
7. Mount cup spring (5), paying attention to the correct installation position, and washer (8) on to ring (6).Press down cup spring preload using a press, and snap inretaining ring (7). Refer to Image1.8.1.
Image1.8.1
8. Adjust the service control brake.
9. Purge the air from brake system.
10. Add oil to the differential.
Notes:
- For LBF and LBS machines, Cat MTO is the only type of oil recommended.
- For LBS and LBF machines, DO NOT USE oil additive. There is no need to fill the rear axle final drives, there is a communication channel between the differential and final drives.
Note: The oil change interval should be decreased to 500 hours if more than 50% of the service hours is used for roading and loading.