Caterpillar cat d300 d articulated truck (prefix 5mg) service repair manual (5mg00001 and up)

Service Repair Manual
Models
D300D ARTICULATED
TRUCK

Shutdown SIS
Previous Screen
Product: ARTICULATED TRUCK
Model: D300D ARTICULATED TRUCK 5MG
Configuration: D300D ARTICULATED TRUCK 5MG00001-UP (MACHINE)
Disassembly and Assembly
D300D ARTICULATED TRUCK POWER TRAIN
Media Number -SENR8213-03 Publication Date -01/07/2005 Date Updated -05/10/2005
SENR82130003
Final Drive Planet Carriers And Ring Gears
SMCS - 4055-011; 4055-012; 4092-015; 4092-016; 4092
Remove Final Drive Carriers And Ring Gears
Start By:
a. remove axles (front or rear)
1. Fasten tool (A) and a hoist to the final drive planet carrier (1) as shown.
2. Remove bolts (2) that hold the final drive planet carrier (1) to the wheel assembly.
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3. Install two 3/8" - 16 NC forcing screws (3) and loosen final drive planet carrier (1) from the
wheel assembly. Remove the final drive planet carrier from the wheel assembly. The weight of the
final drive planet carrier is 31 kg (68 lb).
4. Remove the O-ring seal from the final drive planet carrier.
5. Remove retaining ring (4) that holds ring gear (5) to the hub assembly and remove ring gear (5).
Install Final Drive Carriers And Ring Gears
1. Put ring gear (1) in position on the hub assembly, and install retaining ring (2) that holds the
ring gear on the hub assembly.
2. Install O-ring seal (3) on the final drive carrier (4), and put clean oil on it.
3. Fasten tool (A) and a hoist to final drive planet carrier (4) as shown.
4. Put final drive planet carrier (4) in position on the wheel assembly.
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5. Install 12 bolts (5) that hold the final drive planet carrier to the wheel assembly. Tighten the
bolts to a torque of 270 ± 25 N·m (200 ± 18 lb ft).
End By:
a. install axles (front and rear)
Disassemble Final Drive Planet Carriers
Start By:
a. remove final drive planet carriers and ring gears
NOTE: Two shafts must be removed from the final drive planet carrier so that one of the gears
can be removed.
1. Remove shafts (1) and (4) from the final drive planet carrier.
2. Remove lockwashers (3) and the thrust washers from each side of the gears (2) and (5).
3. Push gear (8) into the final drive planet carrier, and remove gear (6) from the planet carrier.
4. Remove gear (8) from the planet carrier.
5. Remove shaft (7) and the remaining lockwashers, thrust washers and gear from the final drive
planet carrier.
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6. Remove the two bearing assemblies from each gear.
Assemble Final Drive Planet Carriers
1. Install two bearing assemblies (1) in each gear (4).
NOTE: Thrust washers (5) must be installed next to gears (4), and lockwashers (2) must be
installed between thrust washers (5) and the final drive planet carrier.
2. Install the gear assemblies in the final drive planet carrier as follows:
a. Install gear (4), thrust washers (5) and lockwashers (2) at position (X) in the final drive planet
carrier to hold them.
b. Install another gear (4) at position (Y) in the final drive planet carrier. Push the gear into the
planet carrier to provide clearance so that the last gear can be installed.
c. Install last gear (4) at position (Z) in the final drive planet carrier.
3. Install the thrust washers, and lockwashers (2) on each side of the gears (4) at positions (Y) and
(Z) in planet carrier.
NOTE: Make sure the flat side of shafts (3) are toward the outside diameter of the final drive
planet carrier so that the cover assembly can be installed. For more details concerning positioning
of shafts (3), see Install Axles (Front And Rear).
4. Install shafts (3) at positions (Y) and (Z) in the planet carrier.
End By:
a. install final drive planet carriers and ring gears
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Feb 15 23:11:00 UTC+0800 2020
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Shutdown SIS
Previous Screen
SENR82130004
Shaft-Main Drive (Gear Group-Output To Front Axle
Differential)
SMCS - 3253-010
Remove & Install Shaft-Main Drive (Gear Group-Output To
Front Axle Differential)
1. Remove eight bolts (2).
2. Remove shaft-main drive (1). The weight of the shaft-main drive is 7 kg (16 lb).
NOTE: It may be necessary to raise one of the front wheels off the ground to allow some
movement in the differential and bevel gear group for easier removal of the shaft-main drive
group.
NOTE: For installation of the shaft-main drive, reverse the removal steps.
Sat Feb 15 23:11:55 UTC+0800 2020
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Shutdown SIS
Previous Screen
SENR82130005
Driveshaft, (Transfer Gear Case To Center Axle)
SMCS - 3253-010
Remove & Install Driveshaft, (Transfer Gear Case To Center
Axle)
1. Place tool (A) to driveshaft (1). Use strap to secure driveshaft to transmission jack.
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2. Remove four bolts (2).
4. Lower driveshaft (1) from the machine using tool (A). The weight of the driveshaft is 38 kg (84
lb).
NOTE: For installation of the driveshaft (transfer gear case to center axle), reverse the removal
steps.
Sat Feb 15 23:12:51 UTC+0800 2020
2/2
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Shutdown SIS
Previous Screen
SENR82130006
Driveshaft (Transfer Gear To Mid Bearing)
SMCS - 3253-010
Remove & Install Driveshaft (Transfer Gear To Mid
Bearing)
2. Separate from yoke (3).
3. Reposition rear driveshaft (1) for clearance.
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4. Remove bottom two bolts (4) from mid bearing housing (5).
5. Install tool (A).
6. Remove remaining two bolts (4).
8. Separate driveshaft from transfer gear yoke (6).
9. Using two individuals slide transfer gear to mid bearing driveshaft (8) to the rear of the vehicle
for removal. The weight of the drive shaft is 43 kg (95 lb).
NOTE: For installation of the driveshaft to mid bearing driveshaft, reverse the removal steps.
Sat Feb 15 23:13:47 UTC+0800 2020
2/2
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Shutdown SIS
Previous Screen
SENR82130007
Driveshaft (Mid Bearing To Rear Axle)
SMCS - 3253-010
Remove & Install Driveshaft (Mid Bearing To Rear Axle)
1. Place wood blocks (A) between rear axle A-frame assembly (1) and chassis (4).
2. Remove four bolts (2). Reposition mid-bearing to rear axle driveshaft (3).
3. Place a wood block (B) under the mid bearing rear axle driveshaft (3) to facilitate removal.
Place a nylon strap (C) on the end of the driveshaft.
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4. Remove four bolts (5) from mid bearing yoke (6).
5. Use two individuals to remove the mid bearing to rear axle driveshaft (3). The driveshaft
weighs 29 kg (65 lb).
NOTE: For installation of the driveshaft (mid bearing to rear axle), reverse the removal steps.
Sat Feb 15 23:14:43 UTC+0800 2020
2/2
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Shutdown SIS
Previous Screen
SENR82130008
Gear Group-Transfer
SMCS - 3159-010; 3159-017
Remove & Install Gear Group-Transfer
Start By:
a. drain fluid from gear-group transfer
b. remove driveshaft assembly (output gear to gear group-transfer)
c. remove rear driveshaft group (gear group-transfer to center axle)
d. disconnect rear driveshaft group (mid bearing to rear axle)
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1. Remove bolt (2) and yoke retainer (1).
2. Remove yoke and dirt guard (3).
3. Remove fitting (4) from gear group-transfer (8).
4. Remove bolt (7) and yoke retainer (6).
5. Remove eight bolts (5) from bearing support (9).
6. Install tool (A) and tool (B) to separate lower bearing support (9) from gear group-transfer (8).
7. Remove O-ring seal (10) from the gear group-transfer.
8. Use tool (A) to remove lower bearing support (9). The weight of the bearing support is 29 kg
(65 lb).
NOTE: Set lower bearing support aside. See topic Disassemble & Assemble Gear Group-Transfer
for Disassembly of lower bearing support.
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9. Remove six bolts (11) from carrier (12).
10. Install tool (A) to carrier (12). Remove bolt (13) from lower hitch pin (14). Reposition carrier
(12) as far forward as possible.
NOTE: The repositioning of the carrier allows sufficient clearance for the gear group-transfer to
be removed. Refer to Photo C43693P1 Step #8 showing the splined shaft.
11. Remove bolt (16) from torque restraint assembly (15).
12. Tool (C).
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13. Secure tool (C) to the gear group-transfer.
14. Remove eleven nuts (18) and locking plate assembly (17).
15. Remove gear group-transfer (9) with tool (C) and tool (D).
NOTE: Refer to Topic, Disassemble & Assemble Drive Hitch Shaft Group if further disassemble
of the group is necessary to replace components.
16. Remove hitch seal (19) and inspect for possible damage. If necessary, install a new seal during
assembly.
NOTE: For installation of the gear group-transfer, reverse the removal steps.
End By:
a. install rear driveshaft group (gear group-transfer to midbearing).
b. install rear driveshaft group (gear group-transfer to center axle)
c. install driveshaft assembly (output gear to gear group-transfer)
d. add fluid to the gear group-transfer
Disassemble & Assemble Gear Group-Transfer
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Start By:
a. remove gear group-transfer
1. Remove circlip (2) using tool (A). Remove thrust washer (1) from lower bearing support (3).
NOTE: The lower bearing support was removed during removal of the gear group-transfer.
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2. Remove bearing (4) using tool (B) and tool (F) from lower bearing support (3).
3. Remove gear (5) from lower bearing support (3) using a hydraulic press and tool (F).
4. Use tool (D) to remove circlip (6) from lower bearing support (3) for removal of bearing (7).
5. Remove bearing (7) (not shown) using a hydraulic press and tool (F).
6. Remove circlip (8) using tool (D) to allow removal of lip-type seal (9) (not shown).
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7. Remove lip-type seal (9) (not shown) using a hydraulic press and tool (F).
8. Remove two bolts and attach tool (E) and hoist to the gear group-transfer case. Remove four
bolts securing tool (C) to gear group-transfer case (10). Set gear group-transfer case to suitable
work place for additional disassembly.
9. Remove four bolts (11) and tool (E).
10. Install tool (G). Remove upper bearing support (14). Remove two bolts (13) and retaining
plate (12).
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11. Remove circlip (15) using tool (D) for removal of idler gear pin (16).
12. Use plate (12) and tool (H) with two bolts to remove idler gear pin (16).
13. Slide idler gear (17) in direction of arrow to large opening and remove.
14. Remove thrust washer (18).
15. Remove circlip (21) using tool (A) and thrust washer (20) from upper bearing support (19).
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16. Remove bearing (22) using tool (B) and tool (F).
17. Turn upper bearing support (19) over and use tool (B) and tool (F) to remove bearing support
(19) from gear (23).
18. Use tool (D) to remove circlip (24) from upper bearing support (19) for the removal of bearing
(25).
19. Remove bearing (25) (not shown) using a hydraulic press and tool (F).
9/12
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Caterpillar cat d300 d articulated truck (prefix 5mg) service repair manual (5mg00001 and up)

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Caterpillar cat d300 d articulated truck (prefix 5mg) service repair manual (5mg00001 and up)