Caterpillar Cat 385B EXCAVATOR (Prefix BKX) Service Repair Manual (BKX00001 and up).pdf

Service Repair Manual
Models
385B EXCAVATOR

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 385B EXCAVATOR BKX
Configuration: ISJ HEX COMMONALITY CHART BKX00001-UP (MACHINE)
Disassembly and Assembly
385B and 5090B Excavators Excavator Systems
Media Number -RENR5407-06 Publication Date -01/02/2016 Date Updated -12/02/2016
i01674800
Final Drive - Disassemble
SMCS - 4050-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 138-7575 Link Bracket 3
C 138-7576 Link Bracket 2
D
132-8119 Hydraulic Wrench 1
132-8223 Hydraulic Pump and Motor Gp 1
9U-7418 Hex Bit Socket 1
E 176-6536 Forcing Bolt 2
Start By:
a. Remove the final drive. Refer to Disassembly and Assembly, "Final Drive - Remove".
1. Thoroughly clean the outside of the final drive prior to disassembly.
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Illustration 1 g00865168
2. Fasten the final drive to Tooling (A). Put an alignment mark across the sections of the final
drive for assembly purposes. All parts must be reinstalled in the original locations. The
weight of the final drive is approximately 1020 kg (2250 lb).
3. Remove socket head bolts (1) from the final drive cover.
4. Fasten Tooling (B) and a suitable lifting device to cover (2).
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5. Remove bolts (3). Use a soft faced hammer to break the seal between the cover and the ring
gear. Remove cover (2). The weight of the cover is approximately 95 kg (210 lb).
6. Remove spacer (4) and the shims from the cover.
7. Remove socket head bolts (5) and ring gear (6) from the cover.
8. Remove sun gear (7).
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9. Use a hoist and Tooling (B) to remove carrier assembly (8). The weight of the carrier
assembly is approximately 43 kg (95 lb).
10. Remove retaining ring (9), spacer (10), and sun gear (11).
11. Drive spring pin (13) into shaft (14). Remove shaft (14) and gear assembly (12).
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12. Remove washers (15) and bearing (16) from gear (17). Remove spring pin (13) from shaft
(14).
13. Repeat Steps 11 and 12 for the remaining gear assemblies.
15. Remove retaining ring (19), spacer (20), and gear assembly (21).
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16. Drive spring pin (22) into planetary shaft (24). Remove planetary shaft (24) and gear
assembly (23).
17. Remove thrust washers (27) and bearing (26) from planetary gear (25). Remove spring pin
(22) from shaft (24).
assembly is approximately 132 kg (290 lb). Remove spacer (29).
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20. Drive spring pin (31) into shaft (32). Remove planetary shaft (32) and gear assembly (30).
21. Remove thrust washers (33) and (37), and bearings (34) and (36) from planetary gear (35).
Remove spring pin (31) from shaft (32).
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23. Use a hoist and Tooling (B) to remove ring gear (38) from housing (39). The weight of the
ring gear is approximately 155 kg (340 lb).
24. Remove O-ring seal (40) from the main housing.
25. Place wood blocks under the final drive in order to support the motor housing.
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26. Use Tooling (D) to remove bolts (41) from gear (42).
Note: A part of Tooling (D) must be modified. Cut Length (X) on a 9U-7418 Hex Bit
Socket to a length of 14 mm (0.55 inch).
27. Install Tooling (E) in the gear, as shown. Tighten Tooling (E) evenly in order to loosen the
gear. Remove the gear from the motor housing.
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28. Remove shims (43) from the motor housing.
29. Remove bolts (44). Use Tooling (C) and a hoist to separate main housing (45) from motor
housing (39). The motor housing will rest on the wood blocks. The weight of the main
housing is approximately 250 kg (550 lb).
30. Remove bearing (46) from the main housing.
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ISJ HEX COMMONALITY CHART BKX00001-UP (MACHINE)(SEBP5600 - 00...
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31. Remove Duo-Cone seal (47), and bearing cups (48) and (49) from the main housing.
32. Remove pins (50), if necessary.
33. Remove bearing (51).
34. Remove Duo-Cone seal (52) from the motor housing.
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 385B EXCAVATOR BKX
Configuration: ISJ HEX COMMONALITY CHART BKX00001-UP (MACHINE)
Disassembly and Assembly
385B and 5090B Excavators Excavator Systems
Media Number -RENR5407-06 Publication Date -01/02/2016 Date Updated -12/02/2016
i01678933
Final Drive - Assemble
SMCS - 4050-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B 138-7576 Link Bracket 3
C 205-8241 Installer 1
D
132-8119 Hydraulic Wrench 1
132-8223 Hydraulic Pump and Motor Gp 1
9U-7418 Hex Bit Socket 1
E 138-7575 Link Bracket 3
F 6V-3175 Double Acting Cylinder 1
3S-6224 Electric Hydraulic Pump Gp 1
1U-9889 Crossblock 1
9S-7338 Crossblock 1
150-1961 Washer 2
150-1786 Plate 2
4C-9634 Puller Stud 1
9U-6832 Nut 1
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2K-7468 Locknut 1
4K-0684 Locknut 2
6V-2078 Stud 2
5P-4807 Cap 2
G 138-7575 Link Bracket 2
1. Make sure that all parts of the final drive are thoroughly clean and free of dirt and debris
prior to assembly.
Note: Check the condition of all the O-ring seals that are used in the final drive. If any of
the seals are worn or damaged, use new parts for replacement.
2. Reassemble the final drive on wood blocks and Tooling (A).
3. Apply 5P-3931 Anti-Seize Compound to the surfaces that contact the bearing cones. Install
the bearing cone with a press. Raise the temperature of bearing (51) and install the bearing.
4. Apply 5P-3931 Anti-Seize Compound to the surfaces that contact pins (50). Install the pins.
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5. Apply 5P-3931 Anti-Seize Compound to the surfaces that contact the two bearing cups.
Install bearing cups (48) and (49).
6. Use Tooling (B) and a suitable lifting device to install main housing (45) on motor housing
(39). The weight of the main housing is approximately 250 kg (550 lb).
7. Install bearing (46) and the bearing cone.
8. Use the following procedure to determine the bearing preload and the correct number of
shims.
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a. Use a depth micrometer in order to measure the step length of the coupling gear (42).
Take measurements at several different locations around the gear. Compute the
average of the measured dimensions and record the number. Call this Dimension (X).
b. Use Tooling (F) to apply a load of 10700 kPa (1550 psi) in order to seat the bearings.
A pressure of 10700 kPa (1550 psi) on the 3S-6224 Electric Hydraulic Pump Gp will
result in a pressure of 10000 kg (22050 lb) on the bearings. Rotate the housing in
order to seat the bearing. Reduce the load on the 3S-6224 Electric Hydraulic Pump
Gp to 4825 kPa (700 psi).
c. Rotate Tooling (F) by 90° and repeat Step 8.b.
d. Maintain the load on the bearings. Use a depth micrometer and measure the distance
between the top face of motor housing and the bearing cone. Take this measurement
in several locations around the bearing. Compute the average of the measured
dimensions and record the number. Call this Dimension (Y).
e. Determine the correct thickness of the shim pack that will be installed between the
bearing cone and the coupling gear. The shim pack thickness is equal to Dimension
(Y) minus Dimension (X). Tolerance for the shim pack is 0.1 mm (0.003 inch).
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Note: If two shims are required, install the thinner shim next to the coupling gear
when the coupling gear is installed.
9. Use Tooling (B) and a suitable lifting device to remove the main housing from the motor
housing. The weight of the main housing is approximately 250 kg (550 lb).
Note: Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
Note: The rubber seals and all surfaces that contact the seals must be clean and dry. After
installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals.
10. Use Tooling (C) to install Duo-Cone seal (47) in the main housing.
11. Use Tooling (C) to install Duo-Cone seal (52) in the motor housing.
Note: Make sure that the Duo-Cone seals are not scratched or damaged during the assembly
of the main housing or during the assembly of the motor housing. After installation of the
main housing on the motor housing, there will be a small gap between the components. The
gap is caused by the Duo-Cone seals. The gap will be eliminated during installation of the
gear.
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12. Fasten Tooling (B) and a hoist to main housing (45). Place the main housing in position on
motor housing (39). Make sure that the Duo-Cone seals are not scratched or damaged
during installation. The weight of the main housing is approximately 250 kg (550 lb).
13. Install bearing (46) and the bearing cone.
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14. Place shims (43) in the correct position on the motor housing. If two shims were required,
put the thinner shim in contact with coupling gear (42). Make sure that all of the holes in the
components are in alignment with each other. Put coupling gear (42) in the original position
on the motor housing.
15. Apply 9S-3263 Thread Lock Compound on the threads of bolts (41). Install the bolts to
secure coupling gear (42) in place. Tighten the bolts evenly and tighten the bolts in
diagonally opposite pairs. Tighten bolts to a torque of 900 ± 100 N·m (665 ± 75 lb ft).
16. Install O-ring seal (40) in the main housing.
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17. Use Tooling (B) and a hoist to position housings (39) and (45) on Tooling (A). Remove the
wood blocks. The weight of both housings is approximately 430 kg (950 lb).
18. Thoroughly clean the mating surface of main housing (39) that contacts ring gear (38).
Apply a bead of 1U-8846 Gasket Sealant on the mating surface of ring gear (38). Use
Tooling (E) and a suitable lifting device. Place the ring gear in position on the main
housing. Make sure that the alignment mark on the main housing and the ring gear line up
with each other. It may be necessary to use a soft faced hammer to seat the ring gear on the
main housing.
19. Assemble carrier assembly (28), as follows:
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a. Apply clean SAE 30 oil on bearings (34) and (36). Install two bearings (34) and (36)
in planetary gear (35).
b. Install thrust washers (33) and (37) on each side of the planetary gear.
c. Install the planetary gear and thrust washers in carrier assembly (28).
d. Install planetary shaft (32) in carrier assembly (28) and through planetary gear
assembly (30). Make sure that the spring pin hole in the planetary shaft is in
alignment with the spring pin hole in the carrier.
e. Install spring pin (31) in the carrier and into the planetary shaft. Make sure that the
spring pin hole in the planetary shaft is in alignment with the spring pin hole in the
carrier.
f. Orient the split in spring pin (31) horizontally to the carrier. Align the split in the
spring pin to the left or to the right. Make a stake mark on each side of the spring pin
hole in the carrier. This will prevent the spring pin from falling out of the spring pin
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hole. Each stake mark should be approximately 1.5 mm (0.06 inch) to 3.00 mm
(0.118 inch) from the outside diameter of the spring pin hole.
g. Repeat Steps 19.a through 19.f in order to install the other three planetary gears in
carrier assembly (28).
20. Fasten Tooling (E) and a hoist to carrier assembly (28). Put the carrier assembly in position
in the ring gear. It may be necessary to move the carrier assembly back and forth during
installation in order to ensure that all gears engage properly.
21. Install spacer (29).
22. Assemble carrier assembly (21), as follows:
a. Apply clean SAE 30 oil on bearing (26). Install bearing (26) in planetary gear (25).
b. Install thrust washers (27) on each side of the planetary gear.
c. Install the thrust washers and the planetary gear in carrier assembly (28).
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d. Install planetary shaft (24) in carrier assembly (28) and through the planetary gear
assembly. Make sure that the spring pin hole in the planetary shaft is in alignment
with the spring pin hole in the carrier.
e. Orient the split in the spring pin (22) horizontally to the carrier. Align the split in the
spring pin to the left or to the right. Make a stake mark on each side of the spring pin
hole in the carrier. This will prevent the spring pin from falling out of the spring pin
hole. Each stake mark should be approximately 1.5 mm (0.06 inch) to 3.00 mm
(0.118 inch) from the outside diameter of the spring pin hole.
f. Repeat Steps 22.a through 22.e in order to install the other two planetary gears in
carrier assembly (28).
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23. Install gear assembly (21), spacer (20), and retaining ring (19).
24. Use a hoist and Tooling (B) to install carrier assembly (18). The weight of the carrier
25. Apply clean SAE 30 oil on bearing (16). Install washers (15) and bearing (16) in gear (17).
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26. Install gear assembly (12), shaft (14), and drive spring pin (13) into shaft (14).
28. Install sun gear (11), spacer (10), and retaining ring (9).
29. Use a hoist and Tooling (B) to install carrier assembly (8). The weight of the carrier
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30. Install sun gear (7).
31. Install the shims and spacer (4) in the cover.
32. Install ring gear (6) and socket head bolts (5) in the cover.
33. Use Tooling (B) and a suitable lifting device to position cover (2). Install bolts (3). The
weight of the cover is approximately 95 kg (210 lb).
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Caterpillar Cat 385B EXCAVATOR (Prefix BKX) Service Repair Manual (BKX00001 and up).pdf

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