transmission planetory assemble

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Product: TRUCK

Model: 777D TRUCK FKR

Configuration: 777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine

Disassembly and Assembly777D Off-Highway Truck Power Train

Media Number -RENR8428-00 Publication Date -01/04/2007 Date Updated -04/04/2007

i06089732

Transmission Planetary - Assemble

SMCS - 3160-016

Assembly Procedure

Required Tools

Tool Part Number Part Description Qty

A 1P-2420 Transmission Repair Stand 1

B 1P-1863 Retaining Ring Pliers 1

C 138-7573 Link Bracket 2

D 1P-0520 Driver Group 1

F 138-7576 Link Bracket 1

G 2P-8312 Retaining Ring Pliers 1

H 1P-1864 Retaining Ring Pliers 1

K 1P-1855 Retaining Ring Pliers 1

L 138-7575 Link Bracket 2

M FT-947 Spring Compressor 2

N 138-7574 Link Bracket 2

Table 1

of 59777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine(S...

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P 138-7574 Link Bracket 1

Illustration 1 g00646497

Install ball bearing (1) , retainer plate (2) , and the dowels on bearing cage assembly (3) . Position the dowels to a depth of 16 ± 0.5 mm (0.63 ± 0.02 inch).

1.

Attach bearing cage assembly (3) to Tooling (A) at locations (W) and (X) .2.


Use Tooling (B) to install retaining ring (4) on bearing cage assembly (3) .3.





Install sun gear (7) in clutch hub (6) . Install retaining ring (5) .4.

Install sun gear (7) and clutch hub (6) as an assembly on bearing cage assembly (3) . Install bolts (8) .

5.




Install friction discs (9) and clutch plates (10) . Install the friction discs (9) and clutch plates (10) in alternating order. Start with a friction disc and end with a friction disc.

6.


Install springs (11) and reaction dowels (12) on bearing cage assembly (3) .7.


Install seal rings (13) in clutch piston (14) . Lubricate the seal rings with the lubricant that is being sealed.

8.




Install clutch piston (14) in clutch housing (16) .9.

Install bearing outer race (16A) and retaining ring (15) in clutch housing (16) .10.


Turn over clutch housing (16) . Attach Tooling (C) and a suitable lifting device to clutch housing (16) . The weight of the clutch housing (16) is approximately 36 kg (80 lb).

11.

Install clutch housing (16) on the bearing cage assembly. The springs should be seated on the bearing cage assembly (13) and the clutch piston (14) (not shown).

12.




Install friction discs (17) and clutch plate (18) . Install friction discs (17) and clutch plates (18) in alternating order. Start with a friction disc and end with a friction disc.

13.


Install ring gear (19) on clutch housing (16) . The teeth of ring gear (19) will mesh with the teeth of friction discs (17) .

14.




Install springs (20) and dowels (21) on clutch housing (16) .15.


Install dowels (23) in clutch housing assembly (22) . Install dowels (23) to a depth of 16 ± 0.5 mm (0.63 ± 0.02 inch).

16.

Install plug (24) and the O-ring seal in clutch housing assembly (22) .17.




Install seal rings (25) in clutch piston (26) .18.


Install piston (26) in clutch housing assembly (22) .19.




Turn over clutch housing (22) . Install dowels (27) in clutch housing assembly (22) . Position dowels (27) to a depth of 16 ± 0.5 mm (0.63± 0.02 inch).

20.


Attach Tooling (C) and a suitable lifting device in clutch housing assembly (22) . Install clutch housing assembly (22) on clutch housing (16) . The springs should be seated on the bearing cage assembly and the clutch piston.

21.





Install tube (28) in planetary carrier (32) .22.

Lubricate bearing (29) with the lubricant that is being sealed. Install bearing (29) and thrust disc (33) on each side of gear (30) . Position gear (30) , bearing (29) , and thrust discs (33) as an assembly in planetary carrier (32) .

23.

Align the hole in shaft (31) with the hole in carrier (32) . Install shaft (31) in planetary carrier (32) .

24.

NOTICE

The spring pins must be replaced with new parts during the assembly of the carrier assembly.

Failure to use new spring pins could result in damage to the carrier

assembly.

Install a new spring pin (34) in shaft (31) . Spring pin (34) must be flush with the outside diameter of planetary carrier (32) . Repeat Steps 22 through 25 for the two remaining shafts.

25.

of 59777D Off-Highway Truck FKR00001-UP (MACHINE) POWERED BY 3508B Engine...




Lubricate bearing (35) with the lubricant that is being sealed. Install bearing (35) in gear (36) . Position thrust disc (40) on each side of gear (36) . Position gear (36) , bearing (35) , and thrust discs (40) as an assembly in planetary carrier (32) .

26.

Align the spring pin hole in shaft (39) and the hole in planetary carrier (32) . Insert shaft (39) inplanetary carrier (32) .

27.

NOTICE

The spring pins must be replaced with new parts during the assembly of the carrier assembly.

Failure to use new spring pins could result in damage to the carrier

assembly.



Install a new spring pin (42) in shaft (39) . Spring pin must be flush with the outside diameter of planetary carrier (32) . Repeat Steps 26 through 28 for the two remaining shafts.

28.


Heat bearing outer race and bearing (43) to a maximum temperature of 135 °C (275 °F). Install the bearing outer race and bearing (43) on planetary carrier (32) .

29.


Turn over planetary carrier (32) . Install seal ring (44) on planetary carrier (32) .30.




Install metal seal ring (45) on ring gear (46) .31.


Turn over ring gear. Install metal seal ring (47) on ring gear (46) . Install dowel (48) . Position dowel (48) to a depth of 3.68 ± .13 mm (0.14 ± 0.005 inch).

32.




Install ring gear (46) in planetary carrier (32) .33.





Use Tooling (D) and a suitable press to install bearing (49) in bearing housing (50) .34.

Note: Install bearing (49) in bearing housing (50) with notch (Y) in the downward position.

Mark the location of notch (50) on bearing (49) for installation purposes.35.

Install O-ring seal (52) on bearing retainer (50) .36.


Mark the location of dowel (48) on ring gear (46) for installation purposes.37.


Install bearing housing (50) and bearing (49) on ring gear (46) . Use marks on top of ring gear (46) and bearing (49) to line up the notch in bearing (49) with the dowel in ring gear (46) .

38.




Use Tooling (B) to install retaining ring (53) on ring gear (46) .39.


Install friction discs (54) and clutch plates (55) . Install friction discs (54) and clutch plates (55) in alternating order. Start with a friction disc and end with a friction disc.

40.




Install seal ring (56) on rotation housing assembly (57) .41.


Install seal ring (58) on clutch piston (59) . Lubricate seal ring (58) with the lubricant that is being sealed.

42.




Position clutch piston (59) on rotation housing assembly (57) . Do not press clutch piston (59) in place.

43.


Install housing (60) . The teeth on housing (60) should mesh with the teeth on clutch piston (59) . Use two guide bolts to align housing (60) , clutch piston (59) , and rotation housing assembly (57) .

44.

Install clutch piston (59) on rotation housing assembly (57) .45.

Remove housing (60) and guide bolts (61) .46.




Install springs (62) on clutch piston (59) .47.


Install seal ring (63) on balance piston (64) . Lubricate seal ring (63) with the lubricant that is being sealed.

48.




Position balance piston (64) on rotation housing assembly (57) . Install bolts (65) and the washers.

49.

Improper assembly of parts that are spring loaded can cause bodily

injury.

To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Tighten bolts (65) evenly.50.




Turn over rotation housing assembly (57) . Install ring carrier (67) and spring pin (66) on rotation housing assembly (57) .

51.

Install seal rings (68) on ring carrier (67) .52.


Position bearing (69) with the retaining ring in the down position, as shown. Use a pipe with an inside diameter of 76.2 mm (3 inch), Tooling D, and a suitable press to install ball bearing (69) on center shaft (70) .

53.


Install center shaft (70) in the rotation housing assembly. Install retaining ring (71) on center shaft (70) .

54.





Install Tooling (C) on housing (60) . Install housing (60) on planetary carrier (32) . Align the teeth of housing (60) with the teeth of the clutch plates. Remove Tooling (C) .

55.

Use two 3/8 in - 16 NC guide bolts to align the holes in rotation housing assembly (57) with the holes in bearing retainer (50) . Position rotation housing assembly (57) and shaft (70) on housing (60) . The teeth of the clutch piston should engage with the teeth of housing (60) . The bolt holes on rotation housing assembly (57) should line up with the bolt holes of housing (60) .

56.

Remove retaining ring (72) from the ball bearing.57.




Note: Do not remove the two guide bolts at this time.

Install bolts (74) and the washers. Tighten bolts (74) at this time.58.

Remove the two guide bolts. Install bolts (73) and the washers. Tighten bolts (73) only after bolts (74) have been tightened.

59.





Install Tooling (F) to center shaft (70) . Attach a suitable lifting device to Tooling (F) . Secure the suitable lifting device to a hoist. The weight of the planetary carrier, the housings, and the center shaft as an assembly is approximately 136 kg (300 lb).

60.

Install the assembly. The teeth of planetary carrier (32) will mesh with the teeth of sun gear (7) (not shown) and ring gear (18) (not shown).

61.


Install manifold (75) on bearing (69) .62.




Use Tooling (G) to install retaining ring (72) on ball bearing (69) .63.


Install plugs (77) and the O-ring seals in center manifold (76) . Attach Tooling (C) to center manifold (76) .

64.




Attach a suitable lifting device to Tooling (C) . Secure the suitable lifting device to a hoist. Install center manifold (76) . The weight of center manifold (76) is approximately 58 kg (128 lb).

65.

Use two 3/8 in - 16 NC guide bolts to align manifold (75) with center manifold (76) . Install three bolts that secure manifold (75) to center manifold (76) . Remove the two guide bolts. Install the remaining two bolts that secure manifold (75) to manifold (76) .

66.


Install two of 12 bolts (78) and the washers.67.




Install seal rings (79) and the dowel on ring carrier assembly (80) .68.


Position ring carrier assembly (80) , as shown. Install bolts (81) .69.

Put a mark on the top of ring carrier assembly (80) . The mark should represent the location of the dowel on ring carrier assembly (80) .

70.




Install seal ring (82) on housing (83) .71.


Install seal ring (84) on clutch piston (85) .72.




Lubricate the seal rings on clutch piston (85) and housing (83) with the lubricant that is being sealed.

73.

Position clutch piston (85) on housing (83) . Position housing (86) on housing (83) for properalignment. The teeth of housing (83) should engage with the teeth of clutch piston (82) . The bolt holes of housing (83) should line up with the bolt holes of housing (86) .

74.

Install clutch piston (85) in housing (86) . Remove housing (86) and the guide bolts.75.


Install springs (87) in clutch piston (85) .76.


Install seal ring (90) on balance piston (89) .77.



Install bearing (88) in balance piston (89) . The notch (Z) in bearing (88) should be in a downward position, as shown. Mark the top of bearing (88) for installation procedures.

78.



Lubricate the seal ring on balance piston (89) with the lubricant that is being sealed. Position balance piston (89) on clutch piston (85) .

79.

Improper assembly of parts that are spring loaded can cause bodily

injury.

To prevent possible injury, follow the established assembly procedure and wear protective equipment.



Install four of six bolts (91) and the washers. Tighten bolts (91) evenly in order to compress the springs.

80.

Install Tooling (C) and a suitable lifting device on balance piston (89) . The weight of balancepiston (89) , clutch piston (85) , the bearing, and the housing as single unit is approximately 45 kg (100 lb).

81.

Install balance piston (89) , clutch piston (85) , bearing (88) , and the housing as a single unit. The notch on bearing (88) should line up with the dowel on ring carrier assembly (80) .

82.

Remove Tooling (C) . Install two remaining bolts (91) and the washers.83.


Use Tooling (B) to install retaining ring (93) on ring carrier assembly (80) .84.

Install seal ring (92) on ring carrier assembly (80) .85.




Install Tooling (C) in housing (86) . Install housing (86) by hand. The teeth of housing (86) should engage the teeth of clutch piston (85) . The bolt holes of housing (86) should line up with the bolt holes of housing (83) (not shown).

86.


Install metal ring seals (94) on sun gear (95) .87.


Install sun gear (95) .88.




Install friction discs (96) and clutch plates (97) . Install the friction discs (96) and clutch plates (97) in alternating order. Start with a friction disc and end with a friction disc.

89.





Install orifice (104) in shaft (99) .90.

Lubricate bearing (101) with the lubricant that is being sealed. Install bearing (101) in gear (102) . Position one thrust disc (98) on each side of gear (102) . Position gear (102) , bearing (101) , and thrust discs (98) in planetary carrier (100) as an assembly.

91.

Line up the holes for the spring pin (103) . One hole is in shaft assembly (99) . One hole is in planetary carrier (100) . Install shaft assembly (99) in planetary carrier (100) .

92.


NOTICE

The spring pins must be replaced with new parts during the assembly

of the carrier assembly.

Failure to use new spring pins could result in damage to the carrier assembly.

Install a new spring pin (103) in shaft assembly (99) . Spring pin (103) should be flush with the outside diameter of planetary carrier (100) .

93.




Attach Tooling (C) and a suitable lifting device on planetary carrier (100) . Install planetary carrier (100) . The weight of planetary carrier (100) is approximately 23 kg (50 lb).

94.

Install bolts (105) and the washers.95.


Install dowels (107) in clutch housing (106) . Position dowels (107) to a depth of 16 ± 0.5 mm (0.63 ± 0.02 inch).

96.




Turn over clutch housing (106) . Install dowels (108) in clutch housing (106) . Position dowels (108) to a depth of 16 ± 0.5 mm (0.63 ± 0.02 inch).

97.


Attach Tooling (C) and a suitable lifting device to clutch housing assembly (106) . Install clutch housing assembly (106) . The weight of clutch housing assembly (106) is approximately 30 kg (66 lb).

98.

Install bolts (109) and the washers. Remove Tooling (C) .99.




Install ring gear (110) . The teeth of ring gear (110) should mesh with the teeth of the gears on planetary carrier (100) .

100.


Install seal rings (111) on clutch piston (112) .101.




Lubricate the seal rings on clutch piston (112) with the lubricant that is being sealed. Install clutch piston (112) in clutch housing assembly (106) .

102.


Install friction discs (113) and clutch plate (114) . Install the clutch plate (114) between the two friction discs (113) .

103.




Install dowels (115) on clutch housing assembly (106) . Install springs (116) on clutch piston (112) .

104.


Install Tooling (C) and a suitable lifting device to clutch housing (117) . Install clutch housing (117) on clutch housing assembly (106) . The springs should seat in clutch housing (117) and clutch piston (112) (not shown). The weight of clutch housing (117) is approximately 39 kg (85 lb).

105.







107.




Install O-ring seal (120) and metal seal ring (122) on sun gear (121) .108.


Install sun gear (121) on center shaft (70) .109.

Use Tooling (H) to install retaining ring (122) on center shaft (70) .110.




Install cup plugs (123) in ring gear assembly (124) .111.


Use two people to install ring gear assembly (124) . The weight of ring gear assembly (124) is approximately 35 kg (77 lb).

112.




Install locking plates (125) between planetary carrier (100) and ring gear (124) . Install bolts (126) .

113.





Install plug (133) in shaft assembly (131) .114.

Lubricate bearings (128) with the lubricant that is being sealed. Install bearings (128) in gear (129) . Position thrust disc (127) on each side of gear (129) . Position gear (129) , bearings (128) , and thrust discs (127) as an assembly in planetary carrier (130) .

115.

The spring pin hole in shaft assembly (131) should line up with the hole in planetary carrier (130) . Install shaft assembly (131) in planetary carrier (130) .

116.


NOTICE




Install new spring pin (132) until the end of spring pin is flush with planetary carrier (130) .117.




Install Tooling (C) and a suitable lifting device on planetary carrier (130) . Install planetary carrier (130) . The gears on planetary carrier (130) should mesh with the teeth on ring gear (124) . The weight of planetary carrier (130) is approximately 55 kg (120 lb).

118.


Position bearing (133) on the center shaft. The words on bearing (133) should face downward. Install bearing (133) . Use a 1 1/2 inch socket head to install bearing (133) .

119.




Note: Callout (134) is missing from the photograph due to an engineering correction.

Use Tooling (K) to install retaining ring (135) on center shaft (70) .120.


Install drive adapter (136) . Install bolts (137) .121.





Install lockring (138) on sun gear (139) .122.

Position six 1/8 in x 1 in pins (141) between lockring (138) and coupler (140) . Pins (141) will allow coupler (140) to slide over lockring (138) . The sun gear (139) and coupler (140) will be connected as an assembly by lockring (138) .

123.




Install sun gear (139) and coupler (140) as an assembly.124.


Use a screwdriver to install retaining ring (142) . Retaining ring (142) goes between coupler (140) and ring gear (124) (not shown).

125.




Use Tooling (G) to install retaining ring (143) on planetary carrier (130) .126.


Lubricate bearings (145) with the lubricant that is being sealed. Install bearings (145) in gear (146) . Position thrust disc (144) on each side of gear (146) . Position gear (146) , bearings (145) , and thrust discs (144) as an assembly in planetary carrier (147) .

127.

The spring pin hole in shaft (148) should line up with the hole in planetary carrier (147) . Install shaft (148) .

128.




NOTICE




Install new spring pin (149) in shaft (148) . Install spring pin (149) until the end of the spring pin is flush with planetary carrier (147) .

129.


Install O-ring seal (150) and metal seal rings (151) on manifold (152) .130.





Install manifold (152) on planetary carrier (147) . Install seven of the nine bolts (153) and the washers.

131.

Attach Tooling (L) and a suitable lifting device to planetary carrier (147) and manifold (152) .132.

Install planetary carrier (147) and manifold (152) as an assembly. The weight of planetary carrier (147) and manifold (152) as single unit is approximately 57 kg (125 lb).

133.

Remove Tooling (L) . Install remaining bolts (153) and the washers.134.





135.

Install springs (156) on clutch piston (119) .136.


Install dowels (158) in plate assembly (157) . Position dowels (158) to a depth of 12.5 ± 0.5 mm (0.5 ± 0.02 inch).

137.

Install 24 dampers (159) in the bolt holes of plate assembly (157) .138.




Turn over plate assembly (157) . Install dowels (160) . Position dowels (160) to a depth of 12.5 ± 0.5 mm (0.5 ± 0.02 inch).

139.


Use two people to install plate assembly (157) . The weight of plate assembly is approximately 30 kg (66 lb). The springs should seat in plate assembly (157) and clutch piston (119) (not shown).

140.




Install ring gear (161) .141.


Install reaction dowels (162) .142.


143.

Install springs (163) .144.







146.

Attach Tooling (P) (not shown) and a suitable lifting device to clutch housing assembly (168) at position (V) . Turn over clutch housing assembly (168) . The weight of the clutch housing assembly is approximately 100 kg (220 lb).

147.




Attach Tooling (M) in order to hold the clutch piston to clutch housing assembly (168) . Attach Tooling (N) and a suitable lifting device to clutch housing assembly (168) . Install clutch housing assembly (168) on plate assembly (157) . Springs (163) (not shown) should seat in plate assembly (157) and clutch piston (167) (not shown).

148.

Note: Do not remove Tooling (N) at this time.


Install ball (170) and plug (169) in clutch housing assembly (168) .149.






Use Tooling (N) (not shown) to secure the transmission planetary. Remove the two bolts that hold the transmission planetary to Tooling (A) at position (W) and (X) .

151.

Install the remaining ten bolts (78) and the washers.152.




Install the transmission planetary in the transmission case. Remove forcing screws (173) . The weight of the transmission is approximately 1000 kg (2200 lb).

153.



Remove Tooling (N) and the suitable lifting device from the transmission. Attach thetransmission case (174) to Tooling (A) . Position transmission case (174) on a flat surface horizontally. The weight of the transmission planetary and transmission case (174) is approximately 1100 kg (2420 lb).

155.




Use Tooling (D) to install sleeve bearing (175) in input shaft (177) .156.

Install O-ring seal (176) on input shaft (177) .157.


Install input shaft (177) in the transmission planetary.158.

Install O-ring seal (178) on the transmission case.159.

End By:

Install the transmission hydraulic control. Refer to Disassembly and Assembly, "Transmission Hydraulic Control - Install".

a.

Connect the transmission to the transfer gears. Refer to Disassembly and Assembly, "Transmission and Transfer Gears - Connect".

b.

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transmission planetory assemble

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