R

NEHS0975
December 2006

TOOL
OPERATING
MANUAL
Using 291-4194 Separation Group to Separate Front
Spindle/Hub From Suspension Cylinder Rod
SMCS: 7051-076
Important Safety Information The message that appears under the warning
explains the hazard and can be either written
or pictorially presented.
Operations that may cause product damage
are identified by “NOTICE” labels on the
product and in this publication.
Caterpillar cannot anticipate every possible
circumstance that might involve a potential
hazard. The warnings in this publication
and on the product are, therefore, not
all-inclusive. If a tool, procedure, work
method, or operating technique that is not
specifically recommended by Caterpillar is
Think Safety used, you must satisfy yourself that it is
safe for you and for others. You should
also ensure that the product will not be
Most accidents that involve product operation, damaged or be made unsafe by the
maintenance, and repair are caused by failure operation, lubrication, maintenance or
to observe basic safety rules or precautions. repair procedures that you choose.
An accident can often be avoided by The information, specifications, and illustrations
recognizing potentially hazardous situations in this publication are on the basis of
before an accident occurs. A person must be information that was available at the time that
alert to potential hazards. This person should the publication was written. The specifications,
also have the necessary training, skills, and torques, pressures, measurements,
tools to perform these functions properly. adjustments, illustrations, and other items can
Improper operation, lubrication, change at any time. These changes can affect
maintenance, or repair of this product can the service that is given to the product. Obtain
be dangerous and could result in injury or the complete and most current information
death. before you start any job.
Do not operate or perform any lubrication,
maintenance, or repair on this product until
you have read and understood the WARNING
operation, lubrication, maintenance, and
repair information. When replacement parts are required for this
product, Caterpillar recommends using
Safety precautions and warnings are provided Caterpillar replacement parts or parts with
in this manual and on the product. If these equivalent specifications including, but not
hazard warnings are not heeded, bodily injury limited to, physical dimensions, type,
or death could occur to you or to other strength, and material.
persons.
The hazards are identified by the “Safety Alert Failure to heed this warning can lead to
Symbol” and followed by a “Signal Word” such premature failures, product damage,
as “DANGER”, “WARNING”, or “CAUTION”. personal injury, or death.
The Safety Alert “WARNING” label is shown
below.

WARNING
The meaning of this safety alert symbol is as
follows:
Attention! Become Alert! Your Safety is
Involved.

2
Contents Literature Information
Literature Information This manual should be stored with the tool
Safety Section . . . . . . . . . . . . . . . . . . . . . . . 3 group.
General Information Section . . . . . . . . . . . . 3 This manual contains safety information,
Operation Section . . . . . . . . . . . . . . . . . . . . 3 operation instructions, and maintenance
information.
Maintenance Section . . . . . . . . . . . . . . . . . . 3
Safety Icon Nomenclature . . . . . . . . . . . . . . 4 Some photographs or illustrations in this
publication show details that can be different
Personal Protection/Important Information 4
from your service tool. Guards and covers
Prohibited Action . . . . . . . . . . . . . . . . . . . . 4 might have been removed for illustrative
Hazard Avoidance . . . . . . . . . . . . . . . . . . . 4 purposes.
Safety Warnings Section Continuing improvement and advancement of
Personal Protection . . . . . . . . . . . . . . . . . . . 5 product design might have caused changes to
Machine Operation Hazards . . . . . . . . . . . . 5 your service tool, which are not included in this
publication.
Hose Safety . . . . . . . . . . . . . . . . . . . . . . . . . 6
Trapped Pressure . . . . . . . . . . . . . . . . . . . . 6 Whenever a question arises regarding your
service tool or this publication, please consult
Fluid Penetration . . . . . . . . . . . . . . . . . . . . . 6
Dealer Service Tools (DST) for the latest
General Information Section available information.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 7
Serial Numbers Affected . . . . . . . . . . . . . . . 7 Safety Section
Weight Specifications . . . . . . . . . . . . . . . . . 7 The Safety section lists basic safety
Additional Required Tooling. . . . . . . . . . . . . 7 precautions.
References. . . . . . . . . . . . . . . . . . . . . . . . . . 8 Read and understand the basic precautions
Additional Contact Information . . . . . . . . . . 8 listed in the Safety section before operating or
Operation Section performing maintenance and repair on this
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 service tool.
Tooling Installation . . . . . . . . . . . . . . . . . . . . 9 General Information Section
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 12
The General Information section describes
Tooling Removal. . . . . . . . . . . . . . . . . . . . . 13 tooling functions and features. It provides
Maintenance Section useful information on individual parts,
Inspection/Cleaning . . . . . . . . . . . . . . . . . . 14 additional tooling, and resources.
Service Parts . . . . . . . . . . . . . . . . . . . . . . . 14
Operation Section
The Operation section is a reference for the
new operator and a refresher for the
experienced operator.
Photographs and illustrations guide the
operator through correct procedures for using
the tool group.
Operating techniques outlined in this
publication are basic. Skill and techniques
develop as the operator gains knowledge of
the service tool and its capabilities.

Maintenance Section
The Maintenance section is a guide to
equipment care.

3
Safety Section Hazard Avoidance (continued)

Safety Icon Nomenclature Maximum pressure

Personal Protection/Important Pressurized air

Information
Read the manual Pressurized fluid

Read applicable manuals Safety alert symbol

Eye protection Slipping hazard

Ear protection Tripping hazard

Face protection

Inspect equipment

Prohibited Action
No smoking

Hazard Avoidance
Bending hazard (hydraulic hose)

Crushing hazard

Crushing hazard (foot)

Fire hazard

High-pressure fluid hazard

Impact hazard (hydraulic hose)

Lifting hazard

4
Safety Warnings Machine Operation Hazards
Personal Protection
WARNING
WARNING Inspect all component parts of this
tool before each daily use. Check
To avoid personal injury or death, for damage or excess wear on any
carefully read and understand all part. Replace all damaged or worn
instructions before attempting to parts immediately. Never operate equipment
operate any equipment or tools. with a known malfunction or leak.
Do not operate or work on a machine unless
you read and understand the instructions Components of the 291-4194
and warnings in this and all other applicable Separation Group and
manuals. Contact Dealer Service Tools for related tooling are heavy. To
replacement manuals. Proper care is your prevent personal injury, use
responsibility. Always follow all State and two people or a lifting device when handling the
Federal health and safety laws and/or local tooling.
regulations. Operators should be
To prevent possible damage to aware that dangers exist
your hearing, always wear ear when using the separation
protection when using this tool group to separate the front
and/or working around noise spindle/hub from the suspension cylinder
generating tools. rod. Improper procedures create risk for the
tool user and bystanders. DO NOT operate
To avoid eye injury, the separation group until everyone is at an
always wear protective adequate distance from the work area.
glasses or face shield. Use only the 1U-5197
Make sure no one can Cylinder Group (80 ton
be injured by flying objects or debris when capacity). Do not apply
using tools or working on a component. more than 68,000 kPa
Clean up all leaked or (10,000 psi) to the hydraulic cylinder. Using
spilled fluids immediately. additional force to remove the spindle/hub
Oil, fuel, or cleaning fluid assembly can result in serious injury or
leaked or spilled onto any death.
hot surfaces or electrical components can
cause a fire, resulting in personal injury or
death.
Personal injury can result
from slips or falls. DO
NOT leave tools or
components laying
around the work area and clean up all spilled
fluids immediately.
Personal injuries
can occur as a
result of using
pressurized air.
Maximum air pressure at the nozzle must be
below 205 kPa (30 psi) for cleaning
purposes. Wear protective clothing,
protective glasses, and a protective face
shield when using pressure air.

5
Hose Safety Trapped Pressure
WARNING WARNING
Avoid damaging hydraulic hoses. Pressure can be trapped
Avoid sharp bends and kinks when in a hydraulic system.
routing hydraulic hoses. Using a Use caution when
bent or kinked hose will cause disconnecting hydraulic
severe back-pressure. Sharp bends and lines or fittings. High pressure oil that is
kinks will internally damage the hose, released can cause a hose to move violently
leading to premature hose failure, resulting while spraying oil. Fluid penetration under
in personal injury. the skin can cause serious injury and
possible death.
Do not drop heavy objects on
hoses. A sharp impact may cause
internal damage to hose wire
strands. Applying pressure to a
Fluid Penetration
damaged hose may cause it to rupture,
resulting in personal injury. WARNING
Keep high-pressure hoses away When checking for a leak,
from flames and excessive heat. use a board or cardboard.
Excessive heat weakens hose Leaking fluid that is under
materials and packings. For pressure can penetrate
optimum performance, do not expose body tissue. Fluid penetration can cause
equipment to temperatures of 65°C serious injury and possible death. A pin hole
[150°F] or higher. leak can cause severe personal injury. If
fluid is injected into your skin, you must
Mismatched couplings
obtain treatment immediately. Seek
and hoses can cause the
treatment from a doctor that is familiar with
coupling to violently
this type of injury.
disconnect from the hose
when placed under pressure; separating
with sudden, extreme force which can result
in property damage, personal injury, or
death.
Replace a hose if any of the following
conditions are present:
- End fittings that are damaged or leaking
- Outer coverings that are chafed or cut
- Wire shields that are exposed
- Outer coverings that are ballooning
- Flexible part of the hoses that are kinked
- End fittings that are displaced

6
General Information Section Weight Specifications
291-4194 Separation Group
Introduction Description Qty Weight
Top Plate 2 27 kg (50 lbs)
WARNING Bottom Plate Assembly 1 34 kg (75 lbs)
This tooling should never be used Rod Assembly 2 16 kg (35 lbs)
for any application other than its Hydraulic Cylinder1 1 29 kg (63 lbs)
intended use; separating 1 Dealer Supplied 1U-5197 Cylinder Group (80 ton capacity).
spindle/hub assemblies from Not Included In 291-4194 Separation Group.
suspension cylinders on 769D, 771D, 773D,
773E, 775D, and 775E Off-Highway Trucks.
Using this tooling for any other purpose can
result in serious injury or even death.
Additional Required Tooling
Additional Required Tooling
The 291-4194 Separation Group is used to
Part No. Description Qty
separate the spindle/hub assembly from the
suspension cylinder rod on specific 769D, 3S-6224 Electric Hydraulic Pump (115V) 1 or
8S-8033 Electric Hydraulic Pump (230V) 1
771D, 773D, 773E, 775D, and 775E
Off-Highway Trucks. This process can be done 1U-5197 Hydraulic Cylinder (80 Ton Capacity) 1
with the components on the vehicle or off the 8F-0024 High Pressure Hose - Length 183 cm (72 in) 2 or
vehicle. 6D-7726 High Pressure Hose - Length 351 cm (138 in) 2

The separation group consists of two

interlocking top plates with bolts and nuts, a
bottom plate, and two threaded rod
assemblies with nuts and washers. The
bottom plate includes a V-shaped retainer
plate for positioning the hydraulic cylinder
during use.
The separation group is designed to work with
dealer supplied power supply, hydraulic
cylinder, and high pressure hoses. A 3S-6224
(115V) or 8S-8033 (230V) Electric Hydraulic
Pump can be used as the power supply.
A 1U-5197 Cylinder Group (80 ton capacity)
fits between the lower plate and suspension
cylinder and is the only cylinder recommended
for this procedure. This cylinder can be
connected to the power supply with two
8F-0024 Hose Assemblies (183 cm [72 inch]
length) or two 6D-7726 Hose Assemblies
(351 cm [138 inch] length).

Serial Numbers Affected

769D BBB00069 - UP
771D BCA00071 - UP
773D,773E BDA00073 - UP
775D, 775E BEC00075 - UP

7
References Operation Section
SENR1422; 769D, 771D Disassembly and
Assembly, Front Suspension Cylinders Setup
SENR1584; 773D, 773E, 775D, and 775E WARNING
Disassembly and Assembly, Front Wheel,
Bearing and Dual Cone Seal - Remove Make sure the truck is
parked on a hard, flat
surface. Make sure the
Additional Contact Information wheels are chocked and
the truck cannot move in a forward or
For further assistance for ordering or for backward direction. Make sure the truck is
information on other specialized tooling properly supported before removing the
available for your service operation, contact: front tire and rim. Failure to follow this
instruction can cause an unstable load
Dealer Service Tools condition, resulting in serious injury or even
501 S.W. Jefferson death.
Peoria, IL U.S.A. 61630-2125
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665 1. Refer to the correct disassembly and
Canada: 1-800-523-8665 assembly manual for the truck being
World: 1-309-675-6277 serviced. Follow the correct procedures to
Fax: 1-309-494-1355 properly support the truck and remove the
[email protected] tire and rim assembly from the spindle/hub.
2. Thoroughly clean the area around the
spindle/hub assembly and suspension.
Remove any build-up of dirt, oil, grease, or
other debris that has accumulated in this
area.

WARNING
Support the spindle/hub
assembly in a method
that will prevent it from
falling, rotating, or
swinging freely when it separates from the
suspension cylinder rod. Improper support
of the spindle hub assembly can cause the
tooling to drop, and can result in property
damage or personal injury.

3. Attach an overhead lifting device, link

brackets, and three leg chain to the
spindle/hub assembly. Support the hub
assembly in a method that will prevent it
from falling, rotating, or swinging when it
separates from the suspension cylinder rod.

8
NOTE: Allow enough travel in the chains to 1. Each top plate (1) weighs 27 kg (50 lbs).
permit separation of the spindle/hub assembly Place the two top plates around the
from the suspension cylinder rod during the suspension cylinder rod. Install bolt (2) and
removal procedure. washer (3) through the two small holes in
the top plates. Secure with washer (3) and
nut (4). Tighten the nuts to standard
torque.
WARNING
Loosen the retainer plate
NOTE: Make sure any build-up of dirt, oil,
bolts in a circular pattern
grease, or other debris that has accumulated
and do not loosen the
at the base of the cylinder rod has been
bolts more than 1/2 turn
removed.
at a time. Refer to the correct disassembly
and assembly manual for complete
instructions. Failure to follow this procedure
can cause the bolts to break, resulting in 2
component damage or personal injury.

4. Refer to the correct disassembly and 1

assembly manual for the procedure to
remove the suspension cylinder retaining
plate and shims.
3
4
Tooling Installation

Components of the 0975-01

291-4194 Separation
Group and related tooling (1) Top Plate. (2) M20 x 2.5 Bolt. (3) Washer.
are heavy. To prevent (4) M20 x 2.5 Nut.
personal injury, use two people or a lifting
device when handling the heavy tooling.
NOTE: The top plate assembly is designed
with adequate clearance between the inside
diameter of the plates and the suspension
cylinder rod to permit rotation of the top plate
after installation. If no clearance is present,
make sure the proper tooling is being used.

9
2. Rotate top plate (1) assembly so one hole 4. Install washer (6) and nut (7) onto the rod
for the rod assembly is on each side of the assembly. Hand tighten the nut against the
spindle/hub, as shown. top plate.

6
1

0975-02 0975-04

(1) Top Plate Assembly. (6) Washer. (7) M48 x 5 Nut.

3. Each rod assembly (5) weighs 16 kg 5. Place the other rod assembly, with the
(35 lbs). Place the rod assembly through square drive end facing up, through the
the hole in the top plate. The rod assembly other hole in the top plate.
must be positioned with the square drive
end facing up.

0975-05

0975-03

(5) Rod Assembly.

10
6. Install washer (6) and nut (7) onto the rod 7. Bottom plate (8) weighs 34 kg (75 lbs).
assembly. Hand tighten the nut against the Use two people to place the bottom plate
top plate. over the two rod assemblies. Hold the
plate in place while installing washer (9)
and nut (10) onto each rod assembly.
Hand tighten the nuts.
7
6

9
0975-06
10
(6) Washer. (7) M48 x 5 Nut.
0975-07

(8) Bottom Plate. (9) Washer. (10) M48 x 5 Nut.

WARNING
Components of the 291-4194
NOTE: The bottom plate has an angular
Separation Group and
retainer designed to prevent the hydraulic
related tooling are heavy. To
cylinder from falling out of the tooling. Position
prevent personal injury, use
the bottom plate to allow easy insertion of the
two people or a lifting device when handling the
hydraulic cylinder. Typically positioning the
tooling.
opening toward the wheel hub on the truck
allows the easiest installation.

11
8 Tighten two large nuts (7) on the top plate to Operation
standard torque. Tighten two large nuts
(10) on the bottom plate to standard torque. 1. Connect the high pressure hydraulic hoses
to the hydraulic cylinder. Connect the other
end of the hoses to the hydraulic power
supply.
WARNING
Use only the 1U-5197
Cylinder Group (80 ton
capacity). Do not apply
more than 68,000 kPa
(10,000 psi) to the hydraulic cylinder. Using
additional force to remove the spindle/hub
assembly can result in serious injury or
death.
Components of the 291-4194
Separation Group and
related tooling are heavy. To
prevent personal injury, use
two people or a lifting device when handling the
tooling.

0975-08
9. The 1U-5197 Hydraulic Cylinder weighs
29 kg (63 lbs). Use two people to place
the hydraulic cylinder between the bottom 2. Make sure the top plate tooling is aligned
plate and suspension cylinder so it is held with the spindle and suspension rod and is
in position by the angular retainer. Position seated against the spindle. Also make sure
the hydraulic cylinder to allow access to the ram on the hydraulic cylinder is aligned
connect high pressure hoses to the with the recessed area on the bottom of the
hydraulic fittings. suspension cylinder rod.

NOTICE
If the ram is not properly seated in the
recessed area of the suspension cylinder rod,
damage to the hydraulic cylinder ram and/or
suspension cylinder rod can result.

0975-08a

12
3. Start the hydraulic power supply and apply Tooling Removal
enough pressure to seat the ram of the
hydraulic cylinder against the bottom of the
suspension cylinder rod. If necessary,
carefully reposition the tooling to make sure Pressure can be trapped
it is correctly seated against the mating in a hydraulic system.
surfaces. Use caution when
disconnecting hydraulic
lines or fittings. High pressure oil that is
released can cause a hose to move violently
WARNING while spraying oil. Fluid penetration under
Support the spindle/hub the skin can cause serious injury and
assembly in a method possible death.
that will prevent it from
falling, rotating, or
swinging freely when it separates from the 1. Fully retract the ram on the hydraulic
suspension cylinder rod. Improper support cylinder. Turn off the hydraulic power
of the spindle hub assembly can cause the supply and release all pressure in the
tooling to drop, and can result in property system.
damage or personal injury. 2. Disconnect the high pressure hoses from
the hydraulic cylinder.
4. Use the hydraulic power supply to apply
only enough pressure to release (separate)
the spindle/hub assembly from the
suspension cylinder rod.
Components of the 291-4194
Separation Group and
NOTE: After the initial “release” or separation, related tooling are heavy. To
the spindle/hub must remain suspended until prevent personal injury, use
the tooling is removed. two people or a lifting device when handling the
tooling.

3. The 1U-5197 Hydraulic Cylinder weighs

29 kg (63 lbs). Use two people to remove
the hydraulic cylinder from the tooling.
4. The bottom plate weighs 34 kg (75 lbs).
Use two people to support the bottom plate
while loosening and removing the two lower
nuts and washers.

NOTE: Prevent the rod assemblies from

rotating during disassembly with a wrench
placed on the square drive at the top of the
rod.

13
5. Use two people to remove the bottom plate. Service Parts Section
6. Each rod assembly weighs 16 kg (35 lbs).
Support each rod assembly while loosening 2 1
and removing the upper nuts and washers. 4
7
7. Remove each rod assembly.
8. Each top plate weighs 27 kg (50 lbs). 3 6
Loosen the bolts and nuts that secure the
two top plates together.
9. Separate and remove the two top plates. 5
10. Carefully lower the spindle/wheel hub 2 4
8
assembly and remove the lifting device,
link brackets, and three leg chain.
6

Inspection/Cleaning Section 7 0975-09

291-4194 Separation Group

Inspect all component parts of this
Item Part No. Description Qty
tool before each daily use. Check
for damage or excess wear on any 1 291-4196 Top Plate Assembly1 1
part. Replace all damaged or worn 2 9X-2475 M20 x 2.5 Bolt2 2
parts immediately. Never operate equipment 3 8T-3282 Washer2 4
with a known malfunction or leak. 4 6V-7742 M20 x 2.5 Nut2 2
5 291-4195 Rod Assembly1 2
6 — Washer3 4
1. Inspect the separation group for damage
or abnormal wear before each daily use. 7 8C-7328 M48 x 5 Nut 4
Replace all worn or damaged parts 8 291-4197 Bottom Plate Assembly1 1
immediately. — 224-0554 Warning Film (Not Shown)4 2
1 Made As Ordered (MAO) Parts Require 8 Week Lead Time.
2. Make sure warning films are in place and 2 Part of 291-4196 Top Plate Assembly.
not damaged. Replace all worn or 3 Dimensions: 54 mm (2.125 in) I.D. x 95 mm (3.375 in) O.D. x
damaged films immediately.
6.36 mm (.250 in) Thick.
4 One Located On Each Top Plate.
3. Make sure all threads are clean. Inspect
for nicks and damage.
4. Clean the separation group with a
non-solvent based cleaner.
5. Store the separation group in a clean, dry,
indoor location.

14
Notes

15
 For information on service tools or shop supplies,
contact Dealer Service Tools on:

Dealer Service Tools

501 S. W. Jefferson
Peoria, IL U.S.A. 61630-2125
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1355
[email protected]

©2006 Caterpillar NEHS0975

16
All Rights Reserved Printed in U.S.A.