R

NEHS1000
June 2008

TOOL
OPERATING
MANUAL
Procedure to Remove Wheel Bearings from
Off-Highway Trucks
SMCS: 4208
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/Inspection Section . . . . . . . . . 3
Safety Section Some photographs or illustrations in this
publication show details that can be different
Safety Icon Nomenclature . . . . . . . . . . . . . . 4
from your service tool. Guards and covers
Personal Protection . . . . . . . . . . . . . . . . . . 4 might have been removed for illustrative
Prohibited Action . . . . . . . . . . . . . . . . . . . . 4 purposes.
Hazard Avoidance . . . . . . . . . . . . . . . . . . . 4 Continuing improvement and advancement of
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . 5 product design might have caused changes to
General Information Section your service tool, which are not included in this
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 7 publication.
Applications . . . . . . . . . . . . . . . . . . . . . . . . . 7 Whenever a question arises regarding your
Additional Required Tooling. . . . . . . . . . . . . 8 service tool or this publication, please consult
Dealer Service Tools (DST) for the latest
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . 8 available information.
301-5718 Bearing Removal Group . . . . . . 8
301-5725 Bearing Removal Group . . . . . . 9 Safety Section
T-Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 The Safety section lists basic safety
Specifications. . . . . . . . . . . . . . . . . . . . . . . 10 precautions.
Operation Section Read and understand the basic precautions
Initial Set-up . . . . . . . . . . . . . . . . . . . . . . . . 11 listed in the Safety section before operating or
Additional Required Tooling. . . . . . . . . . . 11 performing maintenance and repair on this
service tool.
Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 12 General Information Section
Measurement . . . . . . . . . . . . . . . . . . . . . . 12 The General Information section describes
Tooling Assembly. . . . . . . . . . . . . . . . . . . 13 tooling functions and features. It provides
Bearing Cup Removal . . . . . . . . . . . . . . . 20 useful information on individual parts,
301-5718 Tool Usage Chart. . . . . . . . . . . 22 additional tooling, and resources.
301-5725 Tool Usage Chart. . . . . . . . . . . 23 Operation Section
Maintenance Section
The Operation section is a reference for the
Cleaning and Inspection . . . . . . . . . . . . . . 24 new operator and a refresher for the
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 experienced operator.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . 24 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 Impact hazard (hydraulic hose)
Safety Icon Nomenclature
Pinch point
Personal Protection/Important
Information Pressurized air
Read the manual
Pressurized fluid
Eye protection
Projectile hazard
Ear protection
Safety alert symbol
Face protection
Slipping hazard
Foot protection
Tripping hazard
Hand protection

Inspect equipment
AR N I
NG

Legible labels

Prohibited Action
No smoking

Hazard Avoidance
Bending hazard (hydraulic hose)

Crushing hazard

Crushing hazard (foot)

Fire hazard

High-pressure fluid hazard

4
Safety Warnings WARNING
Personal Protection/Important Information
Personal injuries
can occur as a
WARNING result of using
To avoid personal injury or death, pressurized air.
carefully read and understand all Maximum air pressure at the nozzle must be
instructions before attempting to below 205 kPa (30 psi) for cleaning
operate any equipment or tools. purposes. Wear protective clothing,
Do not operate or work on a machine unless protective glasses, and a protective face
you read and understand the instructions shield when using pressure air.
and warnings in this and all other applicable
manuals. Contact Dealer Service Tools for
replacement manuals. Proper care is your Prohibited Action
responsibility. Always follow all State and
Federal health and safety laws and/or local WARNING
regulations.
Potential pinch point. Do not place
To prevent possible damage to your hand between the T-pin and
your hearing, always wear ear wheel assembly when positioning
protection when using this tool slide bars.
and/or working around noise
generating tools.
Do not drop heavy objects on
To avoid eye injury, hoses. A sharp impact can cause
always wear protective internal damage to hoses.
glasses or face shield. Applying pressure to a damaged
Make sure no one can hose can cause it to rupture, resulting in
be injured by flying objects or debris when personal injury
using tools or working on a component. Avoid bent or kinked hydraulic
Clean up all leaked or hoses. Using a bent or kinked
spilled fluids immediately. hydraulic hose can cause severe
Oil, fuel, or cleaning fluid back-pressure. Sharp bends and
leaked or spilled onto any kinks can internally damage the hose,
hot surfaces or electrical components can leading to premature hose failure and can
cause a fire, resulting in personal injury or result in personal injury.
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.

5
Safety Warnings Continued WARNING
Hazard Avoidance
On front wheel assemblies,
positioning crossbar spacers
WARNING inboard of the wheel rim can
Inspect prior to each use for nicks, block bearing removal. This
burrs, dents, cracks, bends, or can result in dangerous breakage and/or release
worn parts. If damage is found, of pressure, causing personal injury or death.
discontinue use until repaired, Sudden movement and/or
inspected, and released for use by an release of pressure, can
approved inspector. cause personal injury or
Make sure all warning labels are in death. Stand well clear of
AR N I
NG
place and are readable. Always the wheel assembly during bearing removal.
replace missing or damaged labels Do not place your hand or any part of your
before using this tool group. body between the wheel assembly, and
bearing removal tooling during operation.
High pressure – make sure
all hydraulic connections For additional product support questions
are completely tightened. concerning this tool, contact the Caterpillar
Check for leaks Dealer Service Tools Hotline at:

Pressure can be trapped U.S.A.: 1-800-542-8665

in a hydraulic system. Illinois: 1-800-541-8665
Use caution when Canada: 1-800-523-8665
disconnecting hydraulic World: 1-309-675-6277
lines or fittings. High pressure oil that is Fax: 1-309-494-1355
released can cause personal injury. [email protected]
Leaking fluid that is under
pressure can penetrate
body tissue. Fluid
penetration can cause
serious injury and possible death. If fluid is
injected into your skin, you must obtain
treatment immediately. Seek treatment from a
doctor that is familiar with this type of injury.
The bearing removal
tooling is heavy. To avoid
personal injury always use
care when handling heavy
components. Overhead lifting devices, with
adequate capacity must be used for assembly
and operation of the tooling.

6
General Information Section WARNING
Introduction The bearing removal
Two tool groups have been created to remove tooling is heavy. To avoid
large bearing cups from the front and rear personal injury always use
wheel assemblies of off-highway trucks. The care when handling heavy
tools have been designed to work in multiple components. Overhead lifting devices, with
applications, by the truck model and wheel adequate capacity must be used for assembly
assembly. Bearing removal tooling is and operation of the tooling.
assembled from various parts within the
301-5718 or 301-5725 Bearing Removal
Groups. The Tool Usage Chart in this manual, The bearing removal tool groups are heavy
provides the complete list of model and wheel and require the use of an overhead lifting
assembly part numbers applicable to this device with adequate capacity. The 301-5718
tooling. Bearing Removal Group weighs approximately
157 kg (344 lbs) and the 301-5725 Bearing
Removal Group weighs approximately 668 kg
(1473 lbs).

Applications
The 301-5718 Bearing Removal Group is used
on 769D through 777F Off-highway Trucks.
This tooling is used for both the inboard and
outboard bearing cups in the front and rear
wheel assemblies. Refer to the “301-5718 Tool
Usage” chart in this manual for a complete
description of the required tooling for each
wheel assembly application.

The 301-5725 Bearing Removal Group is used

on 777D through 797 Off-highway Trucks. This
tooling is also used for both the inboard and
outboard bearing cups in the front and rear
wheel assemblies. Refer to the “301-5725 Tool
Usage” chart in this manual for a complete
description of the required tooling for each
wheel assembly application.

1000-01a

Both bearing removal tool groups are used

with an electric/hydraulic power supply,
hydraulic hoses, couplers, and a pressure
gauge, which are not included in the tool
groups. Refer to the “Additional Tooling”
section for part numbers and tool descriptions.

7
Additional Required Tooling 301-5718 Bearing Removal Group
To properly operate the bearing cup removal 5
6
tooling, the following additional tooling is 1
required.
4

3 11
Part No. Description Quantity
2
3S-6224 Electric/Hydraulic Pump 1 13
6D-7726 Hydraulic Hose 2 10
1P-2376 Coupler Assembly 2
9
8T-5343 Pressure Gauge 1
12

7
For more information on required tooling, refer
to Specifications section and Power Supply
Setup in the Operation section in this manual. 8

1000-01

301-5718 Bearing Removal Group

Nomenclature
Each bearing removal tool group has a
crossbar assembly (1) with adjustable 301-5718 Bearing Removal Group
crossbar spacers (2), and a double acting Item Part No. Description
hydraulic cylinder (4). 1 301-5719 Crossbar
In addition, each bearing removal tool group 2 — Crossbar Spacer Assembly
includes two interchangeable hub assemblies (Not Serviced Separately)
(7 and 10), and two different length puller 5P-2228 Bolt (Qty 4)
studs (6 and 12), used with two fast-runner 3 138-7573 Link Bracket (Qty 2)
nuts (5). 4L-9337 Bolt (Qty 2)
Each hub assembly also has multiple slide bar 8T-4896 Washer (Qty 2)
sets (8 and 11) to accommodate the various 4 316-1489 Hydraulic Cylinder
bearing diameters. 5 9U-6809 Fast Runner Nut-M36 (Qty 2)
6 9U-6811 Puller Stud-M36x1575 mm (62.01 in) long

NOTE: When assembling tooling for a specific 7 301-5722 Hub Assembly (Large)
application, only one puller stud, one hub 8 301-5723 Slide Bar Set
assembly, and one slide bar set will be used 317-7980 Slide Bar-87.0 mm (3.42 in) long
with the appropriate cross bar, based on the 301-5724 Slide Bar Set
Tool Usage Charts in this manual. 317-7981-132.0 mm (5.20 in) long
(Not Serviced Separately)
9 — T-Pin (Qty 3 Per Hub)
10 301-5720 Hub Assembly (Small)
11 301-5721 Slide Bar Set
317-8789 Slide Bar-69.6 mm (2.75 in) long
12 9U-7998 Puller Stud-M36x920 mm (36.22 in) long
13 224-0554 Warning Film (Qty 2)

8
301-5725 Bearing Removal Group 301-5725 Bearing Removal Group Continued
Item Part No. Description
6 12 4C-8150 Puller Stud-M64x1829.0 mm (72.01 in) long
5 1
13 138-7573 Bracket Link Assembly (For Small Hub)
4
5M-3062 Bolt
5P-1075 Washer
3 2
12 14 224-0554 Warning Film (Qty 2)
14
13
3 11 NOTE: Each hub assembly includes three
9 T-pins that secure slide bar sets in position.
10 Replacement T-pins are available through:
7
Carr Lane Manufacturing Co.
8 P.O. Box 191970
St Louis, Missouri 63119-7970 USA
Phone: 314-647-8200, Fax: 314-647-5736
Website: www.carrlane.com
1000-21

301-5725 Bearing Removal Group

301-5725 Bearing Removal Group

Item Part No. Description

1 301-5726 Crossbar
2 — Crossbar Spacer Assembly 1000-20

(Not Serviced Separately)

5P-2526 Bolt (Qty 4) Carr Lane Part No. Used With
3 138-7575 Bracket Link Assembly (Qty 3)
CL-13-TP 301-5727 Hub Assembly
5P-2566 Bolt (Qty 3)
CL-38-TP 301-5720 Hub Assembly
8T-4223 Washer (Qty 3) 301-5722 Hub Assembly
4 316-1489 Hydraulic Cylinder CL-40-TP 301-5730 Hub Assembly
5 9U-6800 Fast Runner Nut-M64 (2)
6 9U-6702 Puller Stud-M64x2616.0 mm (103.0 in) long
7 301-5727 Hub Assembly (Large)
8 301-5728 Slide Bar Set-
317-7985 Slide Bar-190.0 mm (7.48 in) long
301-5729 Slide Bar Set
317-7986 Slide Bar-330.0 mm (13.0 in) long
9 — T-Pin (Qty 3 Per Hub)
10 301-5730 Hub Assembly (Small)
11 301-5731 Slide Bar Set
317-7987 Slide Bar-120.0 mm (4.72 in) long
301-5732 Slide Bar Set
317-7988 Slide Bar-155.0 mm (6.10 in) long

9
Specifications 316-1490 Double Acting Cylinder
(Part of 301-5725 Bearing Removal Group)
301-5718 Bearing Removal Group
163 kg (359 lbs) Overall length 347.6 mm (13.7 in)
Cylinder diameter 247 mm (9.7 in)
Part No. Description Weight
Stroke 203.0 mm (8.0 in)
301-5719 Crossbar 102.4 kg (225.8 lbs)
Weight 111.0 kg (244.7 lbs)
316-1489 Hydraulic Cylinder1 35.4 kg (78.0 lbs)
Capacity 136.0 metric ton (150 ton)
301-5720 Hub Assembly 4.7 kg (10.4 lbs)
Center hole diameter 79.2 mm (3.12 in)
301-5721 Slide Bar Set 1.3 kg (2.9 lbs)
Maximum operating pressure 70,000 kPa (10,153 PSI)
301-5722 Hub Assembly 11.6 kg (25.6 lbs)
Repair seal kit 316-1501
301-5723 Slide Bar Set 4.0 kg (8.7 lbs)
Decal NEEG3087
301-5724 Slide Bar Set 6.2 kg (13.6 lbs)
9U-7998 M36 x 4 Puller Stud2 6.4 kg (14.0 lbs)
9U-6811 M36 x 4 Puller Stud3 10.8 kg (23.7 lbs) Additional Required Tooling
9U-6809 M36 x 4 Nut 0.5 kg (1.2 lbs)
1 Referto 316-1489 Hydraulic Cylinder Specification Chart.
3S-6224 Electric Hydraulic Pump
2 920 mm (36.2 in) Length. 3 1575 mm (62.0 in ) Length.
Power requirements 115 Volts, 50-60 Hz
Motor horsepower 1.125 HP
301-5725 Bearing Removal Group Reservoir capacity 7.6 L (2.0 gal)

729 kg (1607 lbs) Maximum pressure 68,947 kPa (10,000 PSI)

Control valve 3-Position
Part No. Description Weight
Electronic control Toggle switch
301-5726 Crossbar 278.6 kg (614.1 lbs)
316-1490 Hydraulic Cylinder1 111 kg (244.7 lbs)
301-5727 Hub Assembly 84.4 kg (186.2 lbs) 6D-7726 Hydraulic Hose
301-5728 Slide Bar Set 30.0 kg (66.1 lbs) Length 3.5 m (11.5 ft)
301-5729 Slide Bar Set 53.9 kg (118.9 lbs) Inside diameter 6.35 mm (.250 in)
301-5730 Hub Assembly 24.6 kg (51.2 lbs) Maximum pressure 68,947 kPa (10,000 PSI)
301-5731 Slide Bar Set 7.2 kg (15.8 lbs) Coupling thread size 1/4 in NPTF
301-5732 Slide Bar Set 9.9 kg (21.8 lbs)
4C-8150 M64 x 6 Puller Stud2 46.2 kg (101.9 lbs)
9U-6702 M64 x 6 Puller Stud3 66.0 kg (145.6 lbs)
1P-2376 Coupler Assembly
9U-6800 M64 x 6 Nut 6.0 kg. (13.3 lbs) Style Quick disconnect (female)
1 Referto 316-1490 Hydraulic Cylinder Specification Chart. Maximum pressure 68,947 kPa (10,000 PSI)
2 1829 mm (72.0 in) Length. 3 2616 mm (103.0 in ) Length.
Coupling thread size 1/4 in NPT

316-1489 Double Acting Cylinder 8T-5343 Pressure Gauge

(Part of 301-5718 Bearing Removal Group)
Mount style Bottom mount
Overall length 323.7 mm (12.7 in) Thread size 1/4 in NPT
Cylinder diameter 159.0 mm (6.3 in) Maximum pressure
Stroke 165.1 mm (6.5 in) 68,947.6 kPa (10,000 PSI)
Weight 35.4 kg (78.0 lbs) Accuracy Grade A
Capacity 54.4 metric ton (60 ton) Scales 0-70,000 kpa (10,000 PSI)
27, 45, 63.5, 91, and 136 metric tonne
Center hole diameter 53.8 mm (2.12 in)
(30, 50, 70, 100, and 150 ton)
Maximum operating pressure 70,000 kPa (10,153 PSI)
Repair seal kit 316-1500
Decal NEEG3086

10
Operation Section Tool Usage
The first step in the bearing removal process is
Power Supply Setup the correct selection and assembly of the
The electric/hydraulic pump, hoses, and tooling. This is important and required for
pressure gauge may require an initial set-up. each wheel application listed in the Tool
If necessary, use the following procedure for Usage Charts in this manual.
set-up of the power supply. Bearing removal tooling must be assembled
as shown in the Nomenclature section and
described in this manual.
Part No. Description Quantity

3S-6224 Electric/Hydraulic Pump 1

This tooling will not work in every bearing cup
removal application. A Tool Usage chart in
6D-7726 Hydraulic Hose 2
this manual lists part numbers of front and rear
1P-2376 Coupler Assembly 2 wheel assemblies that this tooling will fit.
8T-5343 Pressure Gauge 1
If the wheel assembly part number is not
available, measurements must be taken to
NOTE: 3S-6224 Electric-Hydraulic Pump determine if the tooling can be used.
requires a 115VAC, 50-60 Hz power supply to
operate.
1. Measure the distance the the bearing cup
extends from the edge of the wheel housing
as shown in the illustration. This dimension
WARNING is tooling contact area (A)
High-pressure. Make sure
all hydraulic connections
are completely tightened.
Check for leaks

A
1. Install a 1P-2376 Female Coupler on one
end of each 6D-7726 Hose.
2. Attach the other end of each hose to
3S-6224 Electric Hydraulic Pump. 1000-17
3. Install 8T-5343 Pressure Gauge with
(A) Tooling Contact Area.
pressure [68950 kPa (10,000 psi)] and
tonnage [150 ton (136T)] scales onto
3S-6224 Electric-Hydraulic Pump.

NOTE: For more information on hydraulic

pump connections, refer to the hydraulic pump
operating manual.

11
2. Dimension A (tooling contact area) must Operation
equal or exceed the minimum contact
distance requirement shown below Measurement
(dimension AA).
1. Measure and record wheel dimensions (B)
a. The minimum required distance when and (C) in order to select and assemble the
using the 301-5720 Hub Assembly is applicable bearing cup removal tooling.
5.5 mm (.22 in).
a. Measure and record the distance from
b. The minimum required distance when the top of the wheel housing to the
using the 301-5722 Hub Assembly is bottom of the bearing cup
7.5 mm (.30 in). (dimension B).
c. The minimum required distance when b. Measure and record the top diameter
using the 301-5727 and 301-5730 Hub (C) of the wheel assembly.
Assembly is 10.5 mm (.41 in).

NOTE: Measurement (C) is only required

when using the crossbar spacer assemblies
on the crossbar.

B
AA
1000-04

NOTE: Minimum required distance (AA) is the

width of the machined notch on the end of the
slide bar plus 0.5 mm (.02 in). B

Notice C
If distance (A) is less than minimum required 1000-02

distance (AA), this tool must not be used. Rear Wheel Assembly. (B) Vertical Distance.
Using this tooling with less than the minimum (C) Wheel Diameter.
required contact area can damage both the
wheel assembly and the tooling. If the contact
area is less than required, refer to the “Altering
the Wheel” section in SEBF9118 Procedure to
Remove Large Wheel Bearings for additional
information on reworking the wheel assembly
in order to use the tooling.

12
 C Tooling Assembly

WARNING
B
The bearing removal
tooling is heavy. To avoid
personal injury always use
care when handling heavy
B components. Overhead lifting devices with
adequate capacity, must be used for assembly
and operation of the tooling.

C
1. Refer to the Tool Usage charts and
1000-03 Nomenclature charts to determine the
Front Wheel Assembly. (B) Vertical Distance. specific components for the applicable
(C) Wheel Diameter. wheel assembly.

2. Use the Tool Usage chart to choose the NOTE: When assembling tooling for a specific
proper tool group and tooling for the application, only one puller stud, one hub
specific wheel and bearing. assembly, and one slide bar set will be used
with the appropriate cross bar, based on the
Tool Usage Charts in this manual.
NOTE: For rear wheel bearing cup removal,
the crossbar spacer assemblies are optional. 8 9
1
There is normally enough clearance to remove
the bearing without adding the crossbar 2
spacer assemblies. Front wheel bearing cup 4
removal requires the crossbar spacer
assemblies to provide adequate bearing cup
clearance.
3

1000-01b

(1) Crossbar. (2) Hydraulic Cylinder.

(3) Small Hub Assembly. (4) Small Slide Bar Set.
(5) Large Hub Assembly. (6) Large Slide Bar Set.
(7) Short Puller Stud. (8) Long Puller Stud.
(9) Fast Runner Nut.

NOTE: For reference during tooling assembly,

write down the tooling components and T-pin
position required for the specific bearing cup
being removed.

13
2. If crossbar spacers are required, use 3. Securely tighten spacer clamp bolts (3) to
recorded dimension (C) (wheel diameter) lock the crossbar spacers in position.
from the Measurements section to position
crossbar spacer assemblies (2) on
crossbar (1). The contact area must be
positioned over the top face of the wheel WARNING
assembly when the tooling is set in place.
On front wheel assemblies,
Make sure the spacing is equal on both
positioning crossbar spacers
sides of the crossbar centerline.
inboard of the wheel rim can
block bearing removal. This
Each crossbar spacer for 301-5719
can result in dangerous breakage and/or release
Crossbar weighs 11.2 kg (24.7 lbs).
of pressure, causing personal injury or death.
Each crossbar spacer for 301-5726
Crossbar weighs 23.5 kg (51.7 lbs).
NOTE: When using the tooling on front wheel
bearings, the inside edge of crossbar spacer
(2) must be positioned slightly outboard of the
wheel’s inner diameter to allow clearance for
bearing removal. Clamp bolts (3) must be
used to lock spacers on crossbar (1),
outboard of inner wheel lip, as shown.

1
3

1
2
2
C
1000-18

(1) Crossbar. (2) Crossbar Spacers. (C) Recorded

Dimension (Wheel Diameter).

Notice
If the crossbar spacers are positioned
off-center, excessive force will be applied to
one side of the tooling, causing possible
damage.
1000-19

Front Wheel Assembly. (1) Crossbar. (2) Crossbar

Spacer Centered on Wheel Lip. (3) Clamp Bolt.

14
NOTE: For rear wheel bearing cup removal, 4. Attach the crossbar to an overhead lifting
crossbar spacer assemblies (2) are optional. device using chains. Make sure the chains
There is normally enough clearance to remove will not interfere with the installation of the
the bearing cup without adding the crossbar hydraulic cylinder.
spacer assemblies. If crossbar spacers are
required, clamp bolts (3) lock spacers on 301-5719 Crossbar and spacer assembly
crossbar (1), centered over the wheel lip, as weighs 102.4 kg (275.8 lbs).
shown.
301-5726 Crossbar and spacer assembly
weighs 278.6 kg (614.1 lbs).
1
3

1000-06

NOTE: Optional 6V-3145 Load Lever can be

1000-05 used to prevent chain interference with the
hydraulic cylinder.
Rear Wheel Assembly. (1) Crossbar. (2) Crossbar
Spacer Centered on Wheel Lip. (3) Clamp Bolt.

15
 NOTE: When assembling tooling for a specific
WARNING application, only one puller stud, one hub
assembly, and one slide bar set will be used
During assembly, the
with the appropriate cross bar, based on the
hydraulic cylinder is not
Tool Usage Charts in this manual.
securely attached to the
crossbar. The cylinder is
capable of falling at this step of the
6. Install the puller stud and upper fast runner
assembly procedure and could cause
nut.
personal injury or death.
a. Insert the puller stud through the
crossbar and hydraulic cylinder.
5. Position the hydraulic cylinder on top of the
crossbar. 9U-7998 Puller Stud weighs 6.4 kg
(14.0 lbs).
316-1489 Hydraulic Cylinder weighs
35.4 kg (78.0 lbs). 9U-6911 Puller Stud weighs 10.8 kg
(23.7 lbs).
316-1490 Hydraulic Cylinder weighs
b. Install a fast runner nut onto the top of
111.0 kg (244.7 lbs).
the puller stud.

9U-6809 Nut weighs 0.5 kg (1.1 lbs).

NOTE: 316-1489 Hydraulic Cylinder has
removable D-shaped handles. 316-1490
9U-6800 Nut weighs 6.0 kg (13.3 lbs).
Hydraulic Cylinder has lifting eye.

1000-07

1000-08

16
7. Install the hub assembly and lower fast
runner nut. WARNING
a. Install the hub assembly over the puller Individual slide bars can weigh up
stud below the cross bar. to 18kg (39.6 lbs) each and could
cause personal injury if allowed to
301-5720 Hub Assembly weighs fall. Always install T-pins to retain
4.7 kg (10.4 lbs). slide bars in the hub assembly.

301-5722 Hub Assembly weighs

11.6 kg (25.6 lbs). 8. Using the Tool Usage chart, determine
which holes in the hub assembly and slide
301-5730 Hub Assembly weighs bars will be used to properly locate the
24.6 kg (51.2 lbs). slide bars for bearing cup removal. Each
hub assembly is marked with up to three
301-5727 Hub Assembly weighs letter locations (A, B, or C). Each slide bar
84.4 kg (186.2 lbs) is also marked with up to four number
locations (1, 2, 3, or 4). Do not set the final
b. Install the lower nut to secure the hub
locations of the slide bars until the tooling is
assembly on the puller stud.
placed into the wheel hub.
9U-6809 Nut weighs 0.5 kg (1.1 lbs).

9U-6800 Nut weighs 6.0 kg (13.3 lbs).

A A

B B
C C

1
3 2
4

1000-10

(A), (B), (C) Hub Assembly Markings.

(1), (2), (3), (4) Slide Bar Markings.

1000-09

17
9. Insert three slide bars into the hub
assembly. Install T-pin through the slot in WARNING
hub assembly and the center hole in the
The bearing removal
slide bar. Push the slide bars toward the
tooling is heavy. To avoid
center of the hub assembly as far as
personal injury always use
possible.
care when handling heavy
components. Overhead lifting devices, with
adequate capacity, must be used for assembly
and operation of the tooling.

11. Use the overhead lifting device to lift the

complete bearing removal group using the
attached link brackets and lower the
hub/slide bar assembly into the top of the
wheel.
1000-11

NOTE: Do not remove the lifting chains from

the crossbar. Allow the chains to hang loosely,
10. Adjust the height of the hub assembly to with the full weight of the crossbar assembly
the previously recorded dimension (B). on the wheel assembly.
Allow an additional 12 mm (0.5 in) for
clearance when installing the tooling into
the wheel assembly.

1000-12

(B) Recorded Dimension (Top of Wheel Housing to

Bottom of Bearing Cup).

18
 13. Insert T-pins (1) in the outer, center hole of
WARNING slide bars (2). Use the T-pins to push the
slide bars out until they are in position
On front wheels, placing
under the bearing cup face (3).
the crossbar spacers
inboard of the wheel rim
can block bearing
removal. This can result in dangerous 1
breakage and/or release of pressure, 3
causing personal injury or death.

12. Center the crossbar/hub assembly on the

2
wheel assembly. Lift the tooling and
reposition the crossbar if necessary. If the
crossbar spacer assemblies are being
used, make sure the bottom surface fully 1000-14

contacts the wheel flange.

(1) T-pin. (2) Slide Bar. (3) Bearing Cup.

NOTE: When using the tooling on front wheel

14. Refer to the Tool Usage chart. Insert the
bearings, the inside edge of the crossbar
T-pins in the specified hub hole (marked
spacer assembly (1) must be positioned
A, B, C) which aligns with the correct slide
slightly outboard of the wheel inner diameter
bar hole (marked 1, 2, 3, or 4). The
(2) to allow clearance for bearing cup removal.
example shows the pin location “C2”.

2
1

C
A
B

C
A
B

1000-13

Front Wheel Assembly. (1) Crossbar Spacer Assembly.

(2) Inner Diameter of Wheel Lip.
C, 2

WARNING 1000-15

Potential pinch point. To avoid (A), (B), (C) Hub Assembly Markings.
injury, do not place your hand (C, 2) Specified Pin Location Example.
between the T-pin and wheel
assembly when positioning slide
bars.

19
Bearing Cup Removal 5. Use the hydraulic pump control lever to
actuate the cylinder and remove the
1. Adjust the nut on top of the cylinder to raise bearing cup.
the hub until the three slide bars engage
the bottom of the bearing cup.
NOTE: The break out force necessary for
removing the bearing cup may briefly exceed
WARNING the maximum force listed in the Tool Usage
chart, but should never exceed 1.5 times the
High-pressure. Make sure maximum force listing.
all hydraulic connections
are completely tightened.
Check for leaks

2. Connect the hydraulic power supply hoses

to the hydraulic cylinder quick disconnect
fittings.
3. Connect the hydraulic pump power supply
cord to a grounded 115VAC, 50-60 Hz
power supply.
4. Refer to the Tool Usage chart and adjust
the pressure at the hydraulic pump to limit
the maximum cylinder force as shown in the
chart.

NOTE: For more information on adjusting

hydraulic pressure refer to the hydraulic pump
operating manual.

WARNING
Sudden movement and/or
release of pressure, can
cause personal injury or
1000-16
death. Stand clear of the
wheel assembly during bearing cup removal.
Do not place your hand or any part of your
body between the wheel assembly, and 6. Once the bearing cup breaks loose, stop
bearing removal tooling during operation. the hydraulic pump and make sure the
three slide bars are still fully engaged
under the bearing cup. Reposition the
slide bars as needed.

20
7. Start the hydraulic pump and use the 10. Reposition the wheel assembly with the
control lever to completely remove the other bearing cup facing up and repeat
bearing cup from the wheel assembly. the bearing cup removal procedure.

NOTE: After use, disassembly of the tooling is

WARNING recommended. For more information refer to
the Maintenance section in this manual.
The bearing removal
tooling is heavy. To avoid
personal injury always use
care when handling heavy
components. Overhead lifting devices with
adequate capacity, must be used for assembly
and operation of the tooling.

8. Use the overhead lifting device to carefully

remove the tooling and bearing cup from
the wheel assembly.
9. With the bearing cup supported, insert
T-pins in center slots, and push slide bars
inward to release the bearing cup from the
tooling.

1000-01a

1000-11

21
 Front/ Inboard/ Bearing Cup Hub Slide Bar Hub Slide Bar Max Force
Model Wheel Rear Outboard ID mm (in) Assembly 1 Set Hole Hole English Tons
769D/771D 271-3761 Front Inboard 189.25 (7.45) 301-5720 301-5721 B 2 20
271-3761 Front Outboard 172.71 (6.80) 301-5720 301-5721 B 1 20
8X-1047 Rear Inboard 265.70 (10.46) 301-5722 301-5723 B 3 35
8X-1047 Rear Outboard 265.70 (10.46) 301-5722 301-5723 B 3 35
770 271-3761 Front Inboard 189.25 (7.45) 301-5720 301-5721 B 2 20
271-3761 Front Outboard 172.71 (6.80) 301-5720 301-5721 B 1 20
237-3810 Rear Inboard 265.70 (10.46) 301-5722 301-5723 B 3 35
237-3810 Rear Outboard 265.70 (10.46) 301-5722 301-5723 B 3 35
772 271-3761 Front Inboard 189.25 (7.45) 301-5720 301-5721 B 2 20
271-3761 Front Outboard 172.71 (6.80) 301-5720 301-5721 B 1 20
238-9911 Rear Inboard 278.00 (10.94) 301-5722 301-5723 B 4 35
238-9911 Rear Outboard 278.00 (10.94) 301-5722 301-5723 B 4 35
301-5718 Tool Usage Chart

773E/775E 6G-6438 Front Inboard 210.66 (8.29) 301-5720 301-5721 B 4 20

6G-6438 Front Outboard 182.10 (7.17) 301-5720 301-5721 A 3 20
8X-9576 Rear Inboard 307.35 (12.10) 301-5722 301-5724 A 1 35

22
8X-9576 Rear Outboard 338.10 (13.31) 301-5722 301-5724 A 2 35
773F/775F 6G-6438 Front Inboard 210.66 (8.29) 301-5720 301-5721 B 4 20
6G-6438 Front Outboard 182.10 (7.17) 301-5720 301-5721 A 3 20
271-9274 Rear Inboard 307.35 (12.10) 301-5722 301-5724 A 1 35
271-9274 Rear Outboard 338.10 (13.31) 301-5722 301-5724 A 2 35
777D 138-9312 Front Inboard 253.19 (9.97) 301-5722 301-5723 B 2 35
138-9312 Front Outboard 219.49 (8.64) 301-5722 301-5723 A 1 35
777F 138-9312 Front Inboard 253.19 (9.97) 301-5722 301-5723 B 2 35
138-9312 Front Outboard 219.49 (8.64) 301-5722 301-5723 A 1 35
1 Use 301-5719 Crossbar and 316-1489 Hydraulic Cylinder with 301-5720 or 301-5722 Hub Assembly.
 Front/ Inboard/ Bearing Cup Hub Slide Bar Hub Slide Bar Max Force
Model Wheel Rear Outboard ID mm (in) Assembly 2 Set Hole Hole English Tons
777D 216-2624 Rear Inboard 360.31 (14.18) 301-5730 301-5731 B 2 80
216-2624 Rear Outboard 321.61 (12.66) 301-5730 301-5731 B 1 80
777F 285-5297 Rear Inboard 360.31 (14.18) 301-5730 301-5731 B 2 80
285-5297 Rear Outboard 321.61 (12.66) 301-5730 301-5731 B 1 80
785 8X-2634 Front Inboard 338.10 (13.31) 301-5730 301-5731 A 4 80
8X-2634 Front Outboard 318.14 (12.52) 301-5730 301-5731 A 3 80
213-3732 Rear Inboard 454.16 (17.88) 301-5727 301-5728 A 3 150
213-3732 Rear Outboard 454.16 (17.88) 301-5727 301-5728 A 3 150
789 106-7888 Front Inboard 338.10 (13.31) 301-5730 301-5731 A 4 80
106-7888 Front Outboard 318.14 (12.52) 301-5730 301-5731 A 3 80
214-1644 Rear Inboard 533.65 (21.00) 301-5727 301-5728 C 2 150
214-1644 Rear Outboard 533.65 (21.00) 301-5727 301-5728 C 2 150
301-5725 Tool Usage Chart

793 Std 125-5938 Front Inboard 396.86 (14.55) 301-5730 301-5732 B 1 80

125-5938 Front Outboard 318.14 (12.52) 301-5730 301-5731 A 3 80
135-2555 Rear Inboard 533.65 (21.00) 301-5727 301-5728 C 2 150

23
135-2555 Rear Outboard 533.65 (21.00) 301-5727 301-5728 C 2 150
793 XLP 265-3191 Front Inboard 454.16 (17.88) 301-5727 301-5728 A 3 150
265-3191 Front Outboard 369.53 (14.55) 301-5730 301-5732 A 2 80
270-4457 Rear Inboard 558.29 (21.98) 301-5727 301-5728 B 3 150
270-4457 Rear Outboard 558.29 (21.98) 301-5727 301-5728 B 3 150
797 144-0803 Front Inboard 522.62 (20.56) 301-5727 301-5728 C 1 150
144-0803 Front Outboard 454.16 (17.88) 301-5727 301-5728 A 3 150
266-3613 Front Inboard 556.86 (21.92) 301-5727 301-5728 B 3 150
266-3613 Front Outboard 454.16 (17.88) 301-5727 301-5728 A 3 150
210-5709 Rear Inboard 719.77 (28.34) 301-5727 301-5729 A 1 150
210-5709 Rear Outboard 719.77 (28.34) 301-5727 301-5729 A 1 150
278-8811 Rear Inboard 719.77 (28.34) 301-5727 301-5729 A 1 150
278-8811 Rear Outboard 719.77 (28.34) 301-5727 301-5729 A 1 150
2 Use 301-5726 Crossbar and 316-1490 Hydraulic Cylinder with 301-5727 or 301-5730 Hub Assembly.
Maintenance Section Storage

WARNING WARNING
Inspect all parts prior to each use Avoid bent or kinked hydraulic
for nicks, burrs, dents, cracks, hoses. Using a bent or kinked
bends, or worn parts. If damage is hydraulic hose can cause severe
found, discontinue use until back-pressure. Sharp bends and
repaired, inspected, and released for use by kinks can internally damage the hose,
an approved inspector. leading to premature hose failure and can
result in personal injury.

Cleaning and Inspection 1. Store the bearing removal tool groups in a

1. After use, disassemble the bearing removal clean dry location. Protect from rust and/or
group components. corrosion.
2. Clean and inspect components for 2. Store the puller studs so that threads are
damaged or worn parts. protected from damage.
3. Lightly lubricate the threads of puller 3. Store other required tooling in a clean dry
stud(s). location. Coil up hydraulic hoses to avoid
kinks, and protect from damage.
4. Each hub assembly should be cleaned and
lubricated for easy movement of the slide
bars.
Maintenance
5. Inspect slide bar contact area for wear or
damage. WARNING
Make sure all warning labels are in
NOTE: The top and bottom of the slide bars AR N I
NG
place and are readable. Always
are identical and are designed to be used on replace missing or damaged labels
both sides. If the machined bearing cup before using this tool group.
contact area on one side is worn or damaged,
turn the slide bar over and use the other side.

1. Make sure all warning labels are clean and

legible. Replace any damaged or missing
films before use.
2. Follow manufacturers recommendations for
hydraulic pump maintenance, including
checking hydraulic fluid level and replacing
the hydraulic fluid and filter.
3. Clean and lubricate puller stud threads and
other components as required to maintain
smooth operation.

NOTE: For more information on hydraulic

pump maintenance, refer to the hydraulic
pump operating manual.

24
Notes

25
Notes

26
Notes

27
 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]

©2008 Caterpillar NEHS1000

28
All Rights Reserved Printed in U.S.A.