Caterpillar Cat 657E WHEEL SCRAPER (Prefix 6PR) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
657E WHEEL SCRAPER

Shutdown SIS
Previous Screen
Product: WHEEL SCRAPER
Model: 657E WHEEL SCRAPER 6PR
Configuration: 657E WHEEL SCRAPER-COAL BOWL 6PR00001-UP (MACHINE) POWERED BY 3408E Engine
Disassembly and Assembly
3408E and 3412E Engines for Caterpillar Built Machines
Media Number -SENR1013-11 Publication Date -01/07/2015 Date Updated -22/08/2016
i03335022
Gear Group (Rear) - Install
SMCS - 1206-012; 1212-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
B FT-1342 Guide Bolt 2
C 1P-0524(1)
Drive Plate 1
D 1P-0513(1)
Drive Plate 1
(1)
Part of the 1P-0520 Driver Group
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: There are many possible configurations of the rear gear group and flywheel housing. The
following procedure illustrates a typical example.
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...

Illustration 1 g00587668
Typical example
1. Install dowel (23) in the camshaft if the dowel was removed.
Typical example
2. Install camshaft gear (22) in position on the camshaft. Install four bolts (21).
3. Install the O-ring seal on gear (20A).
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4. Lightly lubricate the seal on the end of the crankshaft with clean engine oil.
5. Install Tooling (B) in the crankshaft. Install gear (20A).
6. Use the following procedure for assembly of balancer gear (12).
a. Install ring (20), bearing cup (19), and spacer (18) in balancer gear (12).
Note: Spacer (18) must be installed on the deepest side of gear (12) and against ring
(20).
b. Use a press and Tooling (C) in order to install bearing cup (17). Install bearing cup
(17) on the side of the gear that is stamped with the timing mark. Bearing cup (17)
should be in contact with the spacer.
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Typical example
c. Install bearing (16), spacer (15), bearing (14), and shaft (13) in gear (12).
7. Use the procedure in Step 6 in order to assemble idler gear (11).
Typical example
8. Place idler gear (11) and balancer gear (12) in position on the flywheel housing. Make sure
that the oil holes in shafts (10) are in alignment with the holes that are in the flywheel
housing.
Note: Install balancer gear (12) with the timing mark toward the flywheel housing.
9. Install bolts (9).
10. Use the following procedure in order to assemble adapter assemblies (1).
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Typical example
a. If the bearing race was removed, install race (8). Install race (8) in adapter assembly
(1) until the race makes contact with the counterbore.
Typical example
b. Install ring (6), bolts (5), and O-ring seal (7) on adapter assembly (1).
c. Heat bearing (3) to 135 °C (275 °F) for approximately 30 minutes.
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d. Install bearing (3) on gear (2) until the bearing makes contact with the counterbore.
Typical example
e. Install gear (2) and the bearing in adapter assembly (1).
f. Use a press and Tooling (D) in order to install bearing (4) in adapter assembly (1).
Install the bearing until the bearing makes contact with the counterbore.
End By:
a. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
Remove and Install".
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Jan 30 17:30:02 UTC+0800 2021
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Shutdown SIS
Previous Screen
i04406249
Flywheel - Remove
SMCS - 1156-011
Removal Procedure
Table 1
Required Tools
A
FT-1341 Bracket Assembly 1
1B-3623 Bolt 2
B FT-1342 Guide Bolt 2
C 138-7575 Link Bracket 1
NOTICE
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Typical example
1. Remove six bolts (1) that hold the flywheel in position.
2. Install Tool (A) in order to hold the crankshaft gear in position.
3. Remove the remainder of bolts (1) .
Typical example
4. Install Tools (B) .
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Typical example. Tooling (C) is not the tooling called out in the Table.
5. Fasten Tool (C) to a hoist and place the tool in position in the groove of flywheel (2) .
6. Pull flywheel (2) onto Tool (A) .
7. Remove Tool (A) .
8. Remove Flywheel (2) with Tool (C) .
The weight of the flywheel is approximately 78 kg (172 lb).
9. If necessary, remove the ring gear from flywheel (2) .
Sat Jan 30 17:30:58 UTC+0800 2021
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Shutdown SIS
Previous Screen
i04406250
Flywheel - Install
SMCS - 1156-012
Table 1
Required Tools
A FT-1342 Guide Bolt 2
B 138-7575 Link Bracket 1
NOTICE
1. Heat the ring gear to a maximum temperature of 300 °C (572 °F), and install the ring gear
on the flywheel. Ensure that the chamfer of the gear teeth will be toward the starter pinion
after the flywheel is installed.
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Typical example. Tooling (B) shown is not the tooling called out in the Table.
2. Install Tool (A) in the crankshaft.
3. Fasten Tool (B) to a hoist. Install the tool in the groove of flywheel (2) .
The weight of the flywheel is approximately 78 kg (172 lb).
4. Place flywheel (2) in position on Tools (A) .
Typical example
5. Apply clean engine oil or 5P-0960 Molybdenum Grease to the threads of bolts (2) .
6. Install six of the bolts.
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7. Remove Tools (A) and (B) .
8. Install the remainder of bolts (2) . Tighten all of the bolts to a torque of 270 ± 40 N·m (200
± 30 lb ft).
9. Check the runout of the flywheel.
Note: For information on checking for flywheel runout, refer to Testing and Adjusting,
"Flywheel-Inspect".
Note: For more detailed information regarding the flywheel, refer to Specifications, "Flywheel".
Sat Jan 30 17:31:53 UTC+0800 2021
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Shutdown SIS
Previous Screen
i07051211
Crankshaft Rear Seal - Remove
SMCS - 1161-011
Removal Procedure
Table 1
Required Tools
A 1U-7600 Slide Hammer Puller 1
Start By:
a. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
NOTICE
Note: Ensure that the rear gear remains in place when the crankshaft rear seal and
crankshaft wear sleeve are removed.
1. Install two bolts from the flywheel and suitable washers through the rear gear in the
crankshaft.
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2. Use a punch or Tooling (A) to puncture a hole in seal assembly (1). Use Tooling (A) to
remove seal assembly (1).
Sat Jan 30 17:32:49 UTC+0800 2021
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Shutdown SIS
Previous Screen
i01493839
Crankshaft Rear Seal - Install
SMCS - 1161-012
Table 1
Required Tools for Engines with Rear Gear Train
A
5P-7301 Locator 1
5P-7309 Bolt 2
5P-7310 Bolt 2
8T-2683 Seal Installer 1
9S-8858 Nut 1
Required Tools for Engines without Rear Gear Train
B
5P-1733 Locator 1
5P-1737 Bolt 3
6V-6143 Seal Installer 1
9S-8858 Nut 1
NOTICE
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Note: Once the seal and the wear sleeve are separated, these components cannot be used again.
Refer to Special Instruction, SMHS8508, "Special Handling Information and Installation
Instructions for Crankshaft Seal Groups that Have Hydrodynamic Grooves In the Sealing Lip"
before the seal is serviced.
Note: Do not use any type of lubricant during the installation of the crankshaft seal and the wear
sleeve.
Note: Before you install the wear sleeve, inspect the crankshaft for scratches or any distortion on
the surface of the crankshaft that may lead to an out of round condition. Use a polishing cloth and
remove any imperfections on the crankshaft.
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1. Install crankshaft rear seal (6) and wear sleeve (1) with Tool (A) or Tool (B), as follows:
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Typical example
a. Use 169-5464 Quick Cure Primer to clean the outside diameter of crankshaft (3) and
the inside diameter of wear sleeve (1).
b. Apply 4C-9507 Retaining Compound to the outside diameter of crankshaft (3). Apply
4C-9507 Retaining Compound to the inside diameter of wear sleeve (1).
c. Put locator (2) in position on crankshaft (3). Install the bolts (7) that hold the locator
in position on the crankshaft.
Typical example
d. Install wear sleeve (1) and seal (6) on crankshaft (3). Put installer (4) on locator (2).
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Typical example
e. Lubricate the face of nut (5). Install nut (5) on locator (4).
f. Tighten nut (5) until installer (4) contacts locator (2).
g. Remove Tool (A) or (B) and check the crankshaft seal and the wear sleeve for the
correct installation.
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
Sat Jan 30 17:33:45 UTC+0800 2021
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Shutdown SIS
Previous Screen
i04977629
Flywheel Housing - Remove and Install
SMCS - 1157-010
Removal Procedure
Table 1
Required Tools
A 138-7575 Link Bracket 2
Start By:
A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
B. Remove the crankshaft rear seal and the wear sleeve. Refer to Disassembly and Assembly,
"Crankshaft Rear Seal - Remove".
C. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".
NOTICE
Note: There are many possible configurations of the rear gear group and the flywheel housing.
The following procedure illustrates a typical example.
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Typical example
1. Remove exhaust clamp (1) from the right side of the engine.
Typical example
2. Remove exhaust clamp (2) from the left side of the engine.
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Typical example
3. Remove bolts (6), cover (3), bolts (7), cover (4), bolts (8), cover (5), and the gaskets.
Typical example
4. Remove bolts (9) .
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Typical example
5. Install Tools (A), and a suitable lifting device to adapter assembly (11) .
6. Use the correct sized forcing screws (10) in order to separate adapter assembly (11) from
the flywheel housing.
The weight of the adapter assembly is approximately 31 kg (68 lb).
Typical example
7. Remove two nuts (14) and the washers.
8. Remove adapter assembly (15) .
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Typical example
9. Remove O-ring seal (16) from adapter assembly (15), if necessary.
Typical example
10. Remove pin (20), bolts (18), washer (17), and gear (19) from adapter assembly (15), if
necessary.
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Typical example
11. Remove bolts (21) from adapter assembly (22) .
Typical example
12. Install Tools (A). Attach a suitable lifting device to adapter assembly (22) .
13. Use the correct sized forcing screws (10) in order to remove adapter assembly (22) .
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Typical example
14. Install Tools (B). Attach a suitable lifting device to flywheel housing (23) .
The weight of the flywheel housing is approximately 160 kg (350 lb).
15. Remove hose assembly (24) .
16. Remove bolts (25) .
17. Remove flywheel housing (23) .
18. Remove all of the gasket material from the flywheel housing and the cylinder block.
Table 2
Required Tools
A 138-7575 Link Bracket 1
C - Loctite 596 -
NOTICE
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Note: There are many possible configurations of the rear gear group and the flywheel housing.
The following procedure illustrates a typical example.
Note: Check the condition of the O-ring seals. If the O-ring seals are worn or damaged, use new
parts for replacement.
Note: Use new gaskets for installation.
1. Install a new gasket on the cylinder block.
Note: Do not use a gasket adhesive or any other type of sealant on the gasket. All of the
mating surfaces must be free of contaminants.
Typical example
2. Install Tools (B). Attach a suitable lifting device to flywheel housing (23) .
The weight of the flywheel housing is approximately 160 kg (350 lb).
3. Remove plug (26) .
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Typical example
4. Place flywheel housing (23) in position. Use hole (27) in order to make an alignment of the
"V" marks on the balancer gear and the rear crankshaft gear. Make sure to have the number
one cylinder at top center.
5. Install bolts (25) .
Note: Discard bolts used in locations (15) and (16). Use new bolts in these two locations.
6. Use the following torque sequence:
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a. Torque bolts 1 thru 21 in numerical sequence to 40 ± 7 N·m (30 ± 5 lb ft).
b. Torque bolt 1 thru 8 in numerical sequence to 135 ± 15 N·m (100 ± 11 lb ft).
c. Torque bolts 9 thru 21 in numerical sequence to 50 ± 10 N·m (37 ± 7 lb ft).
7. Install hose assembly (24) .
8. Install plug (19) with Tooling (C) on the threads of the plug.
9. Tighten the bolts to the correct torque in the correct numerical sequence. Refer to
Specifications, "Flywheel Housing" for the correct tightening procedure.
Typical example
10. Install Tool (A) in adapter assembly (11). Use a suitable lifting device for lifting the adapter
assembly.
The weight of the adapter assembly is approximately 31 kg (68 lb).
11. Install the gasket for the adapter assembly. Position the adapter assembly on the flywheel
housing.
12. Install washer (13) and bolts (12) .
13. Install bolts (9) .
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Typical example
14. Install adapter assembly (22). Repeat Steps 10 through 13.
Typical example
15. Install pin (20), bolts (18), washer (17), and gear (19) in adapter assembly (15), if the parts
were removed.
16. Install the O-ring seal on adapter assembly (15) .
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Typical example
17. Install adapter (15). Install nuts (14) .
Typical example
18. Position cover (3) and cover (4) on the flywheel housing. Install bolts (6) and bolts (8) .
19. Position cover (4) on the flywheel housing. Install bolts (7) .
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Caterpillar Cat 657E WHEEL SCRAPER (Prefix 6PR) Service Repair Manual Instant Download.pdf

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