Caterpillar cat m318 excavator (prefix 6 es) service repair manual (6es00001 and up)

Service Repair Manual
Models
M318 Excavator

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Product: EXCAVATOR
Model: M318 EXCAVATOR 6ES
Configuration: M318 Excavator 6ES00001-UP (MACHINE) POWERED BY 3116 Engine
Disassembly and Assembly
M318 and M320 Excavators Power Train
Media Number -SENR6258-06 Publication Date -01/08/2008 Date Updated -14/08/2008
i02765718
Differential - Assemble - Rear
SMCS - 3258-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-9352 Engine Stand 1
B
4C-6808 Plate 2
1U-5847 Measuring Shaft As 1
C 4C-3085 Two Jaw Puller 1
D 1P-0520 Driver Group 1
E 1U-5834 Sleeve
F 9U-6046 Seal Installer 1
G
9U-6047 Driver 1
8T-0975 Driver Handle 1
H 6V-7030 Micrometer Depth Gauge Group 1
J 8S-2328 Dial Indicator 1
K 4C-4079 Brake and Electrical Cleaner 1
L 5P-0960 Grease Cartridge 1
M 6V-6640 Sealant 1
N 5P-0960 Grease Cartridge 1
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P 9S-3263 Thread Lock Compound 1
NOTICE
Failure to properly assemble parts or failure to follow established
procedures can lead to damage of the parts and assembly.
To avoid damage to parts, always identify and mark the parts so that
they can be installed in the same location. Ensure that gear surfaces
align. Never force parts during assembly.
Note: If the ring gear or the pinion shaft is damaged, both of the parts must be replaced as a set.
The numbers on the ring gear and the numbers on the pinion shaft must mate. Do not use new
bearings with used bearings in the differential. Mixing new bearings and used bearings will result
in misalignment in the differential and the inability to accurately measure the rolling torque during
the assembly.
Note: Correct measurements and torques are extremely important when the differential is
assembled. Incorrect measurements could cause incorrect tooth contact patterns in the differential.
Incorrect measurements could cause a premature failure. Make sure that all surfaces are clean and
free of oil or dirt prior to taking any measurement. Make sure that all surfaces are clean and free of
oil or dirt prior to assembly.
Illustration 1 g00675868
1. Securely attach the differential carrier housing to Tooling (A) .
2. Install Tooling (B) in the differential housing, as shown. Use the bearing caps to hold
Tooling (B) in position.
3. Use the following procedure to determine the correct shim thickness for the inner pinion
bearing.
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a. Use Tooling (H) to measure the distance from the top of the Measuring Shaft As (part
of Tooling (B) ) to the bottom of the bore in the differential carrier housing, as shown.
Make sure that all previously used shims are removed from the differential carrier
housing. Record this dimension as dimension (Q) .
Example: (Q) = 157.70 mm (6.209 inch)
b. Measure the exact thickness of the Measuring Shaft As (part of Tooling (B) ). Record
this dimension as dimension (R) .
Example: (R) = 15 mm (.60 inch)
c. Divide dimension (R) by two. Record this dimension as dimension (S) .
(R) ÷ 2 = (S)
Example: 15.00 mm (.591 inch) ÷ 2 = 7.50 mm (.295 inch)
d. Subtract dimension (S) from dimension (Q) . Record this dimension as dimension
(X) .
(Q) − (S) = (X)
Example: 157.70 mm (6.209 inch) - 7.50 mm (.295 inch) = 150.20 mm (5.914 inch)
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e. Use Tooling (C) to measure the thickness of a new bearing (34) . Record this
dimension as dimension (T) .
Example: (T) = 36.50 mm (1.437 inch)
Note: A nominal dimension is stamped on the bottom of pinion shaft (31) (112.00
mm (4.409 inch)). The deviation from the nominal dimension is etched on the end of
the pinion shaft (-0.15 mm (-.006 inch)). The part number for the pinion shaft and the
ring gear is also etched on the end of the pinion shaft.
f. Record the nominal dimension that is stamped on the bottom of pinion shaft (19) .
Record this dimension as dimension (U) .
Example: (U) = 112.00 mm (4.409 inch)
g. Record the deviation that is stamped on the bottom of pinion shaft (31) . Record this
dimension as dimension (V) .
Example: (V) = -0.15 mm (-.006 inch)
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h. Add the deviation to the nominal dimension. The result will be the actual dimension
for the pinion shaft. Record this dimension as dimension (W) .
(U) + (V) = (W)
Example: 112.00 mm (4.409 inch) + -0.15 mm (-.006 inch) = 111.85 mm (4.403 inch)
i. Add the thickness of the new bearing (34) to dimension (W) . Record this dimension
as dimension (Y) .
(T) + (W) = (Y)
Example: 36.50 mm (1.437 inch) + 111.85 mm (4.403 inch) = 148.35 mm (5.840
inch)
j. Subtract dimension (Y) from dimension (X) in order to calculate the thickness for
shim (36) . Record this dimension as dimension (Z) .
(X) − (Y) = (Z)
Example: 150.20 mm (5.914 inch) - 148.35 mm (5.840 inch) = 1.85 mm (.074 inch)
Typical example
4. Install the correct thickness of shim (36) . The correct thickness of the shim is dimension
(Z) .
5. Raise the temperature of bearing cup (35) . Install bearing cup (35) in the differential carrier
housing on top of shim (36) . Make sure that the bearing cup is firmly seated against the
shim. Make sure that the bearing cup is correctly seated in the bore.
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6. Lower the temperature of bearing cup (9) . Install bearing cup (9) in the transmission
housing. Use Tooling (D) to make sure that the bearing cup is correctly seated in the bore.
7. Install spacer (8) in the original location in the transmission housing.
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8. Reposition the differential housing, as shown. Clean the bore in the differential housing.
Apply Tooling (K) to the outside diameter of the lip type seal. Use Tooling (D) to install the
lip type seal in the differential housing. Install the seal until the seal makes contact with the
counterbore in the differential housing. Install the lip type seal with the sealing lip outward.
Apply Tooling (L) on the lip of the lip type seal. Install a new O-ring seal on the outer
diameter of the differential housing.
9. Install drive gear (7) in the transmission housing.
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10. ApplyTooling (M) on the mating surfaces of the transmission housing. Install two guide
bolts in the transmission housing. Put differential housing (6) in position on the transmission
housing. Install bolts (5) that hold the differential housing to the transmission housing.
Tighten the bolts to a torque of 80 N·m (60 lb ft).
11. Raise the temperature of bearing cone (34) . Install bearing cone (34) on pinion shaft (31) .
Make sure that the bearing cone is seated against the shoulder on the pinion shaft.
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12. Install bushing (33) and a new O-ring seal (32) on the pinion shaft. Lubricate the O-ring seal
with clean hydraulic oil.
Note: Position the parking brake lever in the disengaged position in order to rotate the
pinion shaft.
13. Install pinion shaft (31) in the differential housing. Make sure that the pinion shaft is
correctly seated in the bearing cup. Make sure that the splines on the pinion shaft correctly
mesh with drive gear (7) . Rotate the pinion shaft for several revolutions. Make sure that the
pinion shaft rotates smoothly.
14. Attach Tooling (C) to pinion shaft (31) and the differential housing, as shown. Tooling (C)
will hold the pinion shaft in place when the differential housing is inverted.
15. Invert the differential housing. Make sure that Tooling (C) remains attached to the pinion
shaft and the differential housing.
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16. Install Tooling (E) , as shown. Use Tooling (E) prior to installing any shims. Use Tooling
(E) prior to installing the other bearings.
17. Use a soft faced hammer to strike Tooling (E) until drive gear (7) is completely seated on
the splined portion of the pinion shaft.
18. Use the following procedure to adjust the rolling torque of the pinion shaft:
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a. Install the original shims (37) on the pinion shaft. The value of shims (37) is 2.60 mm
(.102 inch).
b. Raise the temperature of bearing cone (38) . Install bearing cone (38) on the pinion
shaft. Make sure that the bearing cone is correctly seated.
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c. Install flange (3) .
d. Install a new O-ring seal and plate (2) . Install bolts (1) . Tighten the bolts to a torque
of 46 N·m (34 lb ft).
19. Remove Tooling (C) .
20. Use a suitable torque wrench to measure the rolling torque of the pinion shaft. Attach the
torque wrench to the outside diameter of flange (3) . Make sure that the torque wrench is in
alignment with the radius of the flange. Slowly rotate the pinion shaft. The rolling torque of
the pinion shaft should be 3.0 ± 0.5 N·m (26 ± 4 lb in). If the rolling torque of the pinion
shaft is not within the specification, change shim (37) . If the rolling torque is high, install a
thicker shim (37) . If the rolling torque is low, install a thinner shim (37) .
21. Remove bolts (1) , plate (2) , the O-ring seal, and flange (3) .
22. Clean the outside diameter of seal (4) . Use Tooling (F) to install seal (4) in the transmission
housing. Tooling (F) will set the correct depth of the seal in the transmission housing. Apply
Tooling (N) to the lip of the seal (4) .
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23. Install flange (3) .
24. Install the O-ring seal and plate (2) . Install bolts (1) . Tighten the bolts to a torque of 46
N·m (34 lb ft). Make sure that the bolts are positioned precisely in order to allow the
installation of the lock plate.
25. Install the lock plate on Tooling (G) , as shown. The lock plate is held in position by
magnets.
26. Use Tooling (G) and a soft faced hammer to install the lock plate over bolts (1) .
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27. Use a hammer and a punch to install clamping pins and the spring pins in differential case
half (23) . Install the pins in the original locations. Drive the clamping pins (27) into the
differential case half until the pins bottom out. Make sure that the slots in the clamping pins
are in a circumferential position. Make sure that the slots in the clamping pins are separated
by 180 degrees.
28. Put ring gear (26) in a press. Position differential case half (23) in the original location on
the ring gear. Align the clamping pins in the differential case half with four holes (25) in the
ring gear. Use the press to install the differential case half in the ring gear. Make sure that
the differential case half is firmly seated.
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29. After ring gear (26) and differential case half (23) have been pressed together, install two
bolts (17) that are 180 degrees from each other. Thread the bolts through the differential
case half and into the ring gear. Perform this operation at several locations in the differential
case half. This will ensure perfect alignment. This will also ensure that both halves of the
differential will bolt together.
30. Install thrust washer (24) in differential case half (23) . Make sure that the tab on the thrust
washer is inserted into the corresponding notch in the differential case half.
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31. Install one of the two differential gears (21) on top of thrust washer (24) . Apply a small
amount of clean hydraulic oil on the thrust washer in order to allow easy movement during
the assembly.
32. Assemble the spider gear assembly (22) . Install four bevel gears (29) on spider (30) . Install
thrust washers (28) on the spider, as shown. Make sure that the tab on each of the thrust
washers is oriented upward. Lubricate each of the thrust washers and each of the bevel gears
on the spider in order to allow easy movement during assembly.
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33. Install spider gear assembly (22) in differential case half (23) , as shown. Make sure that the
tabs on thrust washers (28) are oriented upward, as shown.
34. Install the other differential gear (21) . Make sure that all four bevel gears (29) mesh with
differential gear (21) .
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35. Install thrust washer (19) in differential case half (20) . Make sure that the tab on the thrust
washer is inserted into the corresponding notch in the differential case half.
36. Place both halves of the differential carrier in a press. Apply only enough pressure in order
to allow both differential case halves to make contact. Install differential case half (20) on
differential case half (23) . Note the alignment marks that were placed on both differential
case halves during the disassembly. Install bolts (17) that hold the differential case halves
together. Tighten the bolts to a torque of 145 N·m (105 lb ft).
Note: Inspect the differential carrier closely. Make sure that the thrust washers are in place.
Make sure that the differential gears and the bevel gears are free to move.
37. Raise the temperature of bearing cones (16) . Install a bearing cone (16) on each end of the
differential carrier. Make sure that both bearing cones are seated against the shoulder of the
differential carrier.
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38. Install both bearing races (14) on differential assembly (15) . Place the differential assembly
into the differential housing. Make sure that the ring gear and the pinion shaft mesh. Note
the alignment marks that were placed on the ring gear and the differential housing. This will
indicate the correct position for the differential assembly.
39. Install adjusting nuts (11) . Tighten one adjusting nut and loosen the other adjusting nut
until the ring gear makes contact with the pinion shaft. Check the differential assembly in
order to ensure that the bearings on both sides are completely seated in the bearing races.
No side play is allowed. Check the backlash by slowly rotating the ring gear and the pinion
shaft. Make sure that the ring gear and the pinion gear do not bind. Make sure that a small
amount of backlash exists.
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40. ApplyTooling (P) on the locating pins. Install the locating pin in each bearing cap (12) .
41. Check the identification marks and install bearing caps (12) . Install bolts (13) that hold the
bearing caps in position. Tighten the bolts to a torque of 195 N·m (145 lb ft).
42. Use the following procedure to set the backlash:
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a. The correct backlash is engraved on the ring gear. The engraving is behind the gear
teeth. Record this dimension.
b. Install Tooling (J) , as shown. Turn the differential all the way in one direction and
zero the dial indicator. Make sure that the tip of the dial indicator is making good
contact with a gear tooth on the ring gear.
c. Adjust adjusting nut (11) on the ring gear side of the differential until the required
backlash is obtained.
d. Tighten adjusting nut (11) on the opposite side until the differential is free of end
play.
e. Tighten adjusting nut (11) for 30 degrees. This will obtain the required preload.
f. Check the backlash again. If necessary, correct the backlash adjustment.
g. Rotate the ring gear, the differential and the pinion gear for several complete
revolutions. Make sure that the differential rotates easily and does not bind.
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h. Use a large micrometer in order to check the installation dimension. The installation
dimension should be 216.00 ± 0.05 mm (8.504 ± 0.002 inch).
i. Install Tooling (J) , as shown. Make sure that the tip of the dial indicator is making
good contact with the side of the ring gear. Zero the dial indicator. Rotate the ring
gear for one full revolution. The maximum permissible runout must not be more than
0.08 mm (0.003 inch).
43. After the backlash and the differential bearing preload have been set, check the tooth contact
between the ring gear and the pinion shaft. Use the following procedure to check the tooth
contact between the ring gear and the pinion shaft:
a. Apply a small amount of Prussian Blue, red lead or paint on the teeth of the ring gear.
Rotate the pinion shaft and inspect the marks that are made on the ring gear teeth.
Correct tooth contact (no load)
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Correct tooth contact (load)
b. Illustration 44 shows the correct tooth contact for no load. The area of contact begins
near the toe of the ring gear and ends halfway to the heel of the tooth. Illustration 45
shows the correct tooth contact for loaded conditions.
Short toe contact
c. Short toe contact will be the result if the pinion shaft is too far away from the ring
gear. The teeth on the pinion shaft will make contact with the convex surfaces of the
teeth at the toe end. The teeth on the pinion shaft will also make contact with the
concave surfaces of the teeth at the heel end. Short toe contact must be corrected by
an increase to the thickness of shim (36) . Shim (36) is used between the bearing for
the pinion shaft and the differential carrier housing. The pinion shaft will move in the
direction of the arrow in Illustration 46. Check the backlash and the tooth contact
again. Move the ring gear in the direction of the arrow in order to keep the correct
backlash.
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Short heel contact
d. Short heel contact will be the result if the pinion shaft is too near to the centerline of
the ring gear. The teeth on the pinion shaft will make contact with the concave
surfaces of the teeth at the toe end. The teeth on the pinion shaft will also make
contact with the convex surfaces of the teeth at the heel end. Short heel contact must
be corrected by a decrease in the thickness of shim (36) . Shim (36) is used between
the bearing for the pinion shaft and the differential carrier housing. The pinion shaft
will move in the direction of the arrow in Illustration 47. Check the backlash and the
tooth contact again. Move the ring gear in the direction of the arrow in order to keep
the correct backlash.
44. After all of the dimensions are within tolerances, lock both adjusting nuts (11) so that the
nuts cannot rotate. Install a pin (10) in each bearing cap (12) . Use a hammer and a punch in
order to drive each pin into the bearing cap. Lock each adjusting nut by driving the pins into
a groove on each adjusting nut.
Note: Position the parking brake lever in the engaged position.
Note: The transmission can be filled with oil prior to installing the transmission and the rear
differential in the machine.
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