Caterpillar Cat D6T TRACK-TYPE TRACTOR (Prefix GCT) Service Repair Manual Instant Download.pdf

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D6T TRACK-TYPE TRACTOR GCT
Configuration: D6T TRACK-TYPE TRACTOR STD, XL Differential Steering GCT00001-UP (MACHINE) POWERED BY C9 Engine
Disassembly and Assembly
D6T Track-Type Tractor Power Train
Media Number -KENR5126-07 Publication Date -01/01/2013 Date Updated -25/07/2018
i06151275
Bevel and Transfer Gears - Disassemble
SMCS - 3011-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 3
B 138-7575 Link Bracket 1
C 8H-0663 Bearing Puller 1
D 8T-2839 Spanner 1
E 1P-1863 Retaining Ring Pliers 1
F
1P-2321 Puller Assembly 1
5P-4170 Step Plate 1
G 5J-0490
Forcing Screw
1/2 inch X 13 X 5 inch
2
H
Forcing Bolt
1/4 inch X 20
1
Start By:
A. Separate the transmission and bevel gears.
Note: Put identifying marks on all of the shims as the shims are removed. The identifying marks
will ensure correct installation at assembly.
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D6T TRACK-TYPE TRACTOR STD, XL Differential Steering GCT00001-UP (MAC...
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g00504390
1. Remove bolts (1) and roller brackets (2) from each side of the transfer gear case.
2. Remove and discard bolts (4) that hold transfer gear case (3) to the bevel gear case.
3. Install Tooling (A) and attach a suitable lifting device to Tooling (A) . Remove transfer gear
case (3) from the bevel gear case. The weight of transfer gear case (3) is approximately 101
kg (223 lb).
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4. Remove bolts (5) that hold cage (6) to transfer gear case (3) .
5. Install Tooling (G) . Tighten Tooling (G) evenly. Remove the cage and the shims from the
transfer gear case.
6. Remove lip seal (7) and O-ring seal (8) from cage (6) .
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NOTICE
Bearing cup (9) and bearing (10) will be damaged if the bearing cups
are removed.
7. Remove bearing cup (9) and bearing (10) from cage (6) , if necessary.
8. Remove transfer gear (11) from transfer gear case (3) .
NOTICE
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Bearing cones (12) will be damaged if the bearing cones are removed
from transfer gear (11) .
9. Remove bearing cones (12) from transfer gear (11) , if necessary.
10. Remove the bolts and install Tooling (G) in cage (13) . Tighten Tooling (G) evenly and
remove cage (13) and the shims from transfer gear case (3) .
11. Remove bearing cup (14) from cage (13) .
12. Remove bearing cup (15) from transfer gear case (3) .
13. Remove the bolt and the retainer from pinion gear assembly (16) .
14. Install Tooling (B) and attach a suitable lifting device. Remove pinion gear assembly (16)
from the bevel gear case. The weight of pinion gear assembly (16) is approximately 33 kg
(73 lb).
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15. Remove the bearing cup for the pinion gear assembly from the bevel gear case.
16. Put the pinion gear assembly in a suitable press. Remove transfer gear (18) and bearing cone
(17) from bevel pinion gear (20) .
17. Use Tooling (C) and a suitable press to remove bearing cone (19) from bevel pinion gear
(20) .
18. Bend the locking tab away from spanner nut (22) .
19. Place a pry bar between the bolt heads on the bevel gear. The prybar will prevent rotation of
the bevel gear shaft.
20. Use Tooling (D) and remove spanner nut (22) . Remove lockwasher (21) and the tongue
washer.
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21. Use the lifting sling and a suitable lifting device to support the bevel gear and shaft (23) in
order to remove the bearings. The weight of the bevel gear and shaft (23) is approximately
55 kg (121 lb).
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22. Remove the bolts and install Tooling (G) . Tighten Tooling (G) evenly and remove cage
(24) , bearing cone (26) , spacer (27) , and bearing cone (26) . Remove shims (25) from the
bevel gear case.
23. Remove bearing cup (28) , center ring (29) , and bearing cup (28) from cage (24) .
8/10
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24. Remove the bolts and Tooling (G) . Tighten Tooling (G) evenly and remove cage (29A) and
the bearing from the bevel gear case.
25. Use a suitable lifting device and remove bevel gear and shaft (23) from the bevel gear case.
26. Install Tooling (H) and remove dowel (30) from cage (29A) . Remove race and roller
assembly (31) .
9/10
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27. Use Tooling (E) and remove the retaining ring from bevel gear shaft (23) .
28. Use Tooling (F) and remove bearing race (33) from the bevel gear shaft.
29. Remove bolts (32) and the nuts. Install Tooling (H) in bevel gear (34) . Tighten Tooling (H)
evenly and remove the bevel gear from the bevel gear shaft.
30. Remove the tube assemblies from the bevel gear housing.
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Jun 19 11:46:02 UTC+0800 2021
10/10
D6T TRACK-TYPE TRACTOR STD, XL Differential Steering GCT00001-UP (M...
2021/6/19

Shutdown SIS
Previous Screen
i03861136
Bevel and Transfer Gears - Assemble
SMCS - 3011-016
Assembly Procedure
Table 1
Required Tools
A 1P-1863 Retaining Ring Pliers 1
B 8T-2839 Spanner 1
C 138-7575 Link Bracket 1
D 1P-0520 Driver Group 1
E 138-7575 Link Bracket 3
F 8T-5096 Dial Indicator 1
G 4C-8733 Tapered Gauge 1
H 5J-0490
Forcing Screw
1/2 inch X 13 X 5.00 inch
2
J 1D-1090
Forcing Screw
5/8 inch X 11 X 3.50 inch
1
K 1U-7234 Feeler Gauge 1
L 5P-3931 Anti-Seize Compound 1
M 7M-7260 Liquid Gasket 1
1/16
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1. Put bevel gear (5) in position on bevel gear shaft (3). Install bolts (2) and the nuts.
2. Install Tooling (H). Use a pry bar to hold bevel gear (5) and shaft (3). Tighten bolts (2) to a
torque of 475 ± 60 N·m (350 ± 44 lb ft).
3. Raise bearing race (1) to a maximum temperature of 135°C (275°F). Install the bearing race
(1) on the bevel gear shaft.
4. Use Tooling (A) and install retaining ring (4) on bevel gear shaft (3).
5. Install tube assemblies (6) in the bevel gear case.
6. Use a suitable lifting device to put the bevel gear and shaft (3) in position in the bevel gear
case.
7. Put bearing cone (7) in position on the bevel gear shaft.
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8. Align the dowel hole in the race and the roller assembly (9) with the hole in cage (8) and
install the bearing in the cage. Install dowel (10) in the cage that holds the bearing in place.
9. Position cage (8) on the bevel gear case and install bolts (11). Tighten the bolts to a torque
of 135 ± 20 N·m (100 ± 15 lb ft).
10. Lower the temperature of two bearing cups (12). Install the bearing cups with center ring
(13) in cage (14).
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4/16
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11. Install cage (14) without the shims. Loosely install bolts (15) that hold cage (14) to the
bevel gear case.
12. Install bearing cone (17), spacer (18A), and bearing cone (17) on the bevel gear shaft.
13. Align the notch in the bevel gear shaft with the tooth on tongue washer (16) and install
tongue washer (16).
14. Align the teeth on lockwasher (17A) with the notch in the bevel gear shaft and put the lock
in position.
15. Put Tooling (L) on the threads and the face of spanner nut (18). Install spanner nut (18) on
the bevel gear shaft.
16. Use Tooling (B) to tighten spanner nut (18) to a torque of 612 ± 68 N·m (450 ± 50 lb ft).
17. Raise bearing cone (20) to a maximum temperature of 135°C (275°F) and install the bearing
cone on bevel pinion gear (19). Use a 0.03 mm (0.001 inch) feeler gauge to make sure that
the bearing cone is seated against the shoulder of the pinion gear.
18. Align the splines and install transfer gear (22) on bevel pinion gear (19).
5/16
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19. Raise bearing (21) to a maximum temperature of 135°C (275°F) and install the bearing on
the pinion shaft. Use a 0.03 mm (0.001 inch) feeler gauge to make sure that the bearing is
seated against shoulder (23) of the pinion.
20. Install Tooling (C) on the pinion and attach a suitable lifting device. Lower the pinion and
pinion gear assembly (24) into position in the bevel gear case.
21. Lower the temperature of bearing cup (25) and install the bearing cup in transfer gear case
(26).
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22. Lower the temperature of bearing cup (28) and install the bearing cup in cage (27).
23. Raise bearing cones (29) to a maximum temperature of 135°C (275°F). Install the bearing
cones on lower transfer gear (30). Use a 0.03 mm (0.001 inch) feeler gauge to make sure
that the bearings are seated against shoulders on the transfer gear.
24. Put lower transfer gear (30) in position in transfer gear case (26).
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25. Use Tooling (D) and install bearing (33) in cage (32).
26. Lower the temperature of bearing cup (31) and install the bearing cup in cage (32).
27. Put Tooling (M) in the seal bore of cage (32). Use Tooling (D) and install lip seal (34) in
cage (32). Put clean oil on the lip of the seal.
28. Put glycerin on O-ring seal (35) and install the seal in the cage.
29. Leave out the shims and put cage (27) in position on transfer gear case (26). Install two
bolts (36). Space the bolts at 180 degrees. Do not tighten the bolts.
30. Leave out the shims and put cage (32) in position on transfer gear case (26). Install bolts
(37) and (38). Space the bolts at 180 degrees. Do not tighten the bolts.
8/16
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31. Install Tooling (E) on transfer gear case (26) and attach a suitable lifting device.
32. Install the retainer and bolt (39). Tighten bolt (39) to a torque of 270 ± 40 N·m
(200 ± 30 lb ft).
NOTICE
Be sure that bolts (36), (37), and (38) that hold cages (27) and (32) in
place on the transfer gear case are loose.
33. Put transfer gear case (26) in position on the bevel gear case. Install bolts (40) and washers.
Tighten the bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
34. Use the following Steps to adjust the end play for the lower transfer gear:
a. In order to seat the bearings, rotate the transfer gear at least three revolutions. Then,
tighten bolts (37) and (38) evenly to a torque of 2.25 N·m (20 lb in).
b. Then, rotate the transfer gear at least three revolutions. Tighten bolts (37) and (38)
evenly to a torque of 4.5 N·m (40 lb in).
9/16
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c. Use Tooling (K) to measure the gap between cage (32) and the transfer gear case.
Make the measurement at the edge of the cage in line with the center of bolts (37) and
(38). Average the two measurements.
d. Add 0.23 mm (0.009 inch) to the average figure that was obtained in Step 34.c. This
figure will be the correct thickness for the shims that should be used.
35. Remove cage (32). Put the correct thickness of shims in position on the transfer gear case.
Put cage (32) in position and install the bolts that hold the cage in place. Tighten the bolts to
a torque of 135 ± 20 N·m (100 ± 15 lb ft). The bearing end play will be 0.10 ± 0.05 mm
(0.004 ± 0.002 inch). It will not be necessary to check the bearing end play if this procedure
for adjustment has been followed. If a measurement of the bearing end play is desired, refer
to “Measurement of the Bearing End Play for the Bevel Pinion and Transfer Gears” in this
section.
36. Put two roller bracket (41) in position and install the bolts that hold each one. Tighten the
bolts to a torque of 270 ± 40 N·m (200 ± 30 lb ft).
37. Use the following Steps to adjust the end play for the upper transfer and pinion gear:
a. In order to seat the bearings, rotate the transfer gear at least three revolutions. Then,
tighten bolts (36) evenly to a torque of 4.5 N·m (40 lb in).
b. Then, rotate the transfer gear at least three revolutions. Tighten bolts (36) evenly to a
torque of 9.0 N·m (80 lb in).
c. Use Tooling (K) to measure the gap between cage (27) and the transfer gear case.
Make the measurement at the edge of the cage in line with the center of bolts (36).
Average the two measurements.
d. Add 0.43 mm (0.017 inch) to the average figure that was obtained in Step 37.c. This
figure will be the correct thickness for the shims that should be used.
38. Remove cage (27). Put the correct thickness of shims in position on the transfer gear case.
Put cage (27) in position and install the bolts that hold the cage in place. Tighten the bolts to
a torque of 135 ± 20 N·m (100 ± 15 lb ft). The bearing end play will be 0.10 ± 0.05 mm
(0.004 ± 0.002 inch). It will not be necessary to check the bearing end play if this procedure
for adjustment has been followed. If a measurement of the bearing end play is desired, refer
10/16
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to “Measurement of the Bearing End Play for the Bevel Pinion and Transfer Gears” in this
section.
39. Put the bevel gear case on the side so that the bevel gear shaft is in a vertical position with
the bevel gear at the bottom.
NOTICE
It is important for the bevel gear case to be in this position. The bevel
gear must be held as far away from the pinion gear as possible when
the gear clearance (backlash) is set.
40. Install Tooling (J) in the transfer gear case. Tighten Tooling (J) until there is no movement
in the pinion gear. Be sure that Tooling (J) is between the teeth of the gear.
41. Put Tooling (F) in position and check the clearance (backlash) between the bevel gear and
the pinion gear. The clearance (backlash) must be 0.30 + 0.12 mm − 0.10 mm
(0.012 + 0.005 inch − 0.004 inch). Check the clearance (backlash) on three different teeth
that are evenly spaced around the gear.
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42. The difference between the high measurement and the low measurement must not be more
than 0.15 mm (0.006 inch).
43. Install the correct amount of shims (42) under bearing cage (14). Install the six bolts in the
cage and tighten the bolts to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
44. Check the gear clearance (backlash) in order to be certain that the clearance is still correct.
If the clearance is not correct, add or remove shims (42), as needed.
NOTICE
Tooling (J) must be removed.
45. Remove Tooling (J) from the transfer gear case.
End By:
a. Connect the transmission and the bevel gears.
Measurement of the Bearing End Play for the Bevel Pinion
and Transfer Gears
Table 2
Tooling Setup
Item Part Number Part Description Qty
L 5P-8247 Hardened Washer 4
M 4B-5275 Washer 4
N 1D-4720 Nut 4
P 1P-1837 Bearing Puller Adapter 2
R
Rod
5/8 -11 NC × 24
1
S 2P-8257 Modified Plate 1
T 2P-8260 Installer (liner) 1
U 1D-4720 Nut 5
V 8T-5096 Dial Indicator 1
W 0L-1143 Bolt 1
Y 5M-2894 Washer 4
12/16
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The bearing end play for the bevel pinion and transfer gears should be adjusted according to the
procedure that is given in “Bevel and Transfer Gears - Assemble”. If this procedure is used, the
bearing end play (backlash) should be correctly set at 0.10 ± 0.05 mm (0.004 ± 0.002 inch).
NOTICE
It is very important to load the bearings vertically in both the upward
direction and the downward direction when you make the
measurements. Otherwise, false readings will result.
If a check of bearing end play is desired, the measurement must be made only while the bearings
are being rotated and loaded with the Tooling that is shown.
13/16
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Tooling (S) requires an additional hole that is 16.00 mm (0.630 inch) (5/8 inch) in diameter.
Tooling (s) is also a part of Tooling (T). Drill the hole for Tooling (W) 25 mm (1.0 inch) from the
tapped center hole, as shown.
This is the Tooling that will be used to check the bearing clearance for the input transfer gear. The
transfer gear is clamped to Tooling (P). Tooling (T) is used to force the gear to move. The gear
can be moved upward or the gear can be moved downward with the lever. Tooling (L) fits in
Tooling (P) to center Tooling (R) in the gear.
Note: Use the following Steps to measure the bearing clearance for the input transfer gear.
1. Install the Tooling in the transfer gear so that Tooling (R) and Tooling (P) are centered in
the gear. Install Tooling (R) with the 5/8 by 11 thread on top.
2. Tighten Tooling (U) on top of the adapter in order to prevent movement of the gear. Tooling
(N) can then be used to turn the gear.
3. Fasten Tooling (S) and Tooling (T) to the housing with Tooling (W), as shown. Use Tooling
(Y) to support the plate.
4. Put the slotted end of the lever in a horizontal position on the threaded rod. Be sure that
there is 1.0 mm (0.04 inch) clearance between Tooling (M) and the lever.
5. Lubricate the washers so that the assembly will turn smoothly.
14/16
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6. Put Tooling (V) in position. Be sure that the indicator tip is vertical and that the indicator tip
is in contact with the top adapter. Lubricate the surface of the adapter or lubricate the
indicator tip.
7. Push the adapter downward and hold the adapter down while the lever is up. Use a ratchet
wrench to turn the gear with Tooling (N). Rotate the gear for at least three revolutions.
Watch the needle on the dial indicator. Watch the backward movement and the forward
movement. Stop rotating the gear at the point of the maximum needle movement.
Note: The needle may move back and forth during rotation due to runout in the adapter. The
reading should always be taken at the same location so that the measurement will be
accurate and consistent.
8. Mark the location of Area (X). Mark the location at the point of maximum needle
movement on the surface of the adapter. Set the dial indicator to zero as you force the gear
downward.
9. Pull the gear upward by pulling the lever downward. Do this procedure as you turn the gear
at least three revolutions. Record the maximum reading that is obtained when the indicator
tip is returned to Area (X). This reading will be the actual bearing clearance. The reading
should be 0.10 ± 0.05 mm (0.004 ± 0.002 inch).
10. Repeat the procedure. The result should be identical if the first procedure was correctly
done.
Note: Use the following Steps to measure the bearing clearance for the pinion gear.
11. Screw the 5/8 - 11 NC end of Tooling (R) in the pinion shaft.
12. Put the lever assembly and Tooling (S) in position. Install Tooling (W) in the bearing
retainer. Use Tooling (Y) to support the plate.
13. Adjust Tooling (U) so that the slotted end of the lever is horizontal.
14. Allow 1.0 mm (0.04 inch) clearance between the lever and Tooling (M). Lubricate both
washers.
15. Put Tooling (V) in position, as shown. Be sure that the indicator tip is vertical and that the
indicator tip is in contact with the flat end surface of the pinion gear. Lubricate the flat end
surface of the pinion gear or lubricate the indicator tip.
16. Rotate the pinion for at least three revolutions as you force the pinion gear downward by
lifting up on Tooling (T). Watch the backward movement and the forward movement of the
needle on the dial indicator as the pinion gear is being rotated. Stop rotating the pinion gear
at the point of the maximum needle movement. Mark the location at the point of maximum
needle movement on the surface of the pinion gear. Set the dial indicator to zero as you
force the pinion gear downward.
Note: The needle may move back and forth during rotation due to runout in the surface of
the pinion gear. The reading should always be taken at the same location so that the
measurement will be accurate and consistent.
17. Pull the pinion gear upward by pulling the lever downward. Do this procedure as you turn
the pinion gear at least three revolutions. Record the maximum reading that is obtained
15/16
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when the indicator tip is returned to the marked location. This reading will be the actual
bearing clearance. The reading should be 0.10 ± 0.05 mm (0.004 ± 0.002 inch).
18. Repeat the procedure. The result should be identical if the first procedure was correctly
done.
Sat Jun 19 11:47:01 UTC+0800 2021
16/16
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Shutdown SIS
Previous Screen
i04295991
Transmission - Remove
SMCS - 3030-011
Removal Procedure
Table 1
Required Tools
A
369-6017 Transmission Case Cover 1
142-6893 Adjustable Hook 1
Note: Cleanliness is an important factor. Clean the exterior of the component thoroughly in order
to prevent dirt from entering the internal mechanism.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
1/6
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Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for
installation purposes. Plug all lines, hoses, and tubes in order to prevent fluid loss and to keep
contaminants from entering the system.
1. Drain the oil from the transmission into a suitable container for storage or disposal.
2. Lower the ripper to the ground.
3. Remove bolts (1) . Remove cover (2) and lay cover (2) out of the way.
4. Remove bolts (3) . Remove guard (4) . The weight of guard (4) is approximately 26 kg (58
lb).
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5. Remove guard (5) . Remove tube assembly (6) . Remove bolts (7) and separate the
transmission from the differential case.
6. Disconnect harness assembly (8) . Remove cover (9) .
3/6
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7. Disconnect harness assembly (10) from clips (10A) .
8. Remove bolts (11) , drive shaft (12) , and yoke (13) .
9. Install Tooling (A) . Adjust Tooling (A) to Dimension (Y) . Dimension (Y) is 127 mm (5.0
inch).
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10. Attach a suitable lifting device to Tooling (A) . Adjust Tooling (A) to Dimension (X) .
Dimension (X) is 88.9 mm (3.50 inch).
Note: Place a piece of plywood between the cab window and Tooling (A) in order to protect
glass.
11. Install Tooling (A) onto transmission (14) . Remove bolts (15) from transmission (14) .
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12. Remove transmission (14) . The weight of transmission (14) is approximately 454 kg (1000
lb).
Sat Jun 19 11:48:01 UTC+0800 2021
6/6
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Shutdown SIS
Previous Screen
i02406212
Transmission - Disassemble
SMCS - 3030-015
Disassembly Procedure
Table 1
Required Tools
A 1P-2420 Transmission Repair Stand 1
B 5P-5197 Retaining Ring Pliers 1
C 138-7575 Link Bracket 3
D 5P-4758 Internal Pliers 1
E FT-0947 Spring Compressor 2
F 138-7574 Link Bracket 2
G 3K-4897 Spring Pin 8
Start By:
a. Separate the transmission and bevel gear. Refer to Disassembly and Assembly,
"Transmission and Bevel Gears - Separate".
Note: The transmission modulating valves must be recalibrated if any of the following procedures
are performed:
• The transmission modulating valve and/or the solenoid is replaced.
• The transmission is serviced or replaced.
• The ECM is replaced.
1/20
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Suggest:
If the above button click is invalid.
Please download this document
first, and then click the above link
to download the complete manual.
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1. Position the transmission on Tooling (A). Put alignment marks on all the housings prior to
disassembly.
2. Remove O-ring seal (1).
3. Remove O-ring seals (2A) and plugs (2).
4. Remove retainers (4).
5. Remove tubes (3).
2/20
2021/6/19

6. Remove locknut (6). Push connector (7) out of the case.
7. Disconnect harness assembly (5).
8. Remove bolts (8) and control valve (9).
3/20
2021/6/19

Caterpillar Cat D6T TRACK-TYPE TRACTOR (Prefix GCT) Service Repair Manual Instant Download.pdf

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Caterpillar Cat D6T TRACK-TYPE TRACTOR (Prefix GCT) Service Repair Manual Instant Download.pdf