Caterpillar Cat D6R II TRACK-TYPE TRACTOR (Prefix CAD) Service Repair Manual (CAD00001 and up).pdf

Service Repair Manual
Models
D6R II TRACK-TYPE TRACTOR

Shutdown SIS
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Product: TRACK-TYPE TRACTOR
Model: D6R II TRACK-TYPE TRACTOR CAD
Configuration: D6R Series IIFTC, XL TRACK-TYPE TRACTORS CAD00001-UP (MACHINE) POWERED BY C-9 Engine
Disassembly and Assembly
D6R Series II Track-Type Tractor Power Train
Media Number -RENR4257-03 Publication Date -01/08/2009 Date Updated -01/09/2009
i01645342
Torque Converter - Disassemble
SMCS - 3101-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Description Qty
A 1P-1863 Retaining Ring Pliers 1
B 138-7575 Link Bracket 2
C Forcing Screws (3/8 inch by 16) 2
D 136-1452 Retaining Ring Pliers 1
E 138-7573 Link Bracket 2
F 1P-0510 Driver Gp 1
G Forcing Screws (3/8 inch by 16) 2
H 1P-0520 Driver Gp 1
J 2P-8312 Retaining Ring Pliers 1
Start By:
A. Remove the torque converter. Refer to Disassembly and Assembly, "Torque Converter-
Remove".
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
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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, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00533425
1. Use Tooling (A) in order to remove retaining ring (1) from the shaft.
2. Remove planetary carrier (2) .
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3. Remove retainer (4) and retaining ring (3) from planetary carrier (2) .
4. Use a hammer and a punch in order to push pin (8) into shaft (7) .
5. Remove the following components from the planetary carrier: shaft (7), washers (9) and
planetary gear (6) .
6. Remove bearing (5) from the planetary gear.
7. Remove pin (8) from shaft (7) .
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8. Place wood blocks under the torque converter.
9. Remove the following components from the end of the torque divider: bolt (10), retainer
(11) and yoke (13) .
10. Remove sensor (12). Remove bolts (14) .
11. Install Tooling (B) and attach a hoist and chain (15) to cover (16). Install Tooling (C) in the
cover. Tighten Tooling (C) evenly, and remove cover (16). The cover of the torque
converter weighs approximately 70 kg (150 lb).
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12. Remove O-ring seal (18) and lip seal (17) .
13. Remove two bolts (19) with washers from opposite sides of the torque converter. The bolt
locations are marked drain. Drain the oil from the torque converter.
14. Use Tooling (D) in order to remove retaining ring (20) .
15. Remove shaft (21) and the bearing.
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16. Remove seal ring (24) from shaft (21) .
17. Remove bearing (22) from the shaft.
18. Remove bearing race (23) from the shaft, if necessary.
Note: If the bearing race is removed, the component is damaged.
19. Remove remaining bolts (19) with the washers. Refer to Illustration 7. Install Tooling (C) in
impeller wheel (25) .
20. Install Tooling (E) and attach a hoist and chains (26) to the impeller. Tighten Tooling (c)
evenly, and remove the impeller wheel with the carrier. The impeller wheel with the carrier
weighs approximately 30 kg (65 lb).
NOTICE
Use care in disassembly of the torque converter, in order to avoid
damage to the stator.
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21. Remove bolts (27). Remove stator (28) .
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22. Use wood blocks or a holding tool in order to support the unit of the wheel and of the carrier
close to the center. Use Tooling (F) on the inside diameter of pins (29). Remove carrier
(30) .
23. Remove seal ring (31) and pins (29) from the carrier.
24. Remove the bolts that fasten retainer (32) to the impeller wheel. Use Tooling (G) in order to
remove retainer (32) .
25. Remove Dowel (X) from impeller (25) .
26. Use Tooling (H) in order to remove carrier (33) with the bearing from impeller (25) .
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27. Use Tooling (H) in order to remove bearing (34) from carrier (33) .
28. Use Tooling (J) in order to remove retaining ring (36) from the output flange.
29. Remove turbine wheel (35) from housing (37) and from the output flange. Remove the
spacer that is under turbine wheel (35) .
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30. Turn over housing (37). The housing weighs approximately 35 kg (75 lb). Remove stop pins
(38) .
31. Compress the retaining ring. Remove ring gear (39). Remove the retaining ring.
32. Install Tooling (C) in output flange (40). Tighten Tooling (C) evenly, and remove the output
flange from the housing.
33. Remove seal ring (43) from carrier (42) on output flange (40) .
34. If necessary, use a chisel in order to break carrier (42). Remove the carrier.
Note: If the carrier is removed, the component is destroyed.
35. Use Tooling (F) in order to remove two bearings (41) from output flange (40) .
10/11
D6R Series IIFTC, XL TRACK-TYPE TRACTORS CAD00001-UP (MACHINE) ...
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36. Remove bolts (44) and retainer (45) from the housing.
37. Use Tooling (H) in order to remove bearing (46) from housing (37) .
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Feb 28 12:38:00 UTC+0800 2021
11/11
2021/2/28

Shutdown SIS
Previous Screen
i02720885
Torque Converter - Assemble
SMCS - 3101-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Description Qty
A 1P-1863 Retaining Ring Pliers 1
B 138-7575 Link Bracket 2
C 136-1452 Internal Tip Pliers 1
D 138-7573 Link Bracket 2
E 1P-0510 Driver Group 1
F 1P-0520 Driver Group 1
G 2P-8312 Retaining Ring Pliers 1
H 1U-7234 Feeler Gauge 1
J Guide Bolts (3/8 inch by 24 NF) 2
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
ReferenceRefer to Specifications, "Torque Converter" in the Service Manual for your machine.
1/13
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Note: In order to ensure that the torque divider is capable of efficient operation, take the
measurements in Steps 1 and 2. Then, follow the procedure for assembly of the torque
converter.
1. Check the clearance between the turbine wheel and the stator by performing the following
steps:
a. Place stator (28) on turbine wheel (35). While you hold the stator against one side of
the turbine wheel, measure the clearance between the stator and the turbine wheel
with Tooling (H) .
b. The correct clearance between the stator and the turbine wheel is 1.76 to 1.94 mm
(0.070 to 0.077 inch). Check the clearance at four different points on the turbine
wheel. The maximum clearance for any measurement is 1.1 mm (0.043 inch).
c. The running clearance is one half of the clearance across the diameters. The correct
running clearance is 0.88 to 0.97 mm (0.035 to 0.039 inch). The maximum running
clearance for any measurement is 0.38 mm (0.015 inch).
2. Check the clearance between the impeller wheel and the stator by performing the following
steps:
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a. Use a 7 inch outside micrometer or an 8 inch outside micrometer for outside
diameters in order to measure the diameter of the flange at four points on the stator.
Record the minimum reading.
b. Use a 7 inch inside micrometer or an 8 inch inside micrometer in order to measure the
diameter of the flange at four points on impeller wheel (25). Record the maximum
reading.
c. The clearance across the diameters is the difference between the readings of Steps 2.b
and 2.a. The correct clearance between the stator and the impeller wheel is 1.17 mm
to 1.32 mm (0.046 inch to 0.052 inch). The maximum clearance for any measurement
is 0.61 mm (0.024 inch).
d. The running clearance is one half of the clearance across the diameters. The correct
running clearance is 0.59 to 0.66 mm (0.023 to 0.026 inch). The maximum running
clearance for any measurement is 0.30 mm (0.012 inch).
3. Use Tooling (F) in order to install bearing (46) in housing (37) .
3/13
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4. Place retainer (45) on the housing. Install bolts (44). Tighten the bolts to a torque of 50 ± 7
N·m (37 ± 5 lb ft).
5. Use Tooling (F) in order to install two bearings (41) in output flange (40) by performing the
following steps:
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a. Install one bearing (41) to a 25.4 mm (1.00 inch) depth below the surface of output
flange (40). See Illustration 6.
b. Install one bearing (41) even with the surface of the splined end of output flange (40).
See Illustration 7.
c. After you install bearings (41), check the inside diameter of the bearings. The correct
inside diameter after installation is 44.501 ± 0.013 mm (1.7520 ± 0.0005 inch).
6. If carrier (42) is separate from output flange (40), heat the carrier to a temperature of 152° ±
14°C (305° ± 25°F) for ten minutes. Install carrier (42) on output flange (40). Install seal
ring (43) on the carrier.
7. Apply clean SAE 30W oil to seal ring (43). Pull the ends of the seal ring together. Install
output flange (40) in the housing.
Note: Do not damage the seals during the assembly of the components.
8. Place the retaining ring on the outer groove on output flange (40). The outer groove is
shown in Illustration 6. Compress the ring and install ring gear (39). In order to hold the
ring gear in place, make sure that the retaining ring engages the slot in ring gear (39) .
9. Install stop pins (38) in housing (37) .
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10. Turn over housing (37). Place the spacer that lies under the turbine wheel on the output
flange.
11. Install turbine wheel (35) on the output flange.
12. Use Tooling (G) in order to install retaining ring (36) on the output flange.
13. Use Tooling (F) in order to install bearing (34) in planetary carrier (33) .
6/13
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14. Position planetary carrier (33) with Tooling (J) on impeller wheel (25). Use Tooling (G) in
order to install the planetary carrier on the impeller wheel.
15. Install dowel (X) .
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16. Turn over impeller wheel (25). Place retainer (32) on the impeller wheel. Install the bolts.
Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
17. Install pins (29) in carrier (30) .
18. Install seal ring (31) on the carrier.
19. Apply clean SAE 30W oil to seal ring (31). Pull the ends of the seal ring together.
20. Position carrier (30) on impeller wheel (25) .
Note: The ball should be lined up with the groove in the bearing.
Note: Do not damage the seals during assembly.
21. Use Tooling (F) in order to install carrier (30) in impeller wheel (25) .
8/13
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22. Turn over the impeller wheel (25). Install two guide bolts (26). Place stator (28) on the
impeller wheel and install bolts (27). Tighten the eight bolts to a torque of 40 ± 5 N·m (30 ±
4 lb ft).
9/13
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23. Turn over impeller wheel (25). The impeller wheel with the carrier weighs approximately
30 kg (65 lb). Install Tooling (D) on the impeller wheel. Attach a lifting device. Place
impeller wheel (25) with the carrier on the housing. Remove Tooling (D). See Illustration
20 in order to install bolts (19). Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
24. Heat bearing race (23) to a temperature of 135 °C (275 °F) for ten minutes. Install the
bearing race on shaft (21) .
25. Install seal ring (24) on shaft (21) .
26. Heat bearing (22) to a temperature of 135 °C (275 °F) for ten minutes. Install the bearing on
shaft (20). Apply clean SAE 30W oil to seal ring (24). Pull the ends of the seal ring
together.
27. Install shaft (21) and the bearing in the torque converter.
Note: Do not damage the seals during assembly.
28. Use Tooling (C) in order to install retaining ring (20) .
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29. Install O-ring seal (18) on the carrier. Apply clean SAE 30W oil to the seal.
30. Install lip seal (17) in the carrier with the lip of the seal toward the bearing. Apply clean
SAE 30W oil to the lip of the seal.
31. Install Tooling (B) on cover (16) and attach a hoist. The cover of the torque converter
weighs approximately 70 kg (150 lb).
32. Use two guide bolts (15) in order to install cover (16) on the torque converter. Make sure
that the O-ring seal stays in position when you install the cover.
33. Install bolts (10). Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
34. Install yoke (13). Place sensor (12) on yoke (13). Install retainer (11) and bolt (10). Tighten
bolt (10) to a torque of 115 ± 7 N·m (85 ± 5 lb ft).
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35. Place bearing (5) in planetary gear (6). Place one spacer (9) on each side of planetary gear
(6), and place the components in the planetary carrier. Install shaft (7) .
36. Align the hole in shaft (7) with the hole in the planetary carrier. Install pin (8) even with the
surface of the planetary carrier.
37. Install retaining ring (3) in the inner diameter of planetary carrier (2). Position retainer (4)
next to the spiral ring.
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38. Position planetary carrier (2) in ring gear (36) and on shaft (16). Make sure that the retainer
stays in place.
39. Use Tooling (A) in order to install retaining ring (1) .
End By: Install the torque converter. Refer to Disassembly and Assembly, "Torque Diverter -
Install".
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Feb 28 12:38:53 UTC+0800 2021
13/13
2021/2/28

Shutdown SIS
Previous Screen
i05467849
Torque Converter - Install
SMCS - 3101-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
138-7575 Link Bracket 2
1U-9200 Ratchet Puller 2
1. Install ring (23) and springs (22) .
1/9
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Typical example
2. Install gear (21) and ring (20) .
3. Attach a chain around the ROPS. Attach Tooling (A) to the chains.
2/9
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4. Attach Tooling (A) to torque converter (19) .
3/9
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5. Lower torque converter (19) and remove torque converter (19) . The weight of torque
converter (19) is approximately 145 kg (320 lb).
6. Install the O-ring seal (not shown) on the torque converter.
7. Connect torque converter (19) to the engine. Install bolts (18) .
8. Connect tube assemblies (16) to cooler (17) .
9. Connect hose assembly (15) . Install bolt (13) and bracket (14) .
4/9
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10. Install hose assembly (12) .
11. Install hose assemblies (11) .
5/9
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12. Install bottom guard (10) . Install bolts (9) .
13. Connect hose (8) and tighten hose clamp (7) .
6/9
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14. Connect harness assembly (6) .
15. Connect harness assembly (5) .
7/9
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Caterpillar Cat D6R II TRACK-TYPE TRACTOR (Prefix CAD) Service Repair Manual (CAD00001 and up).pdf

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Caterpillar Cat D6R II TRACK-TYPE TRACTOR (Prefix CAD) Service Repair Manual (CAD00001 and up).pdf