Caterpillar Cat 651E Wheel Tractor (Prefix 4YR) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
651E WHEEL SCRAPER

Shutdown SIS
Previous Screen
Product: WHEEL TRACTOR
Model: 651E WHEEL TRACTOR 4YR
Configuration: 651E Wheel Tractor 4YR00001-UP (MACHINE) POWERED BY 3412E Engine
Disassembly and Assembly
651E & 657E TRACTOR POWER TRAIN
Media Number -SENR9096-02 Publication Date -01/10/2004 Date Updated -11/06/2015
SENR90960018
Transmission Transfer Gears
SMCS - 3159-011; 3159-012; 3159-015; 3159-016
Remove Transmission Transfer Gears
Start By:
a. remove cushion hitch pump *
b. remove electronic speed sensor
*
See machine systems DISASSEMBLY AND ASSEMBLY section.
1. Turn the tractor 90 degrees to the scraper. Drain the oil from the sump in the transmission.
2. Disconnect hose (1) from bearing cage (2). Cap and plug the fittings to keep out dirt and debris.
3. Remove bolts (3). Use two 3/8 in - 16 NC Forcing Screws to remove cage (2) from the transfer
gears. Remove two bolts (4).
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4. Remove gear (5) and coupling (6) from the drive shaft as a unit.
5. Disconnect wiring harness (7) from the light. Remove the four bolts that hold the light bracket
(8) in position on the transfer gears.
6. Remove the bolt and clip (9) that holds the transmission electronic speed sensor wiring harness
in position.
7. Put a block in position between the tube and the transmission case to give support to the tube
when the transfer gears are removed.
8. Remove four bolts (10) that hold the tube in position against the rear of the transfer gears.
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9. Fasten Tooling (A) and a hoist to the transfer gears. Remove bolts (11). Use two 1/2 in - 13 NC
Forcing Screws to remove transfer gears (12) from the machine. The weight of the transfer gears
is approximately 188 kg (415 lb).
10. Remove O-ring seals (13).
Install Transmission Transfer Gears
1. Install O-ring seals (1) on the machine. Put clean oil on each O-ring seal.
2. Install two 1/2 in - 13 NC Guide Bolts in the transmission case. Make sure the O-ring seal is in
position on the transfer gears. Put clean oil on the O-ring seal.
3. Fasten Tool (A) and a hoist to the transfer gears. Install transfer gears (2) on the transmission.
The weight of the transfer gears is approximately 188 kg (415 lb).
4. Install the bolts and washers that hold the transfer gears in position.
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5. Istall two bolts (3).
6. Connect tube (4) to the rear of the transfer gears. Install the four bolts that hold it in place.
Remove the support block that was placed between the tube and transmission case.
7. Install the light bracket (5) and light. Install clips (6) and the bolts that hold the light bracket in
position. Connect the wiring harness to the light.
8. Install clip (7) that holds the transmission electronic speed sensor wiring harness in position.
9. Make sure coupling (8) is in position in gear (9). Install gear (9) on the drive shaft.
10. Install two 3/8 in - 16 NC Guide Bolts in the transfer gears as shown. Make sure the O-ring
seal is in position on the cage. Put clean oil on the O-ring seal.
10. Install the original shims (10) and cage (11).
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11. Fill the transmission with oil to the correct level. See Operation And Maintenance Manual.
End By:
a. install electronic speed sensor
b. install cushion hitch pump *
*
Disassemble Transmission Transfer Gears
Start By:
a. remove transmission transfer gears
b. remove transmission oil filter
c. remove transmission pump
1. Remove coupling (1) from gear (2).
NOTE: Gear (2) was removed when the transmission transfer gears were removed from the
transmission.
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NOTE: On later models, it will be necessary to remove the spiral snap ring in the bore of the gear
before the coupling can be removed from the gear.
2. Remove ring (3) from gear (2).
3. Use Tooling (A) to remove the bearing cones from gear (2).
4. Use Tooling (B) to remove the bearing cup from cage (4).
NOTE: Cage (4) was removed when the transmission transfer gears were removed from the
transmission.
5. Remove the bolts and light (5) from the transfer gear case.
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6. Turn the transfer gear case over. Remove bolts (6). Use two 3/8 in - 16 NC Forcing Screws to
remove cage (7). Remove the shims that are under the cage.
7. Use Tooling (C) to remove the bearing cup from the cage.
8. Remove the bolts that hold gear (9) in position. Use two 3/8 in - 16 NC Forcing Screws (8) to
remove gear (9).
9. Remove gear (10).
10. Use Tooling (D) to remove two bearing cones (11) from gear (10).
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11. Use Tooling (C) to remove bearing cup (12) from the transfer gear case.
12. Turn the transfer gear case over. Use Tooling (C) to remove bearing cup (13) from the transfer
gear case.
13. Remove three bolts (14) and gear (15).
14. Remove spiral ring (16) from gear (15).
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15. Use three 3/8 in - 16 NC Forcing Screws (17) to remove cage (18) and bearing (19) from the
gear.
16. Use Tooling (E) to remove bearing (19) from cage (18).
17. Use Tool (F) to remove ring (20) from the bearing.
18. Remove the bolts that hold shaft (22) in position. Use two 3/8 in - 16 NC Forcing Screws
(21) to remove shaft (22) from the transfer gear case.
19. Remove the shims and the O-ring seal from the shaft.
20. Give support to the bearing cone on the bottom of gear (23). Remove gear (23) from the
transfer gear case.
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21. Remove bearing cones (24) and spacer (25) from gear (23).
22. Use a hammer and a punch to remove bearing cup (26) from gear (23).
23. Use Tooling (E) and a press to remove spacer (28) and the bearing cup behind the spacer.
24. Remove spiral ring (27).
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Assemble Transmission Transfer Gears
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1. Install spiral ring (1) in gear (2). Check dimension (X) on both sides of the gear. Put a mark on
the side of the gear with the larger dimension.
NOTE: Spacer (3) must be installed on the side of the gear that has the greater dimension from
the spiral ring to the face on the gear (see Step 1). Groove (4) in the spacer must be toward the
spiral ring as shown.
2. Install spacer (3) in the gear so it is against the spiral ring.
3. Use Tooling (A) and a press to install bearing cup (5). Install the bearing cup so it is against the
spacer.
4. Turn the gear over and use Tooling (A) and a press to install the other bearing cup.
5. Install spacer (7) and two bearing cones (6) in gear (2).
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6. Give support to the lower bearing cone in gear (2). Install gear (2) in the transfer gear case.
7. Install shaft (8) without the shims and without the O-ring seal. Use a feeler gauge to measure
the gap between the bottom of the shaft and the transfer gear case.
NOTE: Check the gap in four places around the shaft.
8. Remove shaft (8).
9. Install O-ring seal (9) on shaft (10). Install enough shims (10) that are equal in thickness to the
average gap [from Step (7)] minus 0.50 ± 0.05 mm (.020 ± .002 in).
10. Install shaft (8) in the transfer gear case. Install the bolts and washers that hold the shaft in
position.
11. Use Tool (B) to install snap ring (11) on bearing (12).
12. Use Tooling (A) to install bearing (12) in cage (13).
NOTE: Make sure the bearing is installed in the cage so that snap ring (11) is in the counterbore
of the cage. Make sure the end of the bearing that is nearest the snap ring is up when installed in
the cage.
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13. Use Tooling (C) and a press to install the bearing and cage (13) on gear (14).
NOTE: Install cage (13) so that the side of the cage that has the snap ring on the bearing is away
from gear (14).
14. Install spiral ring (15).
15. Install gear (14) in the transfer gear case. Install the three bolts that hold the gear in position.
Tighten the three bolts to a torque of 50 ± 3 N·m (37 ± 2 lb ft).
16. Lower the temperature of bearing cup (16). Install the bearing cone in the transfer gear case.
Use Tooling (A) to make sure the bearing is against its seat in the transfer gear case.
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17. Lower the temperature of bearing cup (17). Install the bearing cup (17) in the transfer gear
case. Use Tooling (A) to make sure the bearing is against its seat in the transfer gear case.
18. Heat bearing cones (18) to a temperature of 135°C (275°F). Install the bearing cones on gear
(19).
19. Install gear (19) in the transfer gear case. Make sure the side of the gear with holes (20) are up
as shown.
20. Install gear (21) on gear (19). Install the bolts that hold it in position. Tighten the bolts to a
torque of 50 ± 3 N·m (37 ± 2 lb ft).
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21. Lower the temperature of the bearing cup for cage (22). Install the bearing cup in the cage.
Use Tooling (A) to make sure the bearing cup is against its seat in the cage.
22. Install the shims and cage (22) on the transfer gear case. Install bolts (23). Tighten bolts (23)
to a torque of 50 ± 3 N·m (37 ± 2 lb ft).
23. Use Tooling (D) to check the bearing end play. Add or subtract shims under cage (22) until the
bearing end play is 0.15 ± 0.05 mm (.006 ± .002 in).
24. Install light (24) on the transfer gear case.
25. Lower the temperature of bearing cup (25). Install the bearing cup in cage (26). Use Tooling
(A) to make sure the bearing cup is against the seat in the cage.
26. Heat bearing cones (27) to a temperature of 135°C (275°F). Install the bearing on gear (28).
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27. Install spiral ring (29) in the gear.
28. Install gear (28), the original shims and cage (26) in the transfer gear case.
NOTE: Make sure the O-ring seal on the cage is removed before the cage is installed.
29. Use Tooling (D) to check the bearing end play. It will be necessary to add or subtract shims
until the bearing end play is 0.15 ± 0.05 mm (.006 ± .002 in).
30. Remove cage (26) and gear (28). Put the O-ring seal on the cage.
NOTE: Gear (28) and cage (26) will be installed in the transfer gear case after the transfer gear
case is installed on the transmission.
31. Install coupling (30) in gear (28).
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NOTE: On later models, install the other spiral ring that is in the middle of gear (28).
End By:
a. install transmission pump
b. install transmission oil filter
c. install transmission transfer gears
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue Feb 16 08:40:12 UTC+0800 2021
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Shutdown SIS
Previous Screen
Product: WHEEL TRACTOR
Model: 651E WHEEL TRACTOR 4YR
Configuration: 651E Wheel Tractor 4YR00001-UP (MACHINE) POWERED BY 3412E Engine
Disassembly and Assembly
651E & 657E TRACTOR POWER TRAIN
Media Number -SENR9096-02 Publication Date -01/10/2004 Date Updated -11/06/2015
SENR90960019
Transmission & Transfer Gears
SMCS - 3002-011; 3002-012; 3030-015; 3030-016
Remove Transmission & Transfer Gears
Start By:
a. remove cushion hitch pump*
1. Turn the tractor 90 degrees to the scraper. Remove the oil from the bevel gear case for the
transmission and from the transmission sump.
2. Remove the cushion hitch pump. See REMOVE CUSHION HITCH PUMP in machine systems
DISASSEMBLY AND ASSEMBLY section.
3. Remove the bolts that hold clip (1) in position on top of the transmission. Move the clip and the
oil line connected to the clip away from the transmission.
4. Disconnect wire harness (2) at the connector on top of the transmission. Move the tractor end of
the harness away from the transmission..
5. Disconnect wire harness (3) at the connector beside the cushion hitch. Clip or tie the
transmission portion of the wiring harness to the transmission.
6. Remove bracket (4) that support the transmission oil lines.
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7. Disconnect hose (5).
8. Remove bolts (6) that hold the cage in position on the transfer gears. Use two 3/8 in - 16 NC
Forcing Screws to remove cage (7), and the shims from the transfer gears.
9. Remove gear (8) from the drive shaft.
10. Pull drive shaft (9) part way out of the transmission. Fasten a strap and a hoist to the drive
shaft and remove it from the transmission. The weight of the drive shaft is approximately 32 kg
(70 lb).
11. Fasten a strap (10) to one of the oil lines above the transmission and to tube (11). Remove the
four bolts that hold the tube against the rear of the transfer gear case.
12. Remove two bolts (12).
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13. Remove the eight bolts that hold oil lines (13) in position on the adapter on the side of the
transmission.
14. Fasten a chain and a hoist to the three lifting eyes on the transmission.
15. Remove guard (14).
16. Remove bolts (15) and nuts (16) that hold the transmission to the differential carrier. Do not
remove nuts (17) that hold the differential carrier to the bevel gear case.
17. Use 5/8 in - 11 NC Forcing Screws to move the transmission away from the differential
carrier. Remove transmission and transfer gears (18) from the machine. The weight of the
transmission and transfer gears is approximately 1586 kg (3500 lb).
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Install Transmission & Transfer Gears
1. Make sure two O-ring seals (2) are in position on the differential carrier. Put clean oil on the O-
ring seals. Make sure the O-ring seal is in position on the end of the transmission.
2. Install transmission and transfer gears (1) on the machine. The weight of the transmission and
transfer gears is approximately 1586 kg (3500 lb).
3. Install the nuts (3) and bolts (4) that hold the transmission in position against the differential
carrier.
4. Install the guard and the bolts that hold guard (5) in position on the machine.
5. Install the bolts that hold oil lines (6) in position on the adapter on the side of the transmission.
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6. Install clamp (7) that supports the oil lines.
7. Make sure the O-ring seal is in position on the end of tube (9). Install the four bolts that hold
tube (9) against the rear of the transfer gear case. Remove strap (8).
8. Install two bolts (10).
9. Use a strap and a hoist to install drive shaft (11). The weight of the drive shaft is approximately
32 kg (70 lb).
10. Install gear (12) on the drive shaft. Use a punch to turn the idler gear, if necessary, to put the
teeth on gear (12) in alignment with the teeth on the idler gear in the transfer gear case.
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11. Install two 3/8 in - 16 NC Guide Bolts in the transfer gears as shown. Make sure the O-ring
seal is in position on the cage. Put clean oil on the O-ring seal. Make sure the O-ring seal is in
position on cage (13). Put clean oil on the seal. Install cage (13) and shims (14) on the transfer
gear case.
12. Connect oil line (15) to the cage.
13. Connect transmission wire harness (16) to the wiring harness from the tractor.
14. Connect wiring harness (17) to the connector beside the cushion hitch.
15. Install bolt (18) and clip for the oil line.
16. Fill the bevel gear case with transmission oil to the correct level.
End By:
a. install cushion hitch pump *
*
Disassemble Transmission
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Start By:
a. remove transmission and transfer gears
b. remove hydraulic control valves
1. Remove transfer gears from transmission (see REMOVE TRANSFER GEARS) and put
transmission case (1) in position on Tool (A) as shown.
2. Fasten Tool (B) and a hoist on No. 7 clutch housing (3).
3. Remove bolts (2) and the No. 3 through No. 7 clutch housings from transmission case (1). The
weight of the No. 3 through No. 7 clutch housings is 522 kg (1150 lb).
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4. Put the No. 3 through No. 7 clutch housings in position on Tool (C).
5. Use Tool (D) to hold the piston in No. 7 clutch housing (3).
6. Fasten Tool (B) and a hoist on No. 7 clutch housing (3) as shown.
7. Remove bolts (4) and No. 7 clutch housing (3) from the No. 6 clutch housing. The weight of the
No. 7 clutch housing is 41 kg (90 lb).
8. Remove piston (5) from the No. 7 clutch housing.
9. Remove ring (6) from piston (5).
10. Remove ring (7) from No. 7 clutch housing (3).
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11. Remove springs (9), five discs (8), four plates (12), separator springs (11) and pins (10) for the
No. 7 clutch.
12. Remove ring (14) and adapter (13) from the carrier.
13. Remove gear (15) from the No. 6 clutch housing.
14. Fasten Tool (B) and a hoist on No. 6 clutch housing (16) and remove it from the No. 5 clutch
housing. The weight of the clutch housing is 63 kg (140 lb).
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18. Put the No. 6 clutch housing on its opposite side and if necessary remove the dowels.
19. Remove springs (21), four discs (20), three plates (22) and the pins for the No. 6 clutch.
20. Use Tool (E) and remove snap ring (23) from the shaft assembly.
21. Fasten Tool (B) and a hoist on carrier (24) and remove it from the gear. The weight of the
carrier is 61 kg (135 lb).
22. Remove bearing (25) from the carrier.
23. Use a hammer and punch to push pins (26) in the outer shafts so the shafts can be removed.
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24. Remove shafts (28) from the carrier and remove gears (27), washers (30) and bearings (29).
After shafts (28) are removed, remove pins (26) from the shafts.
25. Use a hammer and punch to push pins (32) in inner shafts (31) so the shafts can be removed.
26. Remove shafts (31) from the carrier and remove inner gears (35), washers (33) and bearings
(34). After shafts (31) are removed, remove pins (32) from the shafts.
27. Remove spiral ring (37) and gears (36) and (38) from the shaft assembly.
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28. Bend the locks away from bolts (40) and remove bolts (40), the locks and plate (39) from the
carrier.
29. Remove gear (41) from the No. 5 clutch housing.
30. Remove the two bolts that hold No. 5 clutch housing to the plate.
31. Fasten Tool (B) and a hoist on No. 5 clutch housing (42) as shown.
32. Use Tool (D) to hold the piston in No. 5 clutch housing (42) and remove the No. 5 clutch
housing from the plate. The weight of the clutch housing is 41 kg (90 lb).
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36. If necessary, put the No. 5 clutch housing on its opposite side and remove the dowels.
37. Remove the springs, three discs (46), the four plates and the pins for the No. 5 clutch.
38. Remove gear (47) from the carrier.
39. Use two 3/8 in - 16 NC Forcing Screws as shown and remove plate assembly (48) from the
housing assembly. If necessary the dowels from the plate assembly.
40. Remove spiral ring (49) from the retainer assembly.
41. Fasten Tooling (B) and a hoist on carrier (50) and remove the bolts and the carrier from the
No. 4 clutch housing. The weight of the carrier is 29 kg (65 lb).
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Caterpillar Cat 651E Wheel Tractor (Prefix 4YR) Service Repair Manual Instant Download.pdf

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Caterpillar Cat 651E Wheel Tractor (Prefix 4YR) Service Repair Manual Instant Download.pdf