Caterpillar Cat 637G Wheel Tractor (Prefix DFJ) Service Repair Manual (DFJ00001 and up).pdf

Service Repair Manual
Models
637G Wheel Tractor

Shutdown SIS
Previous Screen
Product: WHEEL TRACTOR
Model: 637G WHEEL TRACTOR DFJ
Configuration: 637G Wheel Tractor DFJ00001-UP (MACHINE)
Disassembly and Assembly
637G Wheel Tractor-Scraper
Wheel Tractor Power Train
Media Number -RENR8605-00 Publication Date -01/04/2006 Date Updated -21/04/2006
i02185723
Transmission, Torque Converter and Transfer Gears -
Separate
SMCS - 3003-076; 3030-076; 3101-076; 3159-076
Separation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7574 Link Bracket 1
B - Forcing Bolt 1/2 - 13 by 3 inch 2
Start By:
A. Remove the transmission, the torque converter, and the transfer gears. Refer to Disassembly
and Assembly, "Transmission, Torque Converter and Transfer Gears - Remove".
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...

Illustration 1 g00517771
1. Support the transmission with suitable cribbing (1), as shown.
2. Disconnect clip (2) .
3. Install Tooling (A) and a suitable lifting device onto transfer gear case (3) .
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4. Remove the nuts and bolts (4) that hold transfer gear case (3) to transmission (6). Install
Tooling (B) to threaded holes (5). Use Tooling (B) to separate transfer gear case (3) from
transmission (6) .
5. Remove transfer gear case (3) from transmission (6). The weight of transfer gear case (3) is
approximately 340 kg (750 lb).
6. Remove O-ring seal (7) from transfer gear case (3). Remove O-ring seals (8) from
transmission (6) .
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Jun 20 13:23:41 UTC+0800 2021
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Shutdown SIS
Previous Screen
i02176953
Torque Converter - Disassemble
SMCS - 3101-015
Disassembly Procedure
Table 1
Required Tools
A 2P-8312 Retaining Ring Pliers 1
B 1P-0510 Driver Group 1
C -
Forcing Bolts
3/8 - 16 NC by 4 inch
2
Start By:
a. Remove the torque converter. Refer to Disassembly and Assembly, "Torque Converter -
Remove".
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1. Use Tooling (A) in order to remove retaining ring (1) from carriage support assembly (2).
Remove carriage support assembly (2) from hub (3). Use Tooling (B) and a suitable
hydraulic press in order to remove the sleeve bearing from carriage support assembly (2).
2. Remove bolts (4) from impeller (5). Remove bolts (6) and clamp plate (7) from impeller
hub (8).
3. Install Tooling (C) into impeller (5). Use Tooling (C) in order to remove impeller (5) and
impeller hub (8) from housing (9).
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4. Remove thrust race (10) from impeller (5). Remove impeller hub (8) from impeller (5).
5. Remove thrust bearing (11) and seal ring (12A) from carrier assembly (12).
6. Remove carrier assembly (12) and stator (13) as a unit from housing (9).
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7. Position carrier assembly (12) and stator (13), as shown. Use Tooling (A) in order to
remove retaining ring (14) from stator (13). Remove thrust race (15) from stator (13).
8. Remove freewheel rollers (17) and freewheel springs (16) from freewheel cam (18).
Remove stator (13) from carrier assembly (12).
9. Use Tooling (A) in order to remove retaining ring (19) from stator (13). Remove side plate
(20) from stator (13).
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10. Use Tooling (B) and a suitable press in order to remove freewheel cam (18) from stator
(13).
11. Remove thrust bearing (21) from carrier assembly (12). Remove sleeve bearing (22) from
carrier assembly (12).
12. Remove turbine (23) and hub (3) as a unit from housing (9).
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13. Remove thrust bearing (24) and thrust race (25) from hub (3).
14. Position turbine (23), as shown. Remove thrust race (26) from hub (3). Put an alignment
mark on turbine (23) and hub (3) for installation purposes. Remove bolts (27) from turbine
(23).
15. Remove clamp ring (28) and turbine (23) from hub (3).
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16. Remove thrust bearing (29) and thrust race (30) from housing (9).
17. Remove bolts (31) and flange (32) from housing (9).
18. Remove sleeve bearing (33) from flange (32).
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Shutdown SIS
Previous Screen
i06636123
Torque Converter - Assemble
SMCS - 3101-016
Assembly Procedure
Table 1
Required Tools
A 2P-8312 Retaining Ring Pliers 1
B 1P-0510 Driver Group 1
1. Use Tooling (B) and a suitable hydraulic press to install sleeve bearing (33) into flange (32).
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2. Position flange (32) and install bolts (31) onto housing (9). Tighten bolts (31) to a torque of
120 ± 15 N·m (89 ± 11 lb ft).
3. Install thrust bearing (29) and thrust race (30) into housing (9).
4. Install turbine (23) and clamp ring (28) onto hub (3).
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5. Install bolts (27) into turbine (23). Tighten bolts (27) to a torque of 50 ± 7 N·m
(37 ± 5 lb ft). Install thrust race (26) onto hub (3).
6. Install thrust race (25) and thrust bearing (24) onto hub (3).
7. Install turbine (23) and hub (3) as a unit into housing (9).
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8. Use Tooling (B) and a suitable press to install sleeve bearing (22) into carrier assembly (12).
Install thrust bearing (21) onto carrier assembly (12).
9. Install side plate (20) to stator (13). Use Tooling (A) to install retaining ring (19) to stator
(13).
10. Use Tooling (B) and a suitable hydraulic press to install freewheel cam (18) into stator (13).
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11. Install stator (13) to carrier assembly (12). Install freewheel springs (16) and freewheel
rollers (17) to freewheel cam (18). Always install new freewheel springs (16) and freewheel
rollers (17). Install freewheel springs (16) with the maximum number of loops in freewheel
springs (16) to the outside of freewheel cam (18). Stator (13) should turn freely in the
clockwise direction. Stator (13) should not turn freely in the counterclockwise direction.
12. Install thrust race (15) to stator (13). Use Tooling (A) to install retaining ring (14) onto
stator (13).
13. Install carrier assembly (12) and stator (13) as a unit into housing (9).
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14. Install thrust bearing (11) and seal ring (12A) onto carrier assembly (12).
15. Install impeller hub (8) to impeller (5). Install thrust race (10) onto impeller (5).
16. Install clamp plate (7) and bolts (6) onto impeller hub (8). Tighten bolts (6) to a torque of
50 ± 7 N·m (37 ± 5 lb ft).
17. Install bolts (4) into impeller (5). Tighten bolts (4) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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18. Use Tooling (B) and a suitable press to install the sleeve bearing in carriage support
assembly (2). Install the sleeve bearing until the sleeve bearing is flush with the outside
machined surface of carriage support assembly (2).
19. Install carriage support assembly (2) onto hub (3). Use Tooling (A) to install retaining ring
(1) onto carriage support assembly (2).
End By:
a. Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter -
Install".
Sun Jun 20 13:25:32 UTC+0800 2021
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Shutdown SIS
Previous Screen
i02301155
Transfer Gears - Disassemble
SMCS - 3159-015
Disassembly Procedure
Table 1
Required Tools
B
8B-7548 Push-Puller Tool Gp 1
8B-7551 Bearing Puller Gp 1
1P-0498 Drive Plate 1
C
5P-4170 Step Plate 1
1P-2321 Combination Puller 1
D
8B-7554 Bearing Cup Puller Gp 1
5P-4170 Step Plate 1
1P-0518 Drive Plate 1
E
8B-7560 Step Plate 1
5F-7345 Screw 1
8B-7554 Bearing Cup Puller Gp 1
F -
Bolts
3/8" - 16 NC by 3 inch
3
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Start By:
a. Remove the transfer gear case. Refer to Disassembly and Assembly, "Transfer Gears -
Remove".
b. Remove the transmission oil filter base. Refer to Disassembly and Assembly, "Transmission
Oil Filter Base - Remove and Install".
c. Remove the transmission scavenge pump. Refer to Disassembly and Assembly,
"Transmission Scavenge Pump - Remove".
d. Remove the transmission oil pump. Refer to Disassembly and Assembly, "Transmission Oil
Pump - Remove".
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.
NOTICE
Keep all parts clean from contaminants.
Contamination of the hydraulic system with foreign material will
reduce the service life of the hydraulic system components.
To prevent contaminants from entering the hydraulic system, always
plug or cap the lines, fittings, or hoses as they are disconnected. Cover
any disassembled components and clean them properly before
assembly.
Clean the hydraulic system properly after any major component
exchange or especially after a component failure, to remove any
contamination.
1. Put identification marks on components for installation purposes.
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2. Remove the bolts that secure bearing cage (1) to the transfer gear case. Use Tooling (F) in
order to separate bearing cage (1) from the transfer gear case.
3. Remove bearing cage (1), shims (2), and pump drive gear (3) from the transfer gear case.
5. Remove bearing cage (4), shims (5), and gear (6) from the transfer gear case.
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6. Remove bearing cups (7) and (8) from the transfer gear case. Attach Tooling (A) and a
suitable lifting device onto the transfer gear case. The weight of the transfer gear case is
approximately 340 kg (750 lb). Turn over the transfer gear case. Remove Tooling (A).
8. Remove bearing cage (9), shims (10), and gear (11) from the transfer gear case.
9. Remove bearing cup (12) from the transfer gear case. Attach Tooling (A) and a suitable
lifting device onto the transfer gear case. Turn over the transfer gear case.
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10. Remove bolts (13) that secure bearing cage (14) to the transfer gear case. If necessary, rotate
the gear until the three threaded holes are visible in bearing cage (14). Install Tooling (F)
through gear (15) and into bearing cage (14). Tighten Tooling (F) evenly until bearing cage
(14) and gear (15) separate from the transfer gear case. Remove bearing cage (14) and gear
(15) as a unit from the transfer gear case.
11. Remove retaining ring (16) from gear (15). Remove bearing (17) and bearing cage (14)
from gear (15).
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12. Remove bearing (17) from bearing cage (14).
13. Remove bolts (19) and separate gear (20) from gear (11). Use Tooling (B) to remove
bearing cone (18) from gear (11). Repeat the procedure for the bearing cone on the opposite
side of the gear.
14. Use Tooling (C) to remove bearing cone (21) from gear (6). Repeat the procedure for the
bearing cone on the opposite side of gear (6).
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15. Use Tooling (C) to remove bearing cone (22) from gear (3). Repeat the procedure for the
bearing cone on the opposite side of gear (3).
16. Use Tooling (D) to remove bearing cup (23) from bearing cage (4). Remove O-ring seal
(24) from bearing cage (4).
17. Remove bearing cup (25) from bearing cage (9).
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18. Use Tooling (E) to remove bearing cup (26) from bearing cage (1). Remove O-ring seal (27)
from bearing cage (1).
Sun Jun 20 13:26:28 UTC+0800 2021
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Shutdown SIS
Previous Screen
i07232119
Transfer Gears - Assemble
SMCS - 3159-016
Assembly Procedure
Table 1
Required Tools
G 1P-0510 Driver Group 1
H 8T-5096 Dial Indicator 1
NOTICE
Keep all parts clean from contaminants.
Contamination of the hydraulic system with foreign material will
reduce the service life of the hydraulic system components.
To prevent contaminants from entering the hydraulic system, always
plug or cap the lines, fittings, or hoses as they are disconnected. Cover
any disassembled components and clean them properly before
assembly.
Clean the hydraulic system properly after any major component
exchange or especially after a component failure, to remove any
contamination.
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1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new parts for
replacement.
2. Lubricate O-ring seals with the lubricant that is being sealed.
3. Install bearing (17) into bearing cage (14).
4. Use Tooling (G) to install bearing (17) and bearing cage (14) to gear (15). Install bearing
(17) and bearing cage (14) until the retaining ring groove is visible. Install retaining ring
(16) to gear (15).
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5. Position gear (15) and bearing cage (14) in the transfer gear case. Install bolts (13) that
secure bearing cage (14) to the transfer gear case. Tighten bolts (13) to a torque of
55 ± 10 N·m (41 ± 7 lb ft).
6. Install O-ring seal (27) onto bearing cage (1). Lower the temperature of bearing cup (26).
Install bearing cup (26) to bearing cage (1). Check that bearing cup (26) is seated in the bore
of bearing cage (1).
7. Lower the temperature of bearing cup (25). Install bearing cup (25) to bearing cage (9).
Check that bearing cup (25) is seated in the bore of bearing cage (9).
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8. Install O-ring seal (24) to bearing cage (4). Lower the temperature of bearing cup (23).
Install bearing cup (23) to bearing cage (4). Check that bearing cup (23) is seated in the bore
of bearing cage (4).
9. Raise the temperature of bearing cone (22). Install bearing cone (22) on gear (3). Repeat the
procedure for the bearing cone on the opposite side of gear (3).
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10. Raise the temperature of bearing cone (21). Install bearing cone (21) on gear (6). Repeat the
procedure for the bearing cone on the opposite side of gear (6).
11. Raise the temperature of bearing cone (18). Install bearing cone (18) on gear (11). Repeat
the procedure for the bearing cone on the opposite side of gear (11).
12. Position gear (20) on gear (11). Install bolts (19). Tighten bolts (19) to a torque of
55 ± 10 N·m (41 ± 7 lb ft). Attach Tooling (A) and a suitable lifting device onto the transfer
gear case. The weight of the transfer gear case is approximately 340 kg (750 lb). Turn over
the transfer gear case. Remove Tooling (A).
13. Lower the temperature of bearing cup (12). Use Tooling (G) to install bearing cup (12) to
the transfer gear case. Check that bearing cup (12) is seated in the bore of the transfer gear
case.
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14. Position gear (11) in the transfer gear case. Install bearing cage (9) and shims (10). Install
bolts (28) that hold bearing cage (9) in position. Tighten bolts (28) to a torque of
55 ± 10 N·m (41 ± 7 lb ft).
15. Position Tooling (H) in the transfer gear case, as shown. Make sure that the dial indicator is
in contact with gear (11). Use a pry bar to move gear (11) up and down. Adjust shims (10)
to obtain an end play of 0.15 ± 0.05 mm (0.006 ± 0.002 inch). Tighten bolts (28) to a torque
of 55 ± 10 N·m (41 ± 7 lb ft).
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16. Use Tooling (G) to install bearing cups (7) and (8) to the transfer gear case. Check that
bearing cups (7) and (8) is seated in the bore of the transfer gear case.
17. Position gear (6) in the transfer gear case with the internal snap ring groove facing up.
Install bearing cage (4) and shims (5). Install the bolts (29) that hold bearing cage (4) in
position. Tighten bolts (29) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
18. Attach Tooling (A) and a suitable lifting device to the transfer gear case. Place the transfer
gear case on wood blocks, as shown. Position Tooling (H) on the transfer gear case, as
shown. Make sure that the dial indicator is in contact with gear (6). Use a pry bar to move
gear (6) up and down. Adjust shims (5) to obtain an end play of 0.15 ± 0.05 mm
(0.006 ± 0.002 inch). Tighten bolts (29) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Caterpillar Cat 637G Wheel Tractor (Prefix DFJ) Service Repair Manual (DFJ00001 and up).pdf

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Caterpillar Cat 637G Wheel Tractor (Prefix DFJ) Service Repair Manual (DFJ00001 and up).pdf