Caterpillar Cat D6M TRACK-TYPE TRACTOR (Prefix 4HS) Service Repair Manual (4HS00001 and up).pdf

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D6M TRACK-TYPE TRACTOR 4HS
Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 4HS00001-UP (MACHINE) POWERED BY 3116 ENGINE
Disassembly and Assembly
D6M Track-Type Tractor Power Train
Media Number -SENR8387-06 Publication Date -01/11/2010 Date Updated -31/07/2018
i00963856
Bevel and Transfer Gears - Disassemble
SMCS - 3011-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5F-7343 Bearing Puller Attachment 1
B 8T-2839 Spanner Wrench 1
C 2P-8312 External Retaining Ring Pliers 1
Start By:
a. Separate the transmission and the bevel gears. Refer to Disassembly and Assembly,
"Transmission and Bevel Gears - Separate".
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. Dirt and contaminants can damage the components. All disassembly and assembly
procedures must be performed on a clean work surface. Clean all the interior components in clean
solvent. Dry all the interior components with compressed air. Plug ports and plug hoses on the
machine during repair.
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https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...

Illustration 1 g00742877
1. Remove bracket assemblies (1) and (3) from the bevel gear case. Remove the two magnetic
sensors (not shown) from bevel gear case.
2. Remove yoke (2).
3. Remove four bolts (4). Install two 10 mm forcing screws in the carrier in order to free the
carrier (5). Tighten the screws evenly and remove the carrier.
4. Remove O-ring seal (6) from carrier (5).
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5. Remove bolts (7). Install two 12 mm forcing screws in the cage in order to free the cage (8).
Tighten the screws evenly and remove cage (8) and shims (9).
6. Remove seal (10) and O-ring seal (11) from cage (8).
7. If necessary, remove bearing cup (12) and bearing (13) from cage (8).
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8. Remove bolts (14). Remove cover (16). Remove shims (15).
9. Remove bolts (17). Install two 12 mm forcing screws in the cover in order to free the cover
(18). Tighten the screws evenly and remove the cover.
10. If necessary, remove dowels (20) and remove bearing cup (19) from cover (18).
Note: Gears (22) and (23) must be removed from the case assembly at the same time.
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11. Remove gear (22) and gear (23) from the case assembly.
12. Remove the bolt and retainer (21) from the gear.
13. Use a press and Tooling (A) to remove bearing cone (24) from pinion (25).
14. Use a press in order to remove bearing cone (26) and pinion (25) from gears (23).
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NOTICE
Bearing cones (27) and (28) must be destroyed in order to remove them
from the gear.
15. If necessary, remove bearing cones (27) and (28) from gear (22).
16. If necessary, remove bearing cups (29) and (30) from the case assembly.
17. Bend the tab on washer (31) away from nut (32). Use Tooling (B) in order to remove the nut
from the bevel gear shaft. Remove washer (31) and the washer from the shaft.
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18. Slide shaft (33) enough to attach a suitable lifting device to the shaft. Fasten a suitable
lifting device to shaft (33), and remove the shaft from the case assembly. The weight of the
shaft is 39 kg (86.0 lb).
19. Use Tooling (C) in order to remove snap ring (35) from shaft (33). Remove bearing (34)
from the shaft.
20. Remove bolts (36) that hold gear (37) to shaft (33). Remove the gear from the shaft.
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21. Remove bolts (38). Remove retainer (41). Remove cage (40). Remove shims (39).
22. Remove the two bearing cups (43) and bearing cones (42) from cage (40).
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Feb 14 19:06:07 UTC+0800 2022
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Shutdown SIS
Previous Screen
i00963854
Bevel and Transfer Gears - Assemble
SMCS - 3011-016
Assembly Procedure
Table 1
Required Tools
A 2P-8312 Retaining Ring Pliers 1
B 8T-2839 Spanner Wrench 1
C
FT1986 Stud 1
2P-8257 Plate 1
6B-6684 Nut 5
2P-8260 Cylinder Liner Installer 1
4B-5273 Washer 3
1D-4719 Nut 2
0S-1590 Bolt 1
D 8S-2328 Dial Indicator Group 1
E 1P-520 Driver Group 1
F FT1986 Stud 1
2P-8257 Plate 1
6B-6684 Nut 8
2P-8260 Cylinder Liner Installer 1
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4B-5273 Washer 4
1D-4719 Nut 2
0S-1590 Bolt 1
1P-1838 Adapter 1
1P-1839 Adapter 1
3T-9674 Retainer 1
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. Dirt and other contaminants can damage the
components. All disassembly and all assembly procedures must be performed on a clean work
surface and in a clean hydraulic area. Keep cleaned parts covered and protected at all times.
1. Install bearing cones (1) and bearing cups (2) in cage (3).
2. Put the original amount of shims (5), cage (3) and retainer (6) in position on the case
assembly, and install bolts (4).
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3. Put gear (8) in position on shaft (9), and install bolts (7).
4. Put bearing (10) in position on shaft (9). Install snap ring (11) on the shaft with Tooling (A).
5. Fasten a suitable lifting device to shaft (9). Put the shaft in position in the case assembly.
Remove the suitable lifting device from the shaft. Push the shaft fully into the case.
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6. Put the washer and washer (12) in position on shaft (9).
7. Put 5P-3931 Anti-Seize Compound on the threads and face of nut (13). Install the nut on
shaft (9). Use Tooling (B), and tighten the nut to a torque of 612 ± 68 N·m
(450.0 ± 50.0 lb ft).
8. If bearing cups (14) and (15) were removed, lower the temperature of the bearing cups and
install the bearing cups in the case assembly.
9. The bearing cups must be seated in the case assembly.
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Note: If the bearing cones were removed from gear (18), new bearing cones must be
installed.
10. Heat bearing cones (16) and (17) to a maximum temperature of 135°C (275°F). Install the
bearing cones on gear (18). The bearing cones must be seated on the gear.
11. Put pinion (21) in position in gear (20).
12. Heat bearing cone (19) to a maximum temperature of 135°C (275°F), and install the bearing
cone on pinion (21). The bearing cone must be seated on the pinion.
13. Install the retainer and the bolt in order to hold the bearing on the pinion while the bearing
cools.
14. Heat bearing cone (22) to a maximum temperature of 135°C (275°F), and install the bearing
cone on pinion (21). The bearing cone must be seated on the pinion.
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Note: Gear (18) and gear (20) must be installed in the case assembly at the same time.
15. Install gear (18) and gear (20) in the case assembly.
16. If dowels (24) were removed, install the dowel in cover (25).
17. If bearing cup (23) was removed, replace the bearing cup. Dimension (X) should measure
4.37 mm (0.172 inch).
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18. Put cover (25) in position, and install bolts (27).
19. Remove the bolt and retainer (26).
20. Put shims (29) with a total thickness of 4.37 mm (0.172 inch) and cover (28) in position on
the cover. Install the bolts that hold the cover in place.
21. Install Tooling (C).
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22. Install Tooling (D) with the point of the dial indicator against the inside race of the bearing
cone.
23. Use Tooling (C) to hold the gear and pinion assembly down. Use a ratchet wrench in order
to rotate the gear and pinion assembly at least three revolutions. Watch the dial indicator as
the needle moves. Stop rotating the assembly at the point of maximum needle movement.
24. Zero the dial indicator. Put a mark on the bearing race at the location of maximum needle
movement.
25. Pull the gear and pinion assembly upward with Tooling (C). Rotate the gear and pinion
assembly at least three revolutions. Stop rotating the assembly at the point of maximum
needle movement. Record the measurement on the dial indicator. This reading is the actual
bearing clearance.
26. Repeat steps 23 through 25. The reading should not change.
27. Remove cover (28). Remove enough shims in order to obtain a bearing clearance of
0.05 mm (0.002 inch) to 0.15 mm (0.006 inch).
28. If bearing (31) was removed, install the bearing in cage (32) with Tooling (E).
29. If bearing cup (30) was removed, lower the temperature of the bearing cup, and install the
bearing cup in cage (32).
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30. Put 7M-7260 Liquid Gasket on the seal bore in cage (32) and allow the sealant to dry. Do
not put sealant on the case of seal (33). Install the lip seal (33) with the lip of the seal toward
the bearing.
31. Install O-ring seal (34) on cage (32).
32. Put retainer (26) in position, and install the bolt that holds the retainer in place.
33. Put cage (32) in position without the shims. Install the two bolts (35) directly across from
each other.
34. Tighten bolts (35) to a torque of 2.3 N·m (20.0 lb in).
35. Rotate the gear at least five revolutions. Tighten the bolts to a torque of 4.5 N·m
(40.0 lb in).
36. Rotate the gear again at least five revolutions. Tighten the bolts again to a torque of 4.5 N·m
(40.0 lb in).
37. Use a feeler gauge, and measure the gap between cage (32) and the cover at the location of
bolts (35). Average the two measurements.
38. Remove bolts (35) and cage (32) from the cover.
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39. Install shims (36) that are equal to the measurement in step 37 plus 0.18 mm (0.007 inch).
40. Put cage (32) in position on the shims, and install bolts (35). Tighten the bolts to a torque of
135 ± 15 N·m (100.0 ± 11.0 lb ft).
41. Use Tooling (D) and Tooling (F) to check the end play of the gear per the following steps.
a. Push down the gear and hold the gear with Tooling (F). Rotate the gear with a ratchet
wrench at least five revolutions. Watch for movement of the dial indicator. Stop
rotating the gear at the point of maximum needle movement.
b. Zero the dial indicator. Put a mark at the location of maximum needle movement.
c. Pull the gear upward with Tooling (F). Rotate the gear at least five revolutions. Stop
the gear at the same point of maximum needle movement. Record the measurement.
This measurement is the actual end play of the gear.
42. Repeat Steps 41.a through 41.c. The measurement should not change. The end play of the
gear must be 0.05 mm (0.002 inch) to 0.15 mm (0.006 inch).
43. Fabricate plate (37) out of a 6.35 mm × 38.10 mm × 127.00 mm
(1/4 inch × 1 1/2 inch × 5.0 inch) piece of mild steel.
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44. Install plate (37) in order to hold the gear while the backlash is checked.
45. Put Tooling (D) in position with the point of the dial indicator against gear (8).
46. Use Tooling (D) to measure the backlash of gear (8) at three evenly spaced locations. The
difference in the three measurements should not be more than 0.08 mm (0.003 inch).
47. Add shims or remove shims (38) in order to obtain a backlash of 0.020 mm (0.008 inch) to
0.030 mm (0.012 inch). Remove plate (37) after the backlash has been adjusted.
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Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have
the same sealing properties as a new O-ring. A reconditioning procedure should not be
degraded because of a low cost component such as an O-ring or a gasket. Use 1U-6396 O-
Ring Assembly Compound during the assembly procedure.
48. Install O-ring seal (40) on carrier (39).
49. Put carrier (39) in position, and install the bolts that hold the carrier in place.
50. Install yoke (41).
51. Install bracket assemblies (42) and (43).
52. Install the two magnetic sensors (not shown) to the bevel gear case. Maintain a 0.89 mm
(0.035 inch) gap between the magnetic sensor and the gear tooth.
End By:
a. Connect the transmission and bevel gears. Refer to Disassembly and Assembly,
"Transmission and Bevel Gears - Connect".
Copyright 1993 - 2022 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Feb 14 19:07:10 UTC+0800 2022
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Shutdown SIS
Previous Screen
i04520390
Transmission - Disassemble
SMCS - 3030-015
Disassembly Procedure
Table 1
Required Tools
A 1P-2420 Transmission Repair Stand 1
B 138-7573 Link Bracket 2
D 5P-4758 Retaining Ring Pliers As 1
E
8B-7548 Push-Puller Tool Gp 1
6H-1627 Spacer 1
F 1P-1863 Retaining Ring Pliers 1
G 1P-1859 Retaining Ring Pliers 1
L 8H-0663 Bearing Puller Gp 1
Start By:
A. Separate the transmission and bevel gears. Refer to Disassembly and Assembly,
"Transmission and Bevel Gears-Separate".
B. Remove the transmission hydraulic control valves. Refer to Disassembly and Assembly,
"Transmission Hydraulic Control Valve-Remove".
1. Place the transmission on Tooling (A) .
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2. Install Tooling (B) in housing (1) . Fasten a suitable lifting device to Tooling (B) .
3. Support the weight of housing (1) with a suitable lifting device. Use Tooling (A) in order to
remove snap ring (2) .
4. Remove bolts (4) and manifold (3) from the planetary group.
5. Remove ring (5) and bearing (6) from housing (3) .
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6. Remove plates (9) and discs (8) . Remove springs (7) .
7. Remove piston (10) from the housing assembly.
8. Remove ring (108) and (109) from piston (10) .
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9. Install Tooling (B) in housing (1) . Fasten a suitable lifting device to Tooling (B) .
10. Use Tooling (D) in order to compress ring (12) . Remove housing (1) .
11. Remove rings (14) and (15) from the carrier.
12. Remove ring (12) from housing (1) .
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13. Use Tooling (E) and a press in order to compress the springs in housing (1) . Remove spiral
lock ring (16) from coupling (17) . Slowly release the spring tension with the press.
14. Remove springs (19) and plate (20) . Remove piston (18) and coupling (17) from housing
(1) .
15. Remove rings (21) and (22) from piston (18) .
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16.
17. Remove pin (23) and pin (25) from carrier (24) .
18. If necessary, break carrier (24) , and remove carrier (24) from housing assembly (1) .
Note: On later transmissions, carrier (24) and housing assembly (1) are one piece.
19. Remove discs (27) and plates (26) from gear (13) .
20. Use Tooling (F) in order to remove snap ring (29) . Remove gear (28) in position on the
shaft.
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21. Remove gear (13) .
22. Remove ring (31) and plate 30 from gear (13) .
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23. Remove housing assembly (32) .
24. Remove piston (33) from housing assembly (32) .
25. Remove springs (35) and rods (54) .
26. Remove discs (36) and plates (34) .
27. Remove rings (106) and (107) from piston (33) .
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28. Remove the carrier from gear (38) .
29. Remove ring (40) .
30. Remove ring (41) .
31. Remove pin (44) .
32. Remove shafts (42) . Remove gears (45) and discs (43) from carrier (37) .
33. Remove the bearings from gears (45) .
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34. Remove snap ring (46) that holds the bearing in carrier (47) .
35. Remove shaft (48) .
36. Use Tooling (F) in order to remove snap ring (49) . Remove gear (50) from the shaft.
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Caterpillar Cat D6M TRACK-TYPE TRACTOR (Prefix 4HS) Service Repair Manual (4HS00001 and up).pdf

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Caterpillar Cat D6M TRACK-TYPE TRACTOR (Prefix 4HS) Service Repair Manual (4HS00001 and up).pdf