Caterpillar Cat D6R II TRACK-TYPE TRACTOR (Prefix BPP) Service Repair Manual Instant Download.pdf

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D6R II TRACK-TYPE TRACTOR BPP
Configuration: D6R SERIES II TRACK-TYPE TRACTOR BPP00501-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
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
D6R SERIES II TRACK-TYPE TRACTOR BPP00501-UP (MACHINE) POWERED ...
2021/2/12
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

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:
Illustration 1 g00837218
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:
2/13
2021/2/12

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
2021/2/12

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:
4/13
2021/2/12

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) .
5/13
2021/2/12

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
2021/2/12

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) .
7/13
2021/2/12

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
2021/2/12

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
2021/2/12

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) .
10/13
D6R SERIES II TRACK-TYPE TRACTOR BPP00501-UP (MACHINE) POWERE...
2021/2/12

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).
11/13
2021/2/12

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.
12/13
2021/2/12

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.
Fri Feb 12 11:29:31 UTC+0800 2021
13/13
2021/2/12

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
2021/2/12

Typical example
2. Install gear (21) and ring (20) .
3. Attach a chain around the ROPS. Attach Tooling (A) to the chains.
2/9
2021/2/12

4. Attach Tooling (A) to torque converter (19) .
3/9
2021/2/12

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
2021/2/12

10. Install hose assembly (12) .
11. Install hose assemblies (11) .
5/9
2021/2/12

12. Install bottom guard (10) . Install bolts (9) .
13. Connect hose (8) and tighten hose clamp (7) .
6/9
2021/2/12

14. Connect harness assembly (6) .
15. Connect harness assembly (5) .
7/9
2021/2/12

16. Install four bolts (4) .
17. Connect hose assembly (3) to the flywheel housing.
18. Install bracket (2) and install bolt (1) .
8/9
2021/2/12

19. Check the level of the power train oil. Refer to Operation and Maintenance Manual,
SEBU7299, "Transmission System Oil Level - Check" for the correct procedure.
20. Install the floorplate.
,
End By:
a. Install the drive shaft. Refer to Disassembly and Assembly, "Drive Shaft - Remove and
Install".
b. Install the bottom guards. Refer to Disassembly and AssemblyRENR4261, "Bottom Guard -
Install".
Fri Feb 12 11:30:31 UTC+0800 2021
9/9
2021/2/12

Shutdown SIS
Previous Screen
i01689260
Transmission and Bevel Gears - Remove
SMCS - 3010-011; 3150-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
FT-1897 Bracket 1
138-7575 Link Bracket 2
B Forcing Bolt (1/2 by 13 NC by 3) 2
C 180-3033 Stand 1
D 8S-9906 Ratchet Puller 1
E 138-7573 Link Bracket 2
F 138-7574 Link Bracket 2
Start By:
A. Remove the drive shaft. Refer to Disassembly and Assembly, "Drive Shaft - Remove and
Install".
B. Remove the axles. Refer to Disassembly and Assembly, "Axle - Remove and Install".
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.
NOTICE
1/6
2021/2/12

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.
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. This helps to prevent fluid loss and this
helps to keep contaminants from entering the system.
1. Lower the ripper to the ground. Remove the ripper shanks or invert the ripper shanks.
2. Drain the power train oil into a suitable container for storage or disposal. The capacity of
the power train oil system is 148 L (38.5 US gal).
3. Attach a suitable lifting device to the ripper assembly. Remove the cylinder pin and lower
the ripper assembly to the ground.
4. Remove bolts (1) and bolts (2). Remove guard assembly (3) .
Note: Do not disconnect the ripper lines.
2/6
2021/2/12

5. Remove bolts (4) and remove guard (5) .
6. Remove bolts (6) and cover (7). Install Tooling (A). Remove bolts (8) and cover (9). Attach
a suitable lifting device to Tooling (A) .
3/6
2021/2/12

7. Remove cover (10). Disconnect tube assembly (11) .
8. Disconnect harness assembly (12). Remove bolts (13) .
9. Attach a suitable lifting device to Tooling (A). Apply a small amount of lifting pressure to
Tooling (A). Install Tooling (B) and separate the transmission and bevel gears from the
case.
4/6
2021/2/12

Suggest:
If the above button click is invalid.
Please download this document
first, and then click the above link
to download the complete manual.
Thank you so much for reading

10. Place the transmission and bevel gears on Tooling (C). Remove Tooling (A) .
11. Remove the pin from the left hand link (14). Attach Tooling (D) and lift the link out of the
way.
5/6
2021/2/12

12. Install bolts (6) and cover (7) and attach Tooling (E). Attach a suitable lifting device to
Tooling (E). Lift the transmission and bevel gears on the rails. Allow the transmission to
rest on the ripper.
13. Attach Tooling (F) to the transmission and bevel gears (15). Remove the transmission and
bevel gears. Use a pry bar to balance the transmission and bevel gears (15). The weight of
transmission and bevel gears is approximately 816 kg (1800 lb).
Fri Feb 12 11:31:30 UTC+0800 2021
6/6
2021/2/12

Caterpillar Cat D6R II TRACK-TYPE TRACTOR (Prefix BPP) Service Repair Manual Instant Download.pdf

Recommended

Recommended

More Related Content

Similar to Caterpillar Cat D6R II TRACK-TYPE TRACTOR (Prefix BPP) Service Repair Manual Instant Download.pdf

Similar to Caterpillar Cat D6R II TRACK-TYPE TRACTOR (Prefix BPP) Service Repair Manual Instant Download.pdf (15)

More from f8ioseoodkmmd

More from f8ioseoodkmmd (20)

Recently uploaded

Recently uploaded (17)

Caterpillar Cat D6R II TRACK-TYPE TRACTOR (Prefix BPP) Service Repair Manual Instant Download.pdf