Caterpillar_Cat_D6M_TRACK-TYPE_TRACTOR__Prefix_2YS__Service_Repair_Manual__2YS00001_and_up_.pdf

Transcript

1. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i01361761 Torque Converter - Assemble SMCS - 4170-077 Assembly Procedure Table 1 Tools Needed A B C D E F G 1P-1855 Retaining Ring Pliers 1 1P-510 Driver Group 1 6V-2156 Link Bracket 2 2P-8312 External Retaining Ring Pliers 1 1P-520 Driver Group 1 8B-7551 Bearing Puller Assembly 1 8S-2328 Dial Indicator Group 1
2. Illustration 1 g00712901 Illustration 2 g00712902 1. Install race (34) and ring (33) in one side of stator (31) . 2. Lower the temperature of adapter (35). Install the adapter in stator (31) . 3. Install race (34) and ring (33) in the other side of stator (31) . Illustration 3 g00712904 4. Heat the bearing and carrier (48) to maximum temperature of 135°C (275.0°F). Install the parts on carrier (39), as shown. 5. Install ring (47) on carrier (39) . 6. Install ring (49) on carrier (48) .
3. Illustration 4 g00712905 7. Use a press in order to install bearing (45) on shaft (44) . 8. Install ring (46) on the shaft. Illustration 5 g00712908 9. Install bearing (45) and shaft (44) in carrier (39) as an assembly. 10. Install ring (43) in order to hold the bearing in position. 11. Use Tool (D) in order to install snap ring (46) on shaft (44) .
4. Illustration 6 g00712911 12. If race (42) was removed, lower the temperature of the race. Install the race in gear (40) . Illustration 7 g00712912 13. Put impeller (20) in position on gear (40) . 14. Align the bolt holes in hub (37) with the holes in gear (40). Put hub (37) in position on impeller (20) . 15. Install eight bolts (41). Tighten the bolts to a torque 50 N·m ± 7 N·m (37.0 lb ft ± 5.0 lb ft).
5. Illustration 8 g00712913 Illustration 9 g00712914 16. Check the clearance between stator (31) and impeller (20) in the following manner. a. Put retainer (38), the race and bearing (36) in position on hub (37) . b. Put stator (31) in position on bearing (36) . c. Put Tool (G) in position with the point of the dial indicator against the surface of stator (31), as shown. d. Push stator (31) toward Tooling (G) until the stator makes contact with the impeller. Adjust the dial indicator until the dial indicator is on zero. Slide the stator 180 degrees from Tooling (G) until the stator makes contact with the other side of the impeller. Make a record of this dimension. e. Make this check at several locations around the housing. Make a record of each of the dimensions measured. The largest dimension that is measured is used for the clearance between the two parts. The total clearance that is measured across the diameters must be 0.49 mm to 1.01 mm (0.019 inch to 0.040 inch) for new parts. The maximum clearance with worn parts is 1.50 mm (0.059 inch). f. Remove the stator, bearing (36), the race and retainer (38) .
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7. Illustration 10 g00712916 17. Put turbine (25) in position on hub (23). Install bolts (26). Tighten the bolts to a torque of 50 N·m ± 7 N·m (37.0 lb ft ± 5.0 lb ft). Illustration 11 g00712919 Illustration 12 g00712920 18. Check the clearance between stator (31) and turbine (25) in the following manner.
8. a. Put retainer (24), the race, and bearing (22) in position on hub (23) . b. Put stator (31) in position on bearing (22) . c. Put Tool (G) in position with the point of the dial indicator against the surface of stator (31), as shown. d. Move the stator toward Tooling (G) until the stator makes contact with the inside diameter in the turbine. Adjust the dial indicator until the dial indicator is on zero. Slide the stator 180 degrees from Tooling (G) until the stator makes contact with the other side of the turbine. Make a record of the dimension measured. e. Make this check at several locations around the turbine. Make a record of each dimension measured. The largest dimension that is measured is used for the clearance between the two parts. The total clearance across the diameters must be 0.49 mm to 1.01 mm (0.019 inch to 0.040 inch) for new parts. The maximum clearance with worn parts is 1.50 mm (0.059 inch). f. Remove stator (31), bearing (22), the race, and retainer (24) from hub (23) . Illustration 13 g00712934 19. Put impeller (20) and the hub in position on carrier (39) .
9. Illustration 14 g00712936 20. Put bearing (36), the race, and retainer (38) in position on hub (37) . Illustration 15 g00712939 21. Put stator (31) in position on the carrier. Use Tool (D) in order to install ring (32) . Illustration 16 g00712940 22. Use Tool (B) in order to install bearing (30) in housing (21) until the bearing is 3.0 mm ± 0.5 mm (0.12 inch ± 0.02 inch) below the surface of the housing. The inside diameter of the bearing must be 60.388 mm ± 0.038 mm (2.3775 inch ± 0.0015 inch) after installation.
10. Illustration 17 g00712942 23. Put race (29), bearing (28) and race (27) in position in housing (21) . Illustration 18 g00712943 24. Put turbine (25) and hub (23) in position in housing (21) . Illustration 19 g00712946 25. Put retainer (24), the race and bearing (22) in position on hub (23) .
11. Illustration 20 g00712950 26. Fasten a hoist and Tooling (C) to carrier (39) . 27. Put impeller (20) in position on housing (21). Install bolts (51). Tighten the bolts to a torque of 50 N·m ± 7 N·m (37.0 lb ft ± 5.0 lb ft). Illustration 21 g00712954 28. Fasten a hoist and Tooling (C) in order to housing (19). Align the ports in housing (19) with the ports in the carrier. Install the housing.
12. Illustration 22 g00712957 29. Use a press and Tool (B) in order to install seal (18) in carrier (17). Install the seal with the lip, as shown. Put clean oil on the lip of the lip seal. Illustration 23 g00712959 30. Put the gasket and carrier (17) in position on the housing. Install bolts (52). Tighten the bolts to torque of 50 N·m ± 7 N·m (37.0 lb ft ± 5.0 lb ft). Illustration 24 g00712970
13. 31. Install the plug (16) in gear (12) until the end of the plug is 1.25 mm ± 0.25 mm (0.049 inch ± 0.010 inch) below the surface of the gear. Illustration 25 g00712972 32. If bearing (15) was removed, heat the bearing to a maximum temperature of 135°C (275.0° F). Install the bearing on gear (12) . Illustration 26 g00712975 33. If bearing cups (14) were removed, lower the temperature of the bearing cups. Install the bearing cups in adapter (9) .
14. Illustration 27 g00712985 34. Put adapter (9) in position on gear (12) . 35. Heat bearing (13) to a maximum temperature of 135°C (275.0°F). Install the bearing on gear (12) . 36. Use Tool (A) in order to install snap ring (11) on gear (12) . Note: Gear (12) must be free to turn by hand after the gear is installed in the adapter. Illustration 28 g00712986 37. Install the two O-ring seals on adapter (9) . 38. Put adapter (9) in position in the housing. Install bolts (10) .
15. Illustration 29 g00713191 39. Use Tool (E) in order to install bearings (8) on each side of gear (7) . 40. Put gear (7) in position in the housing. Illustration 30 g00713193 41. Install the O-ring seal on adapter assembly (6). Put the adapter assembly in position in the housing. Install bolts (5) .
16. Illustration 31 g00713194 42. Put yoke (3) and O-ring seal (4) on the shaft. Illustration 32 g00713196 43. Put retainer (1) in position on the yoke. Install bolt (2). Tighten bolt (2) to a torque of 120 N·m ± 15 N·m (90.0 lb ft ± 11.0 lb ft). End By: Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Dec 17 00:16:16 UTC+0800 2021
17. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i00965402 Torque Converter - Install SMCS - 4170-077 Installation Procedure Table 1 Tools Needed A B C 1U-7505 Hydraulic Jack 1 6V-2082 Lifting Hook 1 5P-9736 Link Bracket 2 8S-9906 Ratchet Puller 1 Illustration 1 g00713786 1. Put the torque converter in position under the machine.
18. 2. Fasten a hoist to Tooling (B). Fasten Tooling (C) to Tooling (B) and the torque converter. 3. Use Tool (C) and raise the torque converter off the ground. Illustration 2 g00713790 4. Put Tool (A) in position under torque converter (11). Fasten the torque converter to Tool (A) . Illustration 3 g00713797 5. Install two 3/8 inch - 16 NC guide bolts (12) in the flywheel housing. 6. The O-ring seal must be in position on the torque converter housing. 7. Put the torque converter in position on the flywheel housing. Install the four bolts that hold the torque converter in place. 8. Remove Tool (A) .
19. Illustration 4 g00713801 9. Install two bolts (8) . Illustration 5 g00713806 10. Put tube assembly (6) and clamp (7) in position. Install the bolt that holds the parts in place. Illustration 6 g00713807 11. Connect hoses (3), (4), and (5) .
20. Illustration 7 g00713814 12. Put bracket (1) in position. Install the bolt that holds the bracket in place. 13. Connect two wire harnesses (2). Put the wire harnesses in position in the clips. Refer to the Disassembly And Assembly Manual, Senora for the procedure to install the implement pump., End By: a. Install the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Torque Converter Outlet Relief Valve - Install". b. Install the power train oil pump. Refer to Disassembly and Assembly, "Power Train Oil Pump - Install". c. Install the implement pump. Refer to Disassembly and AssemblySENR9486, "Implement Pump - Install". d. Install the drive shaft. Refer to Disassembly and Assembly, "Main Drive Shaft - Remove and Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Dec 17 00:17:12 UTC+0800 2021
21. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i00965409 Torque Converter Outlet Relief Valve - Remove SMCS - 4170-077 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. 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 in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. 1. Remove the floorplate.
22. Illustration 1 g00714222 Illustration 2 g00714240 2. Remove bolt (3) and move clip (1) away from the relief valve. Reinstall bolt (3) . 3. Remove bolt (4) and move clip (2) away from the relief valve. Reinstall bolt (3) . 4. Disconnect tube assembly (5) from relief valve (6) . 5. Remove the bolts and torque converter outlet relief valve (6) from the torque converter. 6. Remove the O-ring seals from the torque converter outlet relief valve. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Dec 17 00:18:08 UTC+0800 2021
23. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i00963441 Torque Converter Outlet Relief Valve - Disassemble SMCS - 4170-077 Disassembly Procedure Start By: A. Remove the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Torque Converter Outlet Relief Valve - 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. Illustration 1 g00689829 1. Remove adapter (2) and O-ring seals (1) from body (3) .
24. Illustration 2 g00689834 2. Remove bolts (4) and (5). Remove covers (6) and (7). Remove the O-ring seals from the body. Illustration 3 g00689836 3. Remove spring (10), spacers (9), and spool (8) from body (3) . Illustration 4 g00689839
25. 4. Remove ring (12), retainer (14), spring (13), and poppet (11) from spool (8) . Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Dec 17 00:19:03 UTC+0800 2021
26. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i00963439 Torque Converter Outlet Relief Valve - Assemble SMCS - 4170-077 Assembly Procedure 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. Illustration 1 g00688830 1. Put poppet (1), spring (4), and retainer (3) in position in spool (2). Install retainer (5) .
27. Illustration 2 g00688832 Note: Spacers (8) are used to make an adjustment to the pressure needed in order to open the torque converter outlet relief valve. 2. Install spool (2), spacers (8), and spring (7) in body (6) . Illustration 3 g00688837 3. Put O-ring seals (9) in position on each end of body (6). Install covers (6) and (10) .
28. Illustration 4 g00688839 4. Make sure that the O-ring seal is in place in adapter (12). Install the adapter on body (6) . 5. Put O-ring seals (11) in position in body (6) . End By: Install the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Torque Converter Outlet Relief Valve - Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Dec 17 00:19:59 UTC+0800 2021
29. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i00965407 Torque Converter Outlet Relief Valve - Install SMCS - 4170-077 Installation Procedure Illustration 1 g00714240
30. Illustration 2 g00714222 1. Put the two O-ring seals in position in relief valve (6) . 2. Put the relief valve in position on the torque converter housing. Install the bolts that hold the relief valve in place. 3. The O-ring seal must be in place in tube assembly (5). Connect the tube assembly to the relief valve. 4. Remove bolt (4). Put clip (2) in position on the relief valve. Install bolt (4) . 5. Remove bolt (3). Put clip (1) in position on the relief valve. Install bolt (3) . 6. Install the floorplate. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Dec 17 00:20:55 UTC+0800 2021
31. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i00963549 Transmission Brake - Remove SMCS - 4170-077 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. 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 in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. 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. 1. Drain the oil from the transmission and bevel gear case.
32. Illustration 1 g00691362 2. Remove bolts (1), cover (2), and the gasket from the rear of the transmission case. Illustration 2 g00691359 3. Remove bolts (4) and transmission brake (3) from the transmission. 4. Remove the O-ring seal from the transmission brake. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Dec 17 00:21:50 UTC+0800 2021
33. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i00963547 Transmission Brake - Disassemble SMCS - 4170-077 Disassembly Procedure Start By: A. Remove the transmission brake. Refer to Disassembly and Assembly, "Transmission Brake - 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. Illustration 1 g00691340 1. Use a hammer and a punch to drive the dowels out of housing assembly (1) . 2. Remove springs (3) and pad assemblies (2) .
34. Illustration 2 g00691336 3. Remove pistons (5) from housing assembly (1) . 4. Remove seal (4) and the O-ring seal from each piston. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Dec 17 00:22:46 UTC+0800 2021
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37. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i00963546 Transmission Brake - Assemble SMCS - 4170-077 Assembly Procedure 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. Illustration 1 g00691336 1. Install the O-ring seal and seal (4) on both pistons. Put clean oil on the seals. 2. Install pistons (5) in housing assembly (1) .
38. Illustration 2 g00691340 3. Install pad assemblies (2) in the housing assembly. 4. Put springs (3) in position between the pad assemblies. Install the dowels. End By: Install the transmission brake. Refer to Disassembly and Assembly, "Transmission Brake - Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Fri Dec 17 00:23:42 UTC+0800 2021
39. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 2YS Configuration: D6M XL & D6M LGP TRACTORS / POWERSHIFT / 2YS00001-UP (MACHINE) POWERED BY 3116 ENGINE Disassembly and Assembly D6M Track-Type Tractor Power Train Media Number -SENR9482-04 Publication Date -01/01/2011 Date Updated -31/01/2011 i00963548 Transmission Brake - Install SMCS - 4170-077 Installation Procedure 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. Illustration 1 g00691359 1. Put the O-ring seal in position on transmission brake (3) . 2. Put transmission brake (3) in position in the transmission. Install bolts (4) .
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