Caterpillar_Cat_D6R_II_TRACK-TYPE_TRACTOR__Prefix_ACJ__Service_Repair_Manual__ACJ00001_and_up_.pdf

Transcript

1. Service Repair Manual Models D6R II TRACK-TYPE TRACTOR
2. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6R II TRACK-TYPE TRACTOR ACJ Configuration: D6R Series SERIES IIFTC,LGP TRACK-TYPE TRACTOR ACJ00001-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 i01618664 Final Drive - Disassemble SMCS - 4050-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 3 A 1A-2029 Bolt 3 B 1P-510 Driver Group 1 C FT-1934 Beam 1 C 6V-3160 Cylinder 1 C 6V-9061 Pump Group 1 C 1D-4621 Bolt 4 D 138-7574 Link Bracket 2 D 2A-1538 Bolt 2 Start By: A. Remove the final drives. Refer to Disassembly and Assembly, "Final Drive - Remove" for the correct procedure. 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.
3. Illustration 1 g00841087 1. Install Tooling (A) on the planetary carrier. Attach a hoist. 2. Remove bolts (1) that hold the planetary carrier to the hub. Remove planetary carrier (3) and the two O-ring seals from the hub. The weight of the planetary carrier is approximately 137 kg (302 lb). 3. Remove three retainers (2) . Illustration 2 g00841089 4. Place support under planetary carrier (3) in order to prevent damage. Use Tooling (B) and a press to remove the three planetary gear shafts. 5. Remove three planetary gears (4) from carrier (3) .
4. Illustration 3 g00841091 6. Remove bearing cones (5) from each gear (4) . 7. Remove the bearing cups from each side of the gears. Illustration 4 g00841092 Illustration 5 g00841093 8. Remove bolts (6) and retainer (7) .
5. 9. Use nylon straps and a hoist to remove the hub and ring gear (8). The weight of the hub and ring gear (8) is approximately 68 kg (150 lb). Illustration 6 g00841094 10. Turn over hub (9) and ring gear (8). Remove retaining ring (10). The weight of hub (9) is approximately 37 kg (82 lb). The weight of ring gear (8) is approximately 32 kg (71 lb). Use nylon straps and a hoist to remove hub (9) . Illustration 7 g00841095 11. Install Tooling (C) on hub (12). Note: Do not lift hub (12) too high. Do not allow hub (12) to contact the fitting on the hydraulic cylinder. 12. Use Tooling (C) to loosen hub (12) from spindle (13). Remove Tooling (C) .
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7. 13. Remove bearing cone (11) . Illustration 8 g00841098 14. Install Tooling (D) and a hoist. Remove hub (12) from spindle (13). The weight of hub (12) is approximately 180 kg (397 lb). Illustration 9 g00841099 15. Turn over hub (12). Remove Duo-Cone seal kit (15). Use a hammer and a punch to remove bearing cup (16) . 16. Turn over the hub. Remove bearing cup (14) from the hub. Note: If the Duo-Cone seal kits will be reused, mark the seal kits for installation purposes.
8. Illustration 10 g00841101 Note: Bearing cone (18) may be damaged if the bearing cone is removed from spindle (13) . 17. Remove Duo-Cone seal kit (19) from spindle (13) . 18. If necessary, remove bearing cone (18) from the spindle. 19. Remove lip seal (17) from spindle (13) . Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jan 12 09:55:36 UTC+0800 2021
9. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6R II TRACK-TYPE TRACTOR ACJ Configuration: D6R Series SERIES IIFTC,LGP TRACK-TYPE TRACTOR ACJ00001-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 i01618668 Final Drive - Assemble SMCS - 4050-016 Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 3 A 1A-2029 Bolt 3 B 1P-510 Driver Group 1 D 138-7574 Link Bracket 2 D 2A-1538 Bolt 2 E 8M-9395 Installer 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. 1. Apply clean oil to all the parts during assembly.
10. Illustration 1 g00841209 2. Use Tooling (B) to install lip seal (17) in spindle (13). Put clean oil on the lip of the seal. 3. Heat bearing cone (18) to a maximum temperature of 135 °C (275 °F). Install bearing cone (18) on spindle (13) . Note: Before the installation of the Duo-Cone seal kit, refer to Disassembly and Assembly, "Duo-Cone Floating Seals - Install" for the correct procedure. 4. Use Tooling (E) to install the Duo-Cone seal kit on spindle (13) . Illustration 2 g00841210 5. Lower the temperature of bearing cups (14) and (16). Install bearing cups (14) and (16) in hub (12) . 6. Use Tooling (E) to install the Duo-Cone seal in hub (12) .
11. Illustration 3 g00841211 7. Install Tooling (D) on hub (12). Attach a hoist to Tooling (D). Carefully position hub (12) on spindle (13) . Illustration 4 g00841212 8. Heat bearing cone (11) to a maximum temperature of 135°C (275°F). Install bearing cone (11) on spindle (13).
12. Illustration 5 g00841094 9. Use nylon straps and a hoist to position hub (9) in gear (8). Install retaining ring (10) . Illustration 6 g00841093 10. Turn over the hub and gear (8). Install nylon straps. Attach a hoist to the nylon straps. Use the hoist and the nylon straps to put the hub and the gear into position in hub (12).
13. Illustration 7 g00841092 11. Put retainer (7) into position. Install bolts (6) while the hub is slowly rotated. Tighten bolts (6) evenly to a torque of 135 ± 15 N·m (100 ± 11 lb ft). The retainer must contact the end of spindle (13) after bolts (6) have been tightened. Illustration 8 g00841213 12. Lower the temperature of bearing cups (20) and (21). Install the bearing cups in three planetary gears (4) .
14. Illustration 9 g00841215 Illustration 10 g00841216 13. Position the planetary carrier in a press. Planetary shaft retainer (2) must be in position with proper support in order to be a positive stop for the shaft. NOTICE The shaft must be correctly installed. If the shaft is incorrectly installed, the bearing preload will be incorrect. This will result in component damage. 14. Position planetary gear (4) in the planetary carrier. 15. Lower the temperature of shaft (22). Use a press to install the shaft in the planetary carrier. After the installation, the end of shaft (22) must be flush with the retainer of the planetary
15. carrier. This will provide the correct bearing preload. The gear must rotate by hand after installation. If the gear does not rotate, the problem must be corrected. Repeat this procedure for all three shafts. Illustration 11 g00841087 16. Install three retainers (2) on shafts (22) . 17. Install Tooling (A). Attach a hoist to Tooling (A). Install the two O-ring seals on the planetary carrier. Align the drain hole in the planetary carrier with the drain hole in the hub. 18. Position the planetary carrier in the hub. 19. Install bolts (1) that hold planetary carrier (3) to the hub. Remove Tooling (A) . End By: Install the final drives. Refer to Disassembly and Assembly, "Final Drive - Install" for the correct procedure. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jan 12 09:56:35 UTC+0800 2021
16. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6R II TRACK-TYPE TRACTOR ACJ Configuration: D6R Series SERIES IIFTC,LGP TRACK-TYPE TRACTOR ACJ00001-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 i03576221 Final Drive - Install SMCS - 4050-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A FT-1952 Installer 1 B 8T-3207 Lifting Bracket 1 5P-8622 Shackle 1 1D-4593 5/8 - 11 by 5 1/2 bolt 2 4K-0367 5/8 - 11 by nut 2 5P-8248 Washer 4
17. Illustration 1 g00826743 1. Adjust the top bracket of Tooling (B) until Dimension (X) is 222.25 mm (8.750 inch). Attach Tooling (B) to the final drive. Illustration 2 g00865095 2. Use Tooling (B) to install final drive (1). The weight of final drive (1) is approximately 454 kg (1000 lb). Illustration 3 g00865094 3. Install bolts (7) that hold the final drive and the steering clutch and brake together. Tighten bolts (7) to a torque of 700 ± 90 N·m (516 ± 66 lb ft).
18. Illustration 4 g00865082 4. Remove Tooling (B) from the final drive. Illustration 5 g00865077 5. Install two bolts (6) to the sprocket segment. Illustration 6 g00865075 6. Install two bolts (5). Illustration 7 g00865024
19. 7. Use Tooling (A) to install axle (4). Remove Tooling (A). Note: Carefully install the axle shaft (4) into the final drive (1). It is possible that the axle shaft (4) could damage the lip seal. Illustration 8 g00865052 8. Install cover (3) and bolts (2) on final drive (1). End By: a. Connect the track. Refer to Disassembly and Assembly, "Track - Connect". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jan 12 09:57:34 UTC+0800 2021
20. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6R II TRACK-TYPE TRACTOR ACJ Configuration: D6R Series SERIES IIFTC,LGP TRACK-TYPE TRACTOR ACJ00001-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 i01667141 Power Train Oil Filter - Remove SMCS - 3067-011-FI Removal Procedure 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, "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. 1. Open the access cover.
21. Illustration 1 g00861043 2. Remove bolts (1). Remove cover assembly (2) from filter housing (3). Remove the filter. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jan 12 09:58:34 UTC+0800 2021
22. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6R II TRACK-TYPE TRACTOR ACJ Configuration: D6R Series SERIES IIFTC,LGP TRACK-TYPE TRACTOR ACJ00001-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 i01618681 Power Train Oil Filter - Disassemble SMCS - 3067-015 Disassembly Procedure Start By: A. Remove the power train oil filter. Refer to Disassembly and Assembly, "Power Train Oil Filter - Remove" for the correct procedure. 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 g00841304
23. Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Remove switch (1), O-ring seal (2), plunger (3), and spring (5) from housing assembly (7) . 2. Remove plug (6) from the cover assembly. 3. Remove bolts (8) that hold cover (4) to the filter housing. 4. Remove plug (9) from the housing. Illustration 2 g00841309 5. Remove locknut (13), retainer (10), the O-ring seal, element (11), stud (14), and two O-ring seals (12) from cover (4) . 6. Inspect the O-ring seals. If necessary, replace the O-ring seals. Thoroughly clean all the parts. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jan 12 09:59:33 UTC+0800 2021
24. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6R II TRACK-TYPE TRACTOR ACJ Configuration: D6R Series SERIES IIFTC,LGP TRACK-TYPE TRACTOR ACJ00001-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 i01618687 Power Train Oil Filter - Assemble SMCS - 3067-016-FI Assembly Procedure Illustration 1 g00841309 1. Install stud (14) into cover (4). Put element (11), retainer (10), the O-ring seal, and locknut (13) in the correct position on the stud. Tighten locknut (13) to a torque of 14 ± 3 N·m (120 ± 24 lb in). 2. Install O-ring seals (12) on cover (4) .
25. Illustration 2 g00841304 Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 3. Put cover (4) in the correct position in housing (7). Install bolts (8) . 4. Install plug (6) in the cover. 5. Install plug (9) in the housing. 6. Install spring (5), plunger (3), O-ring seal (2), and switch (1) into housing (7) . End By: Install the power train oil filter. Refer to Disassembly and Assembly, "Power Train Oil Filter - Install" for the correct procedure. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jan 12 10:00:33 UTC+0800 2021
26. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6R II TRACK-TYPE TRACTOR ACJ Configuration: D6R Series SERIES IIFTC,LGP TRACK-TYPE TRACTOR ACJ00001-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 i01667156 Power Train Oil Filter - Install SMCS - 3067-012-FI Installation Procedure Note: Check the O-ring seal for wear and damage and replace the seals, if necessary. Illustration 1 g00861043 1. Install the filter. Install cover assembly (2) in filter housing (3). Install bolts (1) . Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jan 12 10:01:32 UTC+0800 2021
27. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6R II TRACK-TYPE TRACTOR ACJ Configuration: D6R Series SERIES IIFTC,LGP TRACK-TYPE TRACTOR ACJ00001-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 i01676955 Power Train Oil Pump - Remove SMCS - 3066-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 8S-9906 Ratchet Puller 1 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 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. 1. Remove the floorplates.
28. Illustration 1 g00865718 2. Remove bolt (1) . Illustration 2 g00865724 3. Disconnect tube assembly (2). Disconnect manifold (3). Position tube assembly (2) and manifold (3) out of the way.
29. Illustration 3 g00865738 4. Remove the cable strap. Disconnect harness assembly (4) . Illustration 4 g00865744 5. Remove bolt (5). Remove guard bolts (6). Remove the top half of guard (7) . Illustration 5 g00865837 6. Remove bolts (8). Remove shaft (9). Disconnect hose assembly (10) .
30. Illustration 6 g00865840 7. Remove bolts (11) from both drive coupling (12). Remove both drive couplings (12) . Illustration 7 g00865844 8. Slide shaft (13) out of the drive. Remove guard bolts (14). Remove guard (15) . Illustration 8 g00865846 9. Remove two bolts (16) from suction tube (17) .
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32. Illustration 9 g00865850 10. Attach a chain to the cab roof. Install Tooling (A) . Illustration 10 g00865891 11. Remove bolt (18) and the nut from the back side of power train oil pump (21). Remove bolt (19). Attach a lifting sling to Tooling (A) and to power train oil pump (21). Remove mounting nut (20). Remove power train oil pump (21). The weight of power train oil pump (21) is approximately 41 kg (90 lb). Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue Jan 12 10:02:31 UTC+0800 2021
33. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6R II TRACK-TYPE TRACTOR ACJ Configuration: D6R Series SERIES IIFTC,LGP TRACK-TYPE TRACTOR ACJ00001-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 i01669181 Power Train Oil Pump - Disassemble SMCS - 3066-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-0510 Driver 1 8H-0663 Bearing Puller 1 B 1P-0510 Driver 1 Start By: A. Remove the power train oil pump. Refer to Disassembly and Assembly, "Power Train 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, "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.
34. Illustration 1 g00810958 1. Remove these components from the power train oil pump: switch (1), bolts (2) and manifold (3) . Illustration 2 g00810989 2. Remove bolts (5) and remove flange (4) with the cage from the pump.
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