Caterpillar_Cat_D6M_TRACK-TYPE_TRACTOR__Prefix_4JN__Service_Repair_Manual__4JN00001_and_up_.pdf

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1. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 4JN Configuration: D6M TRACK-TYPE TRACTOR XL, LGP 4JN00001-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 i04026196 Final Drive - Disassemble SMCS - 4050-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 3 B 1P-0510 Driver Group 1 C 1P-0520 Driver Group 1 4C-4865 Hand Hydraulic Pump 1 FT-1934 Beam 1 6V-3160 Hydraulic Cylinder 1 5F-7353 Washer 4 - Bolt (20 mm by 200 mm) 4 D 138-7574 Link Bracket 3 Start By: a. Remove the final drives. Refer to Disassembly and Assembly, "Final Drive - 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. Dirt and contaminants can damage the precision components. All Disassembly and Assembly procedures must be performed on a clean work surface. Clean
2. 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. Illustration 1 g02210755 1. Remove the bolts that hold carrier (1) to the hub. 2. Attach a suitable lifting device and Tooling (A) to carrier (1). Remove the carrier. The weight of the carrier is approximately 98 kg (215 lb). Remove the O-ring seal from the carrier. Illustration 2 g00743498 3. Remove bolts (2) and retainers (3).
3. Illustration 3 g00743501 Illustration 4 g00743502 4. Use a suitable press and Tooling (B) in order to push shafts (4) out of carrier (1). 5. Remove gear (7) and bearing cones (5) and (8) from the carrier. 6. If necessary, remove bearing cups (6) from gear (7). Illustration 5 g00743503 7. Remove bolts (9) and retainer (10).
4. Illustration 6 g02210775 8. Attach a suitable lifting device to hub (12). Remove the hub and gear (11) as an assembly. The weight of the gear and the hub is approximately 34 kg (75 lb). Illustration 7 g02210777 9. Remove ring (13) and hub (12) from gear (11). Illustration 8 g02210778 Note: Do not lift the hub too high. The hub must not contact the fittings on the hydraulic cylinder. 10. Install Tooling (C), as shown. 11. Raise the temperature of bearing cone (14) to a maximum temperature of 120°C (248°F). Use Tooling (C) to remove bearing cone (14) from the spindle. 12. Remove Tooling (C) and the bearing cone. 13. Attach a suitable lifting device and Tooling (D) to hub (15). Remove the hub from spindle (16). The weight of the hub is approximately 159 kg (350 lb).
5. Illustration 9 g02210855 14. Remove Duo-Cone seal (17) from the hub. 15. If necessary, remove bearing cups (18) from the hub. Illustration 10 g02210858 16. Remove Duo-Cone seal (20) and seal (19) from spindle (16). 17. Remove bearing cone (21) from the spindle. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Dec 8 01:07:27 UTC+0800 2021
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7. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 4JN Configuration: D6M TRACK-TYPE TRACTOR XL, LGP 4JN00001-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 i04026199 Final Drive - Assemble SMCS - 4050-016 Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 3 B 1P-0510 Driver Gp 1 D 138-7574 Link Bracket 3 E 1P-0520 Driver Gp 1 F 8T-5289 Spacer 1 G 1U-6436 or 1U-6437 Duo-Cone Seal Installer As 1 H 1U-6396 O-Ring Assembly Compound - 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 precision components. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean area. Keep cleaned parts covered and protected at all times. Note: O-ring seals, gaskets, and seals should always be replaced. A used O-ring may not have the same sealing properties as a new O-ring seal. A reconditioning procedure should
8. not be degraded because of a low-cost component such as an O-ring seal or a gasket. Use Tooling (H) during the assembly procedure. Illustration 1 g02213653 1. Use Tooling (E) in order to install seal (19) in spindle (16). The lip of the seal must face upward, as shown. Note: Make sure that the lip of seal (19) is not damaged during the installation of the axle. 2. Raise the temperature of bearing cone (21) to a maximum temperature of 120°C (248°F) and install bearing cone (21) on spindle (16). Note: Before installing any of the Duo-Cone seals, refer to Disassembly and Assembly, "Duo-Cone Floating Seals - Install". 3. Use Tooling (G) in order to install the Duo-Cone seal on spindle (16). Illustration 2 g02210855 4. Lower the temperature of bearing cups (18) and install bearing cups (18) in the hub. 5. Use Tooling (G) in order to install Duo-Cone seal (17) in the hub.
9. Illustration 3 g02213733 6. Attach Tooling (D) and a suitable lifting device to hub (15). The weight of the hub is approximately 159 kg (350 lb). Lower hub (15) into position on spindle (16). 7. Raise the temperature of bearing cone (14) to a maximum temperature of 120°C (248°F) and install bearing cone (14) on spindle (16). Illustration 4 g02213813 Note: If Tooling (F) is not available or does not fit the spindle, skip to Step 10. Use hub (12) to press bearing cone (14) into position. Press hub (12) until the surface of hub (12) is even with the surface on the spindle. 8. While bearing cone (14) is still hot, position Tooling (F) and install retainer (10) and bolts (9). Tighten bolts (9) to a torque of 135 ± 15 N·m (100 ± 11 lb ft). 9. After bearing cone (14) has cooled, remove retainer (10) and Tooling (F).
10. Illustration 5 g02210777 10. Position hub (12) in gear (11) and install ring (13). Illustration 6 g02210775 11. Attach a suitable lifting device to hub (12). The weight of the gear and the hub is approximately 34 kg (75 lb). Install hub (12) and gear (11) on the spindle. Illustration 7 g00743601 12. Install retainer (10) and bolts (9). Tighten bolts (9) to a torque of 135 ± 15 N·m (100 ± 11 lb ft).
11. 13. Use a feeler gauge in order to verify that there is metal to metal contact between retainer (10) and the spindle. Illustration 8 g00743602 Illustration 9 g00743604 14. If bearing cups (6) were removed from gear (7), lower the temperature of bearing cups (6) and install bearing cups (6) in gear (7). 15. Install bearing cones (5) and (8) in gear (7). 16. Position the bearing cones and gear (7) in carrier (1). Lower the temperature of shaft (4). Use a suitable press in order to install shaft (4) in the carrier. Install shaft (4) until the end of shaft (4) is even with the outer surface of carrier (1).
12. Illustration 10 g00743605 17. Install retainers (3) and bolts (2). There must be metal to metal contact between retainers (3) and the shafts. Illustration 11 g02210755 18. Position the O-ring seal on carrier (1). 19. Attach Tooling (A) and a suitable lifting device to carrier (1). The weight of the carrier is approximately 98 kg (215 lb). Position carrier (1) on the hub assembly and install the bolts that hold carrier (1) in place. End By: a. Install the final drives. Refer to Disassembly and Assembly, "Final Drive - Install". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Dec 8 01:08:23 UTC+0800 2021
13. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 4JN Configuration: D6M TRACK-TYPE TRACTOR XL, LGP 4JN00001-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 i00963997 Final Drive - Install SMCS - 4050-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 8T-3207 Lifting Bracket 1 5P-8622 Shackle 1 6V-9667 Bolt 2 9S-9076 Spacer 2 Illustration 1 g00743487
14. 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. 1. Put O-ring seal (8) in position on the housing. Illustration 2 g00743488 Illustration 3 g00743489 2. Fasten a suitable lifting device and Tooling (A) to final drive (5). 3. Put the final drive in position on the housing and install bolts (4) and (6). 4. Remove Tooling (A) from the final drive.
15. Illustration 4 g00745347 5. Install two bolts (2). 6. Install sprocket segment (1). Torque the bolts to 175 ± 40 N·m (130.0 ± 30.0 lb ft). Torque the bolts again to 380 N·m (280.0 lb ft). Note: Refer to Operation and Maintenance Manual, "Lubricant Viscosities and Refill Capacities" for all fluid capacities and the proper filling procedures. 7. Fill the final drive with oil to the correct level. End By: a. Install the axles. Refer to Disassembly and Assembly, "Axle - Remove and Install". b. Connect the tracks. Refer to Disassembly and Assembly, "Track - Connect". Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Dec 8 01:09:19 UTC+0800 2021
16. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 4JN Configuration: D6M TRACK-TYPE TRACTOR XL, LGP 4JN00001-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 i00964194 Steering Clutch and Brake - Remove SMCS - 4100-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 8T-3207 Lifting Bracket 1 5P-8622 Shackle 1 6V-9667 Bolt 2 9S-9076 Spacer 2 Start By: a. Separate the tracks. Refer to Disassembly and Assembly, "Track - Separate". b. Remove the axles. Refer to Disassembly and Assembly, "Axle - Remove and Install". 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.
17. 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. Drain the oil from the final drive. Illustration 1 g00745347 2. Turn the final drive until sprocket segment (1) is above the pivot shaft housing. Remove the bolts and sprocket segment (1). 3. Remove two bolts (2) from the top of the final drive. Illustration 2 g00747077 4. Adjust bracket (3) on Tooling (A) until the bracket is against the stop on Tooling (A).
18. Illustration 3 g00743489 Illustration 4 g00743488 5. Fasten Tooling (A) to final drive (5). Fasten a suitable lifting device to Tooling (A). Note: Do not remove bolts (6) that hold the steering clutch and brake assembly to the final drive. 6. Remove bolts (4) and (7). Remove the final drive and steering clutch assembly. The weight of the final drive and steering clutch and brake is 544 kg (1200 lb). Illustration 5 g00747076
19. 7. Remove O-ring seals (8) and (9) from the housing. Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Dec 8 01:10:14 UTC+0800 2021
20. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 4JN Configuration: D6M TRACK-TYPE TRACTOR XL, LGP 4JN00001-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 i00964182 Steering Clutch and Brake - Disassemble SMCS - 4100-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7575 Link Bracket 3 Start By: a. Separate the final drive, steering clutches and brakes. Refer to Disassembly and Assembly, "Final Drive, Steering Clutch, and Brakes - 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 precision 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.
21. Illustration 1 g00746866 1. Remove bolts (1) and plate (2). Illustration 2 g00746867 2. Remove sleeve bearings (3) from plate (2). Illustration 3 g00746868 3. Remove input hub (4).
22. Illustration 4 g00746869 4. Remove clutch plates (5) and friction discs (6) from hub assembly (7). Illustration 5 g00746870 Illustration 6 g00746872 5. Remove piston (8) from hub assembly (7). 6. Remove sleeve bearing (9). 7. Remove seals (10) and (11) from piston (8).
23. Illustration 7 g00746873 8. Turn over the brake assembly. 9. Remove ring (12) from hub assembly (7). Illustration 8 g00746874 10. Fasten a suitable lifting device and Tooling (A) to housing (13), and remove the brake assembly from hub assembly (7). The weight of the brake assembly is 86 kg (190.0 lb). Illustration 9 g00746875 11. Remove bearing (14) from housing (13).
24. Illustration 10 g00746876 12. Remove three rings (15) from hub assembly (7). 13. Remove bearing (16) from hub assembly. Illustration 11 g00746877 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. Note: Bolts (19) hold a spring under compression behind the piston. It is important to remove bolts (17) before removing bolts (19). 14. Remove bolts (17) and plate (18) from housing (13).
25. Illustration 12 g00746878 15. Remove brake plates (20) and friction discs (21) from the housing. Illustration 13 g00746879 Note: Bolts (19) hold a spring under compression. Loosen bolts (19) slowly and loosen bolts (19) evenly. 16. Remove bolts (19) and the manifold assembly (22) from housing (13). Illustration 14 g00746880 17. Remove seals (23) and (24) from manifold assembly (22).
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28. Illustration 15 g00746881 18. Remove piston (25) from housing (13). Illustration 16 g00746882 19. Remove springs (26) from housing (13). Note: Note the direction of spring (26) before removing. 20. Remove O-ring seal (27) and (28). Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Wed Dec 8 01:11:10 UTC+0800 2021
29. Shutdown SIS Previous Screen Product: TRACK-TYPE TRACTOR Model: D6M TRACK-TYPE TRACTOR 4JN Configuration: D6M TRACK-TYPE TRACTOR XL, LGP 4JN00001-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 i00964177 Steering Clutch and Brake - Assemble SMCS - 4100-016 Assembly Procedure Table 1 Required Tools Tool Part number Part Description Qty A 138-7575 Link Bracket 3 B 1P-510 Driver Group 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 precision components. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean area. Keep cleaned parts covered and protected at all times. Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.
30. Illustration 1 g00746882 1. Install springs (26) in housing (13). 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. 2. Install O-ring seals (27) and (28). Illustration 2 g00746973 3. Put piston (25) in position in housing (13).
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