Repair Of 6V6080 Torque Multipliers{0765} Caterpillar

Repair Of 6V6080 Torque Multipliers{0765}

Usage:

The procedures shown in this Special Instruction can be used to repair all 6V6080 Torque Multipliers. Earlier torque multipliers with serial numbers below A800 can also be updated with new parts when being repaired. This instruction covers the complete disassembly and assembly of the torque multiplier. Do only that part of the procedure necessary to perform the necessary repairs.

Disassembly Of 6V6080 Torque Multiplier

(1) Check the diameter of four dowel pin drive holes (1). If the holes are less than 6.75 mm Ø (0.266" Ø), use a carbide drill and enlarge the holes to this diameter. Remove all chips and debris.

(2) Place selector pawl (2) in the neutral position, and then tighten selector pawl setscrew (3). Release the output drive assembly retaining ring (4) and remove assembly (5).

(3) Remove button head capscrew (6) and hard washer (7).

(4) Remove input gear assembly (8) and output gear assembly (9) from case (10).

(A) Disassembly Of Output Gear Assembly

(1) Remove protector band (1). Drive and/or press out (from the small hole side) the four dowel pins (2). Remove four output planet gears (3). Older models may have thrust races; see note on page 5.

NOTE: On torque multipliers that require drilling of the dowel pin drive holes, the dowel pins will be staked in and will require additional effort to remove.

NOTE: Torque multipliers with serial numbers lower than A800 may have a thrust race (4) positioned on each side of an older output planet gear (5). Remove and discard these thrust races.

(2) Press two needle bearings (6) from each planet gear (3) with the driver assembly shown on page 15.

(3) Press needle bearing (7) from the center of output gear cage (8) with the driver assembly.

(4) Output planet gear (3) is longer and is used in torque multipliers with Serial Numbers A800-Up. Output planet gear (5) was used with Serial Numbers A799 and lower. Either gear can be used in all torque multipliers and they can be used with each other.

(B) Disassembly Of Input Gear Assembly

(1) Remove needle bearing thrust race (1). Remove three button head capscrews (2).

NOTE: These screws are secured with Loctite, and will require additional effort to remove. When the screw opposite the mark "CW" on input gear cage (3) is removed, a spring and steel ball will be released from the cage.

(2) Lift secondary pinion (4) from gear cage (3).

NOTE: If secondary pinion (4) can not be easily removed, place a socket extension in the hole as shown and tap with a plastic hammer. Be careful not to drop any parts.

(3) Remove three input planet gears (5).

(4) Remove all thrust races (6).

NOTE: Some torque multipliers (A799 and lower) may have a thrust race (6) positioned on each side of each planet gear (5).

(5) Remove input pinion (7). Use the driver assembly shown on page 15 to press needle bearing (8) from each of the planet gears (5). Remove three dowel pins (9) from gear cage (3) using the 5P944 Dowel Puller Group and 5P943 Extractor.

(6) Remove needle bearing (10) from gear cage (3) using the driver assembly.

(7) Release and remove selector pawl setscrew (11). Remove selector pawl (12).

Assembly Of 6V6080 Torque Multiplier

NOTE: Put 5P960 Multipurpose Type Grease on all parts that are installed inside the cage.

(A) Assembly Of Input Gear Assembly

(1) Press three 6V6139 Dowel Pins (1) into input gear cage (2) to the dimension shown.

(2) Put 6V6137 Selector Pawl (3) into gear cage (2) with the square groove of the pawl under the selector setscrew hole. Put 6V6136 Input Pinion (4) in position in gear cage (2). Install and tighten selector pawl screw (5).

(3) Press 2H2213 Needle Bearing (6) into 6V9137 Secondary Pinion (7) until the bearing is even with the flange of the pinion. Press a 6V6761 Needle Bearing (8) into each of three 6V6135 Input Planet Gears (9).

(4) Put one 6L4082 Thrust Race (10) and then one planet gear (9) on each of three dowel pins (1).

NOTE: If the torque multiplier contained six thrust races when disassembled, discard the remaining three thrust races.

(5) Slide pinion (7) down over input pinion (4) and dowel pins (1) until the flange rests on gear cage (2). Install steel ball (11) and spring (12) in the threaded hole opposite the mark "CW" on the gear cage. Put 9S3263 Thread Lock on the threads of three button head capscrews (13). Install the screws as shown. Put 6V6762 Needle Bearing Thrust Race (14) on pinion (7).

(B) Assembly Of Output Gear Assembly

(1) Press 2M1672 Needle Bearing (1) into the center of output gear cage (2) with the driver assembly shown on page 15.

(2) Press a 6V6761 Needle Bearing (3) into each end of four 6V9136 Output Planet Gears (4). Put the planet gears in position in gear cage (2). Press four 6V9153 Dowel Pins (5) into the gear cage (2) until the pins are flush with the surface as shown. Make sure needle bearings (3) are in alignment with pins (5). Put 6V6134 Protractor Band (6) on the gear cage as shown.

NOTE: Torque multipliers with serial numbers lower than A800 may be equipped with 6V6131 Output Planet Gears. However, 6V9136 Planet Gears may be used in place of the original gears or together with the original gears. Torque multipliers with serial numbers between A476 and A799 may require shorter dowel pins. Measure the depth of the dowel holes. If the holes are approximately 57.15 mm (2.250") deep, use 6V6138 Dowel Pins. If the holes are approximately 63.5 mm (2.50") deep, use 6V9135 Dowel Pins.

(3) Put input gear assembly (7) into the side of case (8) opposite the arrow. Install output gear assembly (9) into case (8).

(4) Install hard washer (10) and button head capscrew (11) in the center of the output gear cage (9). Tighten screw (11). See conversion chart on page 14 for correct washer and capscrew.

(5) Put 6V6129 Output Drive Assembly (12) in the square recess of gear cage (9), and install retaining ring (13). Release selector pawl setscrew (14).