615C Series II Wheel Tractor-Scraper Wheel Tractor Power Train Caterpillar

Assembly Procedure

Note: Clean all parts and inspect all parts. If any parts are worn or damaged use new Caterpillar parts for replacement.

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Illustration 1	g00466051

1. Position bevel gear (59) onto lower case assembly (49) and install 24 bolts (58) . Tighten the bolts to a torque of 270 ± 25 N·m (200 ± 18 lb ft).

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Illustration 2	g00466050

2. Turn over lower case assembly (49) and install washer (57) into lower case assembly (49) .

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Illustration 3	g00466049

3. Install gear (56) into lower case assembly (49) .

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Illustration 4	g00466048

4. Install bearings (55) , gears (54) and washers (53) into spider assembly (52) .

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Illustration 5	g00464912

5. Install spider assembly (52) , gear (51) and washer (50) into lower case assembly (49) .

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Illustration 6	g00464911

6. Position upper case assembly (48) onto lower case assembly (49) and install twelve bolts (47) . Tighten the bolts to a torque of 270 ± 25 N·m (200 ± 18 lb ft).

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Illustration 7	g00466196

7. Heat bearing cone (46) to a maximum temperature of 135°C (275°F). Install bearing cone (46) onto differential (39) .

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Illustration 8	g00466198

8. Turn over differential (39) . Heat bearing cone (45) to a maximum temperature of 135°C (275°F). Install bearing cone (45) onto differential (39) .

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Illustration 9	g00464908

9. Install bearing cup (44) , nut (43) and jaw (42) onto differential (39) . Install two bolts (41) into differential (39) .

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Illustration 10	g00466367

10. Position carrier assembly (40) onto Tooling (A) . Use a nylon lifting strap and a hoist and position differential (39) onto carrier assembly (40) .

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Illustration 11	g00467626

11. Install two caps (37) and four bolts (38) onto differential assembly (21) . Tighten the four bolts to a torque of 475 ± 50 N·m (350 ± 37 lb ft).

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Illustration 12	g00466793

12. Heat bearing cone (16) to a maximum temperature of 135°C (275°F). Install bearing cone (16) onto pinion shaft (12) .

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Illustration 13	g00467652

13. Lower the temperature of bearing cup (14) and install bearing cup (14) into housing (7) .

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Illustration 14	g00467655

14. Install housing (7) onto pinion (12) .

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Illustration 15	g00464370

15. Install nut (11) onto pinion (12) . Use Tooling (C) in order to tighten nut (11) . The turning torque for pinion (12) should be 0.7 to 1.1 N·m (6 to 10 lb in). Install washer (10) and nut (9) onto pinion (12) .

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Illustration 16	g00464110

16. Use Tooling (F) and install lip seal (6) into retainer (5) . The lip of the seal should be to the bottom of the retainer. Lubricate the lip seal with lubricant that is being sealed.

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Illustration 17	g00466994

17. Position retainer (5) onto housing (7) and install six bolts (4) .

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Illustration 18	g00467049

18. Change the position of differential (1) onto Tooling (A) . Install two 3/8" - 16 NC guide bolts (60) into differential (1) . Use a nylon lifting strap and a hoist and position housing (7) onto differential (1) . Install three bolts in order to hold housing (7) to differential (1) .

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Illustration 19	g00467437

19. Use the following adjustment procedure for the bearing preload and the gear clearance between the bevel gear and the pinion.

    1. Tighten adjustment nuts (61) and (62) until there is a small amount of preload on the bearings.

    2. Install Tooling (D) on the bevel gear in order to check the gear clearance. Check the backlash at four locations around the bevel gear. Each location should be at 90 degrees. Use the lowest indication on Tooling (D) . The correct gear clearance or backlash is 0.30 ± 0.10 mm (.012 ± .004 inch).

    3. Increase the gear clearance or backlash by loosening adjustment nut (61) and tighten adjustment nut (62) . Decrease the gear clearance or backlash by loosening adjustment nut (62) and tighten adjustment nut (61) .

    4. Tighten adjustment nut (61) to a torque of 3.4 ± 5.6 N·m (30 ± 50 lb in) in order to turn the pinion shaft.

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Illustration 20	g00467431

20. Check the tooth contact between the bevel gear and the pinion after the gear clearance and bearing preload adjustments have been made.

    1. Use a small amount of Prussian blue, red lead or paint on the bevel gear teeth. Turn the pinion in both directions and check the marks that are created on the bevel gear teeth.

    2. The tooth should contact the gear in the center of the gear. When a load is placed onto the gear, the load will be over the correct area of the teeth.
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    Illustration 21	g00467515

    3. When the pinion shaft is too far away from the bevel gear, short toe contact will result. The pinion teeth will be in contact with the toe ends of the convex gear faces. The pinion teeth will also be in contact with the top edge of heel on the concave gear faces. Remove the shims that are between the pinion housing and the differential in order to correct this problem. Check the gear clearance and tooth contact again.
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    Illustration 22	g00467555

    4. When the pinion shaft is too close to the bevel gear, short heel contact will result. The pinion teeth will be in contact with the heel ends of the convex gear faces. The pinion teeth will also be in contact with toe ends of the concave gear faces. Add shims between the pinion housing and the differential in order to correct this problem.

       Note: Several adjustments of the pinion and bevel gear may be needed in order to attain the correct gear clearance or backlash. The gear clearance or backlash should be in correct adjustment before tooth contact is checked.

    5. Remove the Prussian blue, red lead or paint from the bevel gear teeth.

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Illustration 23	g00467808

21. Install two locks (36) and two bolts (35) onto both caps (37) .

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Illustration 24	g00464369

22. Remove the guide bolts from differential (1) . Install the O-ring seal onto differential (1) . Use Tooling (B) and a hoist in order to position housing (7) onto differential (1) . Install twelve bolts (8) . Tighten the bolts to a torque of 270 ± 25 N·m (200 ± 18 lb ft).

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Illustration 25	g00467814

23. Position yoke (3) onto differential (1) . Install bolt (2) and the washer.

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Illustration 26	g00464845

24. Install seal (34) and seal (33) onto piston (29) .

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Illustration 27	g00464843

25. Install piston (29) into cylinder (32) .

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Illustration 28	g00464842

26. Position twelve springs (31) onto piston (29) .

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Illustration 29	g00464841

27. Install two dowel pins (30) into housing (28) .

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Illustration 30	g00464840

28. Position housing (28) onto piston (20) and install twelve bolts (27) .

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Illustration 31	g00464839

29. Install washer (26) and clutch jaw (25) into differential lock (20) .

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Illustration 32	g00464838

30. Install washer (24) and spacer (23) into differential lock (20) .

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Illustration 33	g00464837

31. Use Tooling (E) and install retaining ring (22) in differential lock (20) .

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Illustration 34	g00464376

32. Use two persons to install differential lock (20) onto differential assembly (21) and install four bolts (19) . The differential lock weighs approximately 41 kg (90 lb).

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Illustration 35	g00464375

33. Install hose assembly (17) onto carrier assembly (18) .

End By: Install the differential. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Install". The information is in this manual.