D6T Track Type Tractor Power Train Caterpillar

Assembly Procedure

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Illustration 1	g06132214

1. Raise the temperature of roller bearing race (48). Install roller bearing race (48) on bevel gear and shaft (37).
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   Illustration 2	g06130916

2. Install retaining ring (47) on bevel gear and shaft (37).
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   Illustration 3	g06130915

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   Illustration 4	g06136393

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   NOTICE
   Bearing cone (36), retaining ring (38), bearing cups (39), spacer (45), and bearing cone (46) have to be replaced as a set. Do not mix new parts with old parts.

3. Raise the temperature of bearing cone (46) and spacer (45). Install bearing (46) and spacer (45) on bevel gear and shaft (37).
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   Illustration 5	g06132266

4. Install tube assemblies (42) in the transmission case.

5. Attach a suitable lifting device to bevel gear and shaft (37). The weight of bevel gear and shaft (37) is approximately 59 kg (130 lb).

6. Position bevel gear and shaft (37) in the transmission case.
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   Illustration 6	g06130847

7. Align the dowel hole in race and roller assembly (43) with the hole in bearing cage (41).

8. Install race and roller assembly (43) in bearing cage (41).

9. Install dowel (44) in bearing cage (41).
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   Illustration 7	g06130837

10. Position bearing cage (41) on the transmission case.

11. Install bolts (40). Tighten bolts (40) to a torque of 120 ± 20 N·m (89 ± 15 lb ft).
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    Illustration 8	g06130815

12. Install retaining ring (38) (not shown) in the center of bearing cage (35).

13. Lower the temperature of two bearing cups (39). Install bearing cups (39) in bearing cage (35).
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    Illustration 9	g06133273

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    Illustration 10	g06326102

14. Install bearing cage (35) without the shims.

15. Install bolts (33) that hold bearing cage (35) to the transmission case. Do not tighten bolts (33).

16. Raise the temperature of bearing cone (36). Install bearing cone (36) on the bevel gear and shaft.

17. Install washer (29) (not shown) and bearing lock washer (28).

18. Apply Tooling (K) to the threads and the face of bearing locknut (30). Install bearing locknut (30) on the bevel gear shaft.

19. Use Tooling (F) to tighten bearing locknut (30) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).

20. Increment bearing locknut (30) to the closest tab/groove location and then bend the locking tab on bearing lock washer (28).
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    Illustration 11	g06130749

21. Install speed sensors (32) and bolts (31).
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    Illustration 12	g06134656

22. Raise the temperature of bearing cone (25) to 135°C (275°F) and install bearing cone (25) on bevel pinion gear (24). Use a 0.03 mm (0.001 inch) feeler gauge to ensure that bearing cone (25) is seated against bevel pinion gear (24).
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    Illustration 13	g06134609

23. Align the splines and install transfer gear (23) on bevel pinion gear (24).

24. Raise the temperature of bearing cone (22) to a maximum of 135°C (275°F) and install bearing cone (22) on transfer gear (23). Use a 0.03 mm (0.001 inch) feeler gauge to ensure that bearing cone (22) is seated against transfer gear (23).
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    Illustration 14	g06130695

25. Lower the temperature of bearing cup (26). Install bearing cup (26) into the transmission case.
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    Illustration 15	g06130663

26. Attach Tooling (C) and a suitable lifting device to pinion gear assembly (21). The weight of pinion gear assembly (21) is approximately 33 kg (73 lb).

27. Lower pinion gear assembly (21) into position in the transmission case.

28. Remove Tooling (C) from pinion gear assembly (21).
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    Illustration 16	g06133278

29. Lower the temperature of bearing cup (19) and install bearing cup (19) in transfer case (7).
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    Illustration 17	g06133279

30. Lower the temperature of bearing cup (20) and install bearing cup (20) in bearing cage (18).
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    Illustration 18	g06130305

31. If removed, raise the temperature of bearing cone (15) and bearing cone (16) to a maximum temperature of 135°C (275°F). Install bearing cone (15) and bearing cone (16) on transfer gear (13). Use a 0.03 mm (0.001 inch) feeler gauge to ensure that the bearing cones are seated against transfer gear (13).
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    Illustration 19	g06130299

32. Ensure that retaining ring (14) is installed in the retaining ring groove of transfer gear (13).
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    Illustration 20	g06133283

33. Position transfer gear (13) in transfer case (7).
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    Illustration 21	g06130261

34. If removed, use Tooling (L) to install bearing (12) in bearing cage (8).

35. If removed, lower the temperature of bearing cup (11) and install bearing cup (11) in bearing cage (8).
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    Illustration 22	g06322819

36. Position bearing cage (18) without the shims on transfer case (7). Install two bolts (17). Space the bolts 180 degrees apart. Do not tighten bolts (17).

37. Position bearing cage (8) without the shims on transfer case (7). Install bolts (9). Space the bolts 180 degrees apart. Do not tighten bolts (9).

38. Use Tooling (L) to install seal (10).
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    Illustration 23	g06135123

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    Illustration 24	g06135103

39. Attach Tooling (A) and a suitable lifting device to transfer case (7). The weight of transfer case (7) is approximately 118 kg (260 lb).
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    NOTICE
    Be sure that bolts (9) and (17) that hold bearing cages (8) and (18) in place on transfer case (7) are loose.

40. Position transfer case (7) on the transmission case.

41. Install new bolts (6) and washers. Tighten bolts (6) to a torque of 270 ± 40 N·m (199 ± 30 lb ft).

42. Install roller bracket assembly (2) and bolts (3). Tighten bolts (3) to a torque of 270 ± 40 N·m (199 ± 30 lb ft). Repeat for the roller bracket assembly on the opposite side.

43. Install retainer (5) and bolt (4). Tighten bolt (4) to a torque of 300 ± 40 N·m (221 ± 30 lb ft).
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    Illustration 25	g06326107

44. Install toric ring (1).
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    Illustration 26	g06136027

45. Use the following Steps to adjust the bearing end play for the lower transfer gear:

    1. To seat the bearings, rotate the transfer gear at least three revolutions. Then, tighten bolts (9) evenly to a torque of 2.25 N·m (20 lb in).

    2. Then, rotate the transfer gear at least three revolutions. Tighten bolts (9) evenly to a torque of 4.5 N·m (40 lb in).

    3. Use Tooling (M) to measure the gap between bearing cage (8) and the transfer case. Measure the gap in four different places. Average the four measurements.

    4. Add 0.23 mm (0.009 inch) to the average figure that was obtained in Step 45.c. This figure will be the correct thickness for the shims that should be used.

46. Remove bearing cage (8). Put the correct thickness of shims in position on the transfer case. Put bearing cage (8) in position and install bolts (9) that hold bearing cage (8) in place. Tighten bolts (9) to a torque of 120 ± 20 N·m (89 ± 15 lb ft). The bearing end play will be 0.10 ± 0.05 mm (0.004 ± 0.002 inch).

    Note: Checking bearing end play is not necessary if this procedure for adjustment has been followed. For a recordable measurement of the bearing end play, refer to “Measurement of the Bearing End Play for the Bevel Pinion and Transfer Gears” at the end of this procedure.

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    Illustration 27	g06322822

47. Use the following Steps to adjust the bearing end play for the upper transfer and pinion gear:

    1. To seat the bearings, rotate the transfer and pinion gear at least three revolutions. Then, tighten bolts (17) evenly to a torque of 4.5 N·m (40 lb in).

    2. Then, rotate the transfer and pinion gear at least three revolutions. Tighten bolts (17) evenly to a torque of 9.0 N·m (80 lb in).

    3. Use Tooling (M) to measure the gap between bearing cage (18) and the transfer case. Measure the gap in four different places. Average the four measurements.

    4. Add 0.43 mm (0.017 inch) to the average figure that was obtained in Step 47.c. This figure will be the correct thickness for the shims that should be used.

48. Remove bearing cage (18). Put the correct thickness of shims in position on the transfer case. Put bearing cage (18) in position and install bolts (17) that hold bearing cage (18) in place. Tighten bolts (17) to a torque of 120 ± 20 N·m (89 ± 15 lb ft). The bearing end play will be 0.10 ± 0.05 mm (0.004 ± 0.002 inch).

    Note: Checking bearing end play is not necessary if this procedure for adjustment has been followed. For a recordable measurement of the bearing end play, refer to “Measurement of the Bearing End Play for the Bevel Pinion and Transfer Gears” at the end of this procedure.

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    Illustration 28	g06322834

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    Illustration 29	g06136897

49. Position the transmission case as shown in Illustration 28 with the bevel gear and shaft in a vertical position and the bevel gear at the bottom.
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    NOTICE
    The transmission case must be in this position. The bevel gear must be held as far away from the pinion gear as possible when the gear clearance (backlash) is set.

50. Install Tooling (N) in the transfer case. Tighten Tooling (N) until there is no movement in the pinion gear. Be sure that Tooling (N) is between the teeth of the gear.

51. Put Tooling (P) in position and check the clearance (backlash) between the bevel gear and the pinion gear. The clearance (backlash) must be 0.30 + 0.12 mm − 0.10 mm (0.012 + 0.005 inch − 0.004 inch). Check the clearance (backlash) on three different teeth that are evenly spaced around the gear.

52. The difference between the high measurement and the low measurement must not be more than 0.15 mm (0.006 inch).

53. Install the correct amount of shims (34) under bearing cage (35). Install bolts (33) in bearing cage (35) and tighten bolts (33) to a torque of 120 ± 20 N·m (89 ± 15 lb ft).

54. Check the gear clearance (backlash) to be certain that the clearance is still correct. If the clearance is not correct, add or remove shims (34), as needed.
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    NOTICE
    Tooling (N) must be removed.

55. Remove Tooling (N) from the transfer case.

End By:

1. Connect the transmission and the bevel gears.

Measurement of the Bearing End Play for the Bevel Pinion and Transfer Gears

The bearing end play for the bevel pinion and transfer gears should be adjusted according to the procedure in “Bevel and Transfer Gears - Assemble”. If this procedure is used, the bearing end play (backlash) should be correctly set at 0.10 ± 0.05 mm (0.004 ± 0.002 inch).

Illustration 30	g06138494

Illustration 31	g06139093
Measurement of the bearing end play for the transfer gear

Illustration 32	g06139100
Measurement of the bearing end play for the pinion gear

Note: Use the following Steps to measure the bearing clearance for the transfer gear.

1. The transfer gear is clamped to Tooling (S). Tooling (W) is used to force the transfer gear to turn. Tooling (R) fits in Tooling (S) to center Tooling (V) in the gear.

2. Install the Tooling in the transfer gear so that Tooling (V) and Tooling (S) are centered in the transfer gear.

3. Tighten Tooling (T) on top of the adapter to prevent movement of the transfer gear. Tooling (T) can then be used to turn the transfer gear.

4. Position the slotted end of Tooling (W) in a horizontal position on the threaded rod. Install Tooling (U) and Tooling (T) on Tooling (V).

5. Position Tooling (X). Be sure that the indicator tip is vertical and that the indicator tip is in contact with Tooling (S).

6. Rotate the transfer gear for at least three revolutions. Watch the needle on the dial indicator. Watch the backward movement and the forward movement. Stop rotating the transfer gear at the point of the maximum needle movement.

   Note: The needle may move back and forth during rotation due to runout in the adapter. Take the reading in the same location so that the measurement will be accurate and consistent.

7. Mark the location at the point of maximum needle movement on the surface of the adapter. Set the dial indicator to zero.

8. Force the transfer gear upward by pushing the lever downward. Record the reading. This reading will be the actual bearing clearance. The reading should be 0.10 ± 0.05 mm (0.004 ± 0.002 inch).

9. Repeat Steps 1 through 8. The result should be identical if Steps 1 through 8 were performed correctly.

   Note: Use the following Steps to measure the bearing clearance for the pinion gear.

10. Screw Tooling (V) in the pinion shaft.

11. Place Tooling (W) in position.

12. Adjust Tooling (W) so that the slotted end of the lever is horizontal.

13. Install Tooling (U) and Tooling (T) on Tooling (V).

14. Position Tooling (X) as shown. Be sure that the indicator tip is vertical and that the indicator tip is in contact with the flat end surface of the pinion gear.

15. Rotate the pinion gear for at least three revolutions. Watch the backward movement and the forward movement of the needle on the dial indicator as the pinion gear is being rotated. Stop rotating the pinion gear at the point of the maximum needle movement.

    Note: The needle may move back and forth during rotation due to runout in the surface of the pinion gear. Take the reading in the same location so that the measurement will be accurate and consistent.

16. Mark the location at the point of maximum needle movement on the surface of the pinion gear. Set the dial indicator to zero.

17. Force the pinion gear upward by pushing the lever downward. Record the reading. This reading will be the actual bearing clearance. The reading should be 0.10 ± 0.05 mm (0.004 ± 0.002 inch).

18. Repeat Steps 10 through 17. The result should be identical if Steps 10 through 17 were performed correctly.