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Caterpillar Cat 621H WHEEL TRACTOR (Prefix DBK) Service Repair Manual (DBK00001 and up)

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Caterpillar Cat 621H WHEEL TRACTOR (Prefix DBK) Service Repair Manual (DBK00001 and up)

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  1. Service Repair Manual Models 621H WHEEL TRACTOR

  2. w 1/10(W) Shutdown SIS Previous Screen Product: WHEEL TRACTOR Model: 621H WHEEL TRACTOR DBK Configuration: 621H Wheel Tractor Scraper DBK00001-UP (MACHINE) POWERED BY C13 Engine Disassembly and Assembly 621H, 623H and 627H Wheel Tractor-Scrapers Power Train Media Number -KENR8883-02 Publication Date -01/06/2013 Date Updated -01/07/2013 i07460047 Transfer Gears - Disassemble - Tractor SMCS - 3159-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 439-3940 Bracket As 1 8B-7548 Push-Puller Tool Gp 1 B 8B-7551 Bearing Puller Gp 1 1P-0498 Drive Plate 1 5P-4170 Step Plate 1 C 1P-2321 Combination Puller 1 8B-7554 Bearing Cup Puller Gp 1 D 5P-4170 Step Plate 1 1P-0518 Drive Plate 1 8B-7560 Step Plate 1 E 5F-7345 Screw 1 8B-7554 Bearing Cup Puller Gp 1 Bolts 3/8" - 16 NC by 3 inch F - 3 Start By: https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  3. w 2/10(W) a. Remove the transfer gear case. b. Remove the transmission oil filter base. c. Remove the transmission scavenge pump. d. Remove the transmission oil pump. NOTICE Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination. 1. Put identification marks on components for installation purposes. Illustration 1 g02603076 2. Remove the bolts that secure bearing cage (1) to the transfer gear case. Use Tooling (F) to separate bearing cage (1) from the transfer gear case. 3. Remove bearing cage (1) and shims (2) from the transfer gear case. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  4. w 3/10(W) Illustration 2 g02602859 4. Remove the bolts that secure bearing cage (3) to the transfer gear case. Use Tooling (F) to separate bearing cage (3) from the transfer gear case. 5. Remove bearing cage (3) and shims (4) from the transfer gear case. Illustration 3 g02603657 6. Remove gear assembly (5). Illustration 4 g02603659 7. Remove tube (6) and gear assembly (7). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  5. w 4/10(W) Illustration 5 g02602876 8. Remove bearing cups (8) from the transfer gear case. Attach Tooling (A) and a suitable lifting device onto the transfer gear case. The weight of the transfer gear case is approximately 340 kg (750 lb). Turn over the transfer gear case. Remove Tooling (A). Illustration 6 g01102873 9. Remove the bolts that secure bearing cage (9) to the transfer gear case. Use Tooling (F) to separate bearing cage (9) from the transfer gear case. 10. Remove bearing cage (9), shims (10), and gear (11) from the transfer gear case. Illustration 7 g00529214 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

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  7. w 5/10(W) 11. Remove bearing cup (12) from the transfer gear case. Attach Tooling (A) and a suitable lifting device onto the transfer gear case. Turn over the transfer gear case. Illustration 8 g00529215 12. Remove bolts (13) that secure bearing cage (14) to the transfer gear case. If necessary, rotate the gear until the three threaded holes are visible in bearing cage (14). Install Tooling (F) through gear (15) and into bearing cage (14). Tighten Tooling (F) evenly until bearing cage (14) and gear (15) separate from the transfer gear case. Remove bearing cage (14) and gear (15) as a unit from the transfer gear case. Illustration 9 g00529216 Illustration 10 g00529257 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  8. w 6/10(W) 13. Remove retaining ring (16) from gear (15). Remove bearing (17) and bearing cage (14) from gear (15). Illustration 11 g01048544 14. Remove bearing (17) from bearing cage (14). Illustration 12 g01048548 15. Remove bolts (19) and separate gear (20) from gear (11). Use Tooling (B) to remove bearing cone (18). Remove bearing cone (18) from gear (11). Repeat the procedure for the bearing cone on the opposite side of gear (11). Illustration 13 g02660644 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  9. w 7/10(W) 16. Use Tooling (C) to remove bearing cone (21). Remove bearing cone (21) from gear (5). Repeat the procedure for the bearing cone on the opposite side of gear (5). Illustration 14 g02661176 17. Use Tooling (C) to remove bearing cone (21). Remove bearing cone (21) from gear (7). Repeat the procedure for the bearing cone on the opposite side of gear (7). Illustration 15 g02661799 18. Use Tooling (D) to remove bearing cup (23). Remove bearing cup (23) from bearing cage (1). Remove O-ring seal (24) from bearing cage (1). Illustration 16 g01048553 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  10. w 8/10(W) 19. Remove bearing cup (25) from bearing cage (9). Illustration 17 g02662017 20. Use Tooling (E) to remove bearing cup (26). Remove bearing cup (26) from bearing cage (3). Remove O-ring seal (27) from bearing cage (3). Illustration 18 g02603736 21. Remove the bolt that secure cover (28). Use Tooling (F) to remove cover (28). Remove cover (28). Illustration 19 g02603807 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  11. w 9/10(W) 22. Remove the bolt that secure bearing cage (29). Use Tooling (F) to remove bearing cage (29) and shims (30). Remove bearing cage (29) and shims (30). Illustration 20 g02603842 23. Remove tube (31) and gear assembly (32). Illustration 21 g02662457 24. Use Tooling (C) to remove bearing cone (33). Remove bearing cone (33) from gear (32). Repeat the procedure for the bearing cone on the opposite side of gear (32). Illustration 22 g02603857 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  12. w 10/10(W) 25. Remove bearing cup (34). Illustration 23 g02604416 26. Remove bearing cage (35) and O-ring seal (36). Copyright 1993 - 2021 Caterpillar Inc. Tue Mar 23 14:54:40 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  13. w 1/11(W) Shutdown SIS Previous Screen Product: WHEEL TRACTOR Model: 621H WHEEL TRACTOR DBK Configuration: 621H Wheel Tractor Scraper DBK00001-UP (MACHINE) POWERED BY C13 Engine Disassembly and Assembly 621H, 623H and 627H Wheel Tractor-Scrapers Power Train Media Number -KENR8883-02 Publication Date -01/06/2013 Date Updated -01/07/2013 i04408033 Transfer Gears - Assemble - Tractor SMCS - 3159-016 Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7575 Link Bracket 1 G 1P-0510 Driver Group 1 H 8T-5096 Dial Indicator 1 NOTICE Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  14. w 2/11(W) 1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new parts for replacement. 2. Lubricate O-ring seals with the lubricant that is being sealed. Illustration 1 g02604416 3. Install O-ring seal (36). Lower the temperature of bearing cage (35) before installing. Illustration 2 g02603857 4. Lower the temperature of bearing cup (34) before installing. Illustration 3 g02662457 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  15. w 3/11(W) 5. Raise the temperature of bearing cone (33). Install bearing cone (33) on gear (32). Repeat the procedure for the bearing cone on the opposite side of gear (32). Illustration 4 g02603842 6. Install gear assembly (32) and tube (31). Illustration 5 g02605119 7. Install bolts that secure shims (30) and bearing cage (29) into place. Illustration 6 g02605318 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  16. w 4/11(W) 8. Position Tooling (H) in the transfer gear case, as shown. Make sure that the dial indicator is in contact with gear (32). Use a pry bar to move gear (32) up and down. Adjust shims (30) in order to obtain an end play of 0.15 ± 0.05 mm (0.006 ± 0.002 inch). Tighten bolts that secure cover (29) to a torque of 55 ± 10 N·m (41 ± 7 lb ft) Illustration 7 g02605121 9. Install bolts that secure cover (28) into place. Illustration 8 g02662017 10. Install O-ring seal (27) onto bearing cage (3). Lower the temperature of bearing cup (26). Install bearing cup (26) to bearing cage (3). Check that bearing cup (26) is seated in the bore of bearing cage (3). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  17. w 5/11(W) Illustration 9 g01048553 11. Lower the temperature of bearing cup (25). Install bearing cup (25) to bearing cage (9). Check that bearing cup (25) is seated in the bore of bearing cage (9). Illustration 10 g02661799 12. Install O-ring seal (24) to bearing cage (1). Lower the temperature of bearing cup (23). Install bearing cup (23) to bearing cage (1). Check that bearing cup (23) is seated in the bore of bearing cage (1). Illustration 11 g02661176 13. Raise the temperature of bearing cone (22). Install bearing cone (22) on gear (7). Repeat the procedure for the bearing cone on the opposite side of gear (7). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  18. w 6/11(W) Illustration 12 g02660644 14. Raise the temperature of bearing cone (21). Install bearing cone (21) on gear (5). Repeat the procedure for the bearing cone on the opposite side of gear (5). Illustration 13 g01048548 15. Raise the temperature of bearing cone (18). Install bearing cone (18) on gear (11). Repeat the procedure for the bearing cone on the opposite side of gear (11). 16. Position gear (20) on gear (11). Install bolts (19). Tighten bolts (19) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Illustration 14 g01048544 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  19. w 7/11(W) 17. Install bearing (17) into bearing cage (14). Illustration 15 g00529216 18. Use Tooling (G) to install bearing (17) and bearing cage (14) to gear (15). Install bearing (17) and bearing cage (14) until the retaining ring groove is visible. Install retaining ring (16) to gear (15). Illustration 16 g00529215 19. Position gear (15) and bearing cage (14) in the transfer gear case. Install bolts (13) that secure bearing cage (14) to the transfer gear case. Tighten bolts (13) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Attach Tooling (A) and a suitable lifting device onto the transfer gear case. The weight of the transfer gear case is approximately 340 kg (750 lb). Turn over the transfer gear case. Remove Tooling (A). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  20. w 8/11(W) Illustration 17 g00529214 20. Lower the temperature of bearing cup (12). Use Tooling (G) to install bearing cup (12) to the transfer gear case. Check that bearing cup (12) is seated in the bore of the transfer gear case. Illustration 18 g00529695 Illustration 19 g02605501 21. Position gear (11) in the transfer gear case. Install bearing cage (9) and shims (10). Install bolts that hold bearing cage (9) in position. Tighten bolts that secure bearing cage (9) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  21. w 9/11(W) 22. Position Tooling (H) in the transfer gear case, as shown. Make sure that the dial indicator is in contact with gear (11). Use a pry bar to move gear (11) up and down. Adjust shims (10) in order to obtain an end play of 0.15 ± 0.05 mm (0.006 ± 0.002 inch). Tighten bolts that secure bearing cage (9) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Illustration 20 g02602876 23. Use Tooling (G) to install bearing cups (8) to the transfer gear case. Check that bearing cups (8) is seated in the bore of the transfer gear case. Illustration 21 g02603659 Illustration 22 g02605596 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  22. w 10/11(W) 24. Position gear (7) in the transfer gear case. Install tube (6). Install bearing cage (1) and shims (2). Install the bolts that hold bearing cage (1) in position. Tighten bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft). 25. Attach Tooling (A) and a suitable lifting device to the transfer gear case. Place the transfer gear case on wood blocks, not shown. Position Tooling (H) on the transfer gear case, as shown. Make sure that the dial indicator is in contact with gear (7). Use a pry bar to move gear (7) up and down. Adjust shims (2) in order to obtain an end play of 0.15 ± 0.05 mm (0.006 ± 0.002 inch). Tighten bolts that secure bearing cage (1) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Illustration 23 g02605636 Illustration 24 g02605656 26. Position gear (5) in the transfer gear case. Install bearing cage (3) and shims (4). Install the bolts that hold bearing cage (3) in position. Tighten bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft). 27. Position Tooling (H) on the transfer gear case, as shown. Make sure that the dial indicator is in contact with gear (5). Use a pry bar to move gear (5) up and down. Adjust shims (4) in order to obtain an end play of 0.15 ± 0.05 mm (0.006 ± 0.002 inch). Tighten bolts that secure bearing cage (3) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). End By: a. Install the transmission oil pump. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  23. w 11/11(W) b. Install the transmission scavenge pump. c. Install the transmission oil filter base. d. Install the transfer gear case. Copyright 1993 - 2021 Caterpillar Inc. Tue Mar 23 14:55:38 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  24. w 1/37(W) Shutdown SIS Previous Screen Product: WHEEL TRACTOR Model: 621H WHEEL TRACTOR DBK Configuration: 621H Wheel Tractor Scraper DBK00001-UP (MACHINE) POWERED BY C13 Engine Disassembly and Assembly 621H, 623H and 627H Wheel Tractor-Scrapers Power Train Media Number -KENR8883-02 Publication Date -01/06/2013 Date Updated -01/07/2013 i04577911 Transmission Planetary - Disassemble - Tractor SMCS - 3030-015 Disassembly Procedure Start By: A. Separate the transfer gears from the transmission. B. Remove the transmission hydraulic control valve. Table 1 Required Tools Tool Part Number Part Description Qty A 1P-7407 Eyebolt 2 B FT-0833 Clamp 2 C 2P-8312 Retaining Ring Pliers 1 D FT-1335 Transmission Fixture 1 E 1P-0520 Driver Gp 1 F 1P-2420 Transmission Repair Stand 2 G 1P-7405 Eyebolt 2 H 3/8 -16 by 2 in Forcing Bolts 4 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  25. w 2/37(W) Illustration 1 g02607496 1. Install Tooling (A) and a suitable lifting device onto transmission assembly (1) . Position transmission assembly (1) onto Tooling (F) . The weight of transmission assembly (1) is approximately 703 kg (1550 lb). Illustration 2 g00841452 2. Remove bolts (2) and the washers that secure the transmission assembly to transmission housing (3) . Remove the transmission assembly from transmission housing (3) . Position the transmission assembly onto two suitable blocks. Remove Tooling (A) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  26. w 3/37(W) Illustration 3 g00506814 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. Remove bolts (4) and the washers from clutch housing (5) . Illustration 4 g01083235 4. Use Tooling (B) in order to hold the piston into clutch housing (5) . Install Tooling (A) and a suitable lifting device onto clutch housing (5) . Remove clutch housing (5) from the transmission assembly. The weight of clutch housing (5) is approximately 27 kg (60 lb). Remove Tooling (A) and (B) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  27. w 4/37(W) Illustration 5 g00506820 5. Remove piston (6) from clutch housing (5) . Remove seal ring (7) from piston (6) and from clutch housing (5) . Illustration 6 g01083237 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: Friction discs and clutch plates that are removed from each clutch housing should be kept with the correct clutch housing. Mixing the clutch plates and friction discs may cause improper operation of the transmission or damage to the transmission. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  28. w 5/37(W) 6. Remove springs (8) , dowels (9) , friction discs (10) , and clutch plates (11) from clutch housing (12) . Illustration 7 g00506849 7. Remove ring gear (13) from clutch housing (12) . Illustration 8 g01083343 8. Use Tooling (B) in order to hold the piston into clutch housing (12) . Install Tooling (A) and a suitable lifting device onto clutch housing (12) . Remove clutch housing (12) from housing assembly (14) . The weight of clutch housing (23) is approximately 27 kg (60 lb). Remove Tooling (A) and (B) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  29. w 6/37(W) Illustration 9 g00506903 9. Remove piston (15) from clutch housing (12) . Remove a seal ring (16) from piston (15) and from clutch housing (12) . Illustration 10 g01083344 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. 10. Remove springs (17) , dowels (18) , friction discs (19) , and clutch plates (20) from housing assembly (14) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  30. w 7/37(W) Illustration 11 g02607597 Illustration 12 g00506953 11. Remove retaining ring (21A) and adapter drive (22A) . Remove retaining ring (21) from shaft (22) . Illustration 13 g01083360 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

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  32. w 8/37(W) 12. Install Tooling (G) and a suitable lifting device onto carrier assembly (23) . Remove carrier assembly (23) from housing assembly (14) . Remove Tooling (G) . The weight of the carrier assembly is approximately 34 kg (75 lb). Illustration 14 g00506968 13. Remove bolts (24) and oil slinger (25) from carrier assembly (23) . Remove bearing (26) from carrier assembly (23) . Illustration 15 g01053892 14. Use a hammer and a punch in order to push pin (27) into shaft (28) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  33. w 9/37(W) Illustration 16 g01083400 15. Remove shaft (28) , thrust discs 29, and () planetary gears (30) from carrier assembly (23) . Remove pin (27) from shaft (28) . Illustration 17 g01053896 16. Remove bearings (31) from planetary gear (30) . 17. Repeat Steps 14, 15, and 16 in order to remove the remaining three shaft assemblies. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

  34. w 10/37(W) Illustration 18 g01053901 18. Use a hammer and a punch in order to push pin (32) into shaft (33) . Illustration 19 g01083401 19. Remove shaft (33) , thrust discs 34, and () gear (35) from carrier assembly (23) . Remove tube (36) from shaft (33) . Remove pin (32) from shaft (33) . Illustration 20 g00507145 20. Remove bearings (37) and spacer (38) from gear (35) . 21. Repeat Steps 18, 19, and 20 in order to remove the remaining three shaft assemblies from the carrier assembly. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/3/23

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