12H, 140H, 143H, 160H and 163H Motor Graders Power Train Transmission Caterpillar


Transmission
`
1.1. 6Y-2300 Input Shaft Group
2.1. 6Y-2301 Transmission Clutch (Forward)
3.1. 6Y-2302 Transmission Clutch (Reverse and Second)
4.1. 6Y-2305 Transmission Clutch (First Gear and Third Gear)
5.1. 8E-9317 Transmission Clutch (High Gear and Low Gear)
6.1. Procedure to Measure Running Clearance


Illustration 1g00101356

(1) 6Y-2300 Input Shaft Group

(2) 6Y-2301 Transmission Clutch (Forward)

(3) 6Y-2302 Transmission Clutch (Reverse and Second)

(4) 6Y-2305 Transmission Clutch (First Gear and Second Gear)

(5) 8E-9317 Transmission Clutch (High Gear and Low Gear)



Illustration 2g00101358
Section A-A

6Y-2300 Input Shaft Group



Illustration 3g00101364

(A) ... 1.02 ± 0.99 mm (.040 ± .039 inch)

(B) ... 5.75 ± 0.25 mm (.226 ± .010 inch)

6Y-2301 Transmission Clutch (Forward)



Illustration 4g00101369

(1) Thickness of seven new friction discs and of six new plates ... 46.00 ± 1.04 mm (1.811 ± .041 inch)

Note: The measurement must be made when the friction discs and the plates are compressed.

Note: This dimension is only the thickness of seven new friction discs and six new plates. This dimension does not include the running clearance of the clutch pack.

Running clearance for number one clutch pack (Forward High Gear) ... 3.03 ± .50 mm (0.119 ± 0.020 inch)

Note: Refer to the procedure: Procedure to Measure Running Clearance

Thickness of one new 108-5751 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch)

Install 108-5751 Friction Disc into the clutch pack so that the grooved pattern faces toward the center of the clutch pack. One of the friction discs is located at the front of the clutch pack and one of the friction discs is located at the rear of the clutch pack.

Minimum allowable thickness for reusability ... 3.67 mm (.144 inch)

Thickness of one new 6I-8911 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch)

Minimum allowable thickness for reusability ... 3.33 mm (.131 inch)

Thickness of one new 9U-9995 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch)

(2) Thickness of seven new friction discs and of six new plates ... 46.00 ± 1.04 mm (1.811 ± .041 inch)

Note: The measurement must be made when the friction discs and the plates are compressed.

Note: This dimension is only the thickness of seven new friction discs and six new plates. This dimension does not include the running clearance of the clutch pack.

Running clearance for number two clutch pack (Forward Low Gear) ... 1.65 ± .64 mm (0.065 ± 0.025 inch)

Note: Refer to the procedure: Procedure to Measure Running Clearance

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch)

Minimum allowable thickness for reusability ... 3.33 mm (.131 inch)

Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch)

(3) Diameter of shaft in bearing area ... 69.994 ± 0.007 mm (2.7557 ± .0003 inch)

(4) 9U-8815 Spring

Test length ... 41.03 mm (1.615 inch)
Test force ... 459.6 ± 36.8 N (103.27 ± 8.26 lb)
Free length after test ... 150.6 mm (5.93 inch)
Outside diameter ... 106.0 mm (4.17 inch)

(5) Diameter of shaft in bearing area ... 69.994 ± 0.007 mm (2.7557 ± .0003 inch)



Illustration 5g00101370
Detail A

(B) Install 5H-8985 Spring Pin (6) in 6Y-1119 Seal Carrier (7) with 6.5 mm (.26 inch) maximum protruding out of the carrier.

6Y-2302 Transmission Clutch (Reverse and Second)



Illustration 6g00101372

(1) Thickness of seven new friction discs and of six new plates ... 46.00 ± 1.04 mm (1.811 ± .041 inch)

Note: The measurement must be made when the friction discs and the plates are compressed.

Note: This dimension is only the thickness of seven new friction discs and six new plates. This dimension does not include the running clearance of the clutch pack.

Running clearance for number three clutch pack (Reverse Gear) ... 1.65 ± .64 mm (0.065 ± 0.025 inch)

Note: Refer to the procedure: Procedure to Measure Running Clearance

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (1.570 ± .003 inch)

Minimum allowable thickness for reusability ... 3.33 mm (.131 inch)

Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch)

(2) Thickness of four new friction discs and of three new plates ... 25.00 ± 0.56 mm (.984 ± .020 inch)

Note: The measurement must be made when the friction discs and the plates are compressed.

Note: This dimension is only the thickness of four new friction discs and three new plates. This dimension does not include the running clearance of the clutch pack.

Running clearance for number four clutch pack (Second Gear) ... 1.15 ± .53 mm (0.045 ± 0.021 inch)

Note: Refer to the procedure: Procedure to Measure Running Clearance

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch)

Minimum allowable thickness for reusability ... 3.33 mm (.131 inch)

Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch)

(3) Diameter of shaft in bearing area ... 69.994 ± 0.007 mm (2.7557 ± .0003 inch)

(4) 9U-8815 Spring

Test length ... 41.03 mm (1.615 inch)
Test force ... 459.6 ± 36.8 N (103.27 ± 8.26 lb)
Free length after test ... 150.6 mm (5.93 inch)
Outside diameter ... 106.0 mm (4.17 inch)

(5) 102-5881 Wave Spring

Test length ... 38.20 mm (1.503 inch)
Test force ... 2090 ± 222 N (470 ± 50 lb)
Free length after test ... 50.0 mm (1.97 inch)
Outside diameter ... 106.01 ± 0.66 mm (4.174 ± .026 inch)


Illustration 7g00101373
Detail A

(C) Install 5H-8985 Spring Pin (8) in 6Y-1119 Seal Carrier (7) with 6.5 mm (.26 inch) maximum protruding out of the carrier.



Illustration 8g00101374
Detail B

(D) Installation depth for 6Y-1895 Sleeve Bearing (6) in 6Y-3854 Gear Assembly (9) ... 0.5 ± 0.5 mm (.02 ± .02 inch)

Inside diameter of bearing after assembly ... 69.925 ± 0.039 mm (2.7529 ± .0015 inch)

Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)

6Y-2305 Transmission Clutch (First Gear and Third Gear)



Illustration 9g00101375

(1) Thickness of six new friction discs and of five new plates ... 39.00 ± 0.88 mm (1.535 ± .035 inch)

Note: The measurement must be made when the friction discs and the plates are compressed.

Note: This dimension is only the thickness of six new friction discs and five new plates. This dimension does not include the running clearance of the clutch pack.

Running clearance for number six clutch pack (First Gear) ... 1.91 ± .62 mm (0.075 ± 0.024 inch)

Note: Refer to the procedure: Procedure to Measure Running Clearance

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch)

Minimum allowable thickness for reusability ... 3.33 mm (.131 inch)

Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch)

(2) Thickness of four new friction discs and of three new plates ... 25.00 ± 0.56 mm (.984 ± .022 inch)

Note: The measurement must be made when the friction discs and the plates are compressed.

Note: This dimension is only the thickness of four new friction discs and three new plates. This dimension does not include the running clearance of the clutch pack.

Running clearance for number five clutch pack (Third Gear) ... 1.15 ± .53 mm (0.045 ± 0.021 inch)

Note: Refer to the procedure: Procedure to Measure Running Clearance

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch)

Minimum allowable thickness for reusability ... 3.33 mm (.131 inch)

Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch)

(4) Torque for two bolts ... 55 ± 10 N·m (41 ± 7 lb ft)

(7) 102-5881 Wave Spring

Test length ... 38.2 mm (1.50 inch)
Test force ... 2090 ± 222 N (470 ± 50 lb)
Free length after test ... 50.0 mm (1.97 inch)
Outside diameter ... 106.01 ± 0.66 mm (4.174 ± .026 inch)


Illustration 10g00101376
Detail A

(D) Install 5H-8985 Spring Pin (6) in 6Y-2425 Seal Carrier (5) with 6.5 mm (.26 inch) maximum protruding out of the carrier.



Illustration 11g00101377
Detail B

(E) Installation depth for 6Y-2419 Sleeve Bearing (3) in 6Y-3857 Gear Assembly (9) ... 0.5 ± 0.5 mm (.02 ± .02 inch)

Inside diameter of bearing after assembly ... 69.925 ± 0.039 mm (2.7529 ± .0015 inch)

Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)



Illustration 12g00101378
Detail C

(F) Installation depth for 6Y-1895 Sleeve Bearing (8) in 6Y-3856 Gear Assembly (10) ... 0.5 ± 0.5 mm (.02 ± .02 inch)

Inside diameter of bearing after assembly ... 69.925 ± 0.039 mm (2.7529 ± .0015 inch)

Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)

8E-9317 Transmission Clutch (High Gear and Low Gear)



Illustration 13g00101379

(1) Thickness of seven new friction discs and of eight new plates ... 52.56 ± 1.34 mm (2.069 ± .053 inch)

Note: The measurement must be made when the friction discs and the plates are compressed.

Note: This dimension is only the thickness of seven new friction discs and of eight new plates. This dimension does not include the running clearance of the clutch pack.

Running clearance for number seven clutch pack (Low Gear) ... 4.27 ± .52 mm (0.168 ± 0.021 inch)

Note: Refer to the procedure: Procedure to Measure Running Clearance

Thickness of one new 6Y-7981 Friction Disc ... 4.32 ± 0.10 mm (.170 ± .004 inch)

Minimum allowable thickness for reusability ... 3.65 mm (.144 inch)

Thickness of one new 3P-0337 Plate ... 2.79 ± 0.08 mm (.109 ± .003 inch)

(2) Thickness of six new friction discs and of five new plates ... 39.00 ± 0.88 mm (1.530 ± .035 inch)

Note: The measurement must be made when the friction discs and the plates are compressed.

Note: This dimension is only the thickness of six new friction discs and five new plates. This dimension does not include the running clearance of the clutch pack.

Running clearance for number eight clutch pack (High Gear) ... 1.91 ± .62 mm (0.075 ± 0.024 inch)

Note: Refer to the procedure: Procedure to Measure Running Clearance

Thickness of one new 6I-8912 Friction Disc ... 4.00 ± 0.08 mm (.157 ± .003 inch)

Minimum allowable thickness for reusability ... 3.33 mm (.131 inch)

Thickness of one new 110-7723 Plate ... 3.00 ± 0.08 mm (.118 ± .003 inch)

(4) 8M-4295 Spring

Test length ... 26.9 mm (1.06 inch)
Test force ... 74 ± 6 N (16 ± 1 lb)
Free length after test ... 44.0 mm (1.75 inch)
Outside diameter ... 15.2 mm (.60 inch)

(5) 102-5881 Wave Spring

Test length ... 38.2 mm (1.50 inch)
Test force ... 2090 ± 222 N (470 ± 50 lb)
Free length after test ... 50.0 mm (1.97 inch)
Outside diameter ... 106.01 ± 0.66 mm (4.174 ± .026 inch)

(7) Torque for two bolts ... 55 ± 10 N·m (40 ± 7 lb ft)



Illustration 14g00101380
Detail A

(D) Install 5H-8985 Spring Pin (8) in 6Y-2425 Seal Carrier (6) with 6.5 mm (.26 inch) maximum protruding out of the carrier.



Illustration 15g00101381
View (B)

( E) Installation depth for 9W-6467 Sleeve Bearings (3) in 6Y-2432 Gear Assembly (9) ... 0.5 ± 0.5 mm (.02 ± .02 inch)

Inside diameter of bearing after assembly ... 69.925 ± 0.039 mm (2.7529 ± .0015 inch)

Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)



Illustration 16g00101382
Detail C

(F) ( G) Installation depth for 9W-6467 Sleeve Bearings (10) in 6Y-3858 Gear Assembly (11) ... 0.5 ± 0.5 mm (.02 ± .02 inch)

Inside diameter of bearing after assembly ... 69.925 ± 0.039 (2.7529 ± .0015 inch)

Diameter of shaft in bearing area ... 69.842 ± 0.008 mm (2.7497 ± .0003 inch)

Procedure to Measure Running Clearance



Illustration 17g00101068
Typical Example

Use this procedure in order to check for proper clutch assembly.

Note: Do not use a puller to remove rotor (7) from the clutch assembly.

Remove the following components from the clutch group: bearing (1), disc (2), gear assembly (3), ring (4), gear assembly (5), disc (6), rotor (7), race and bearing (8) and carrier (9).



Illustration 18g00101069

  1. Position the assembled clutch group with the shaft in the vertical position. Position the hub assembly of the clutch that is being measured so that the hub assembly faces upward.

  2. Make sure that hub assembly (10) moves freely.

  3. Position the tip of a dial indicator on the side of the clutch pack of the transmission at location (B). Zero the indicator.

    ------ WARNING! ------

    Personal injury can result from applying air pressure without the lock ring securely in place. Make sure the lock ring (11) is securely in place before applying air pressure to the clutch pack.


  4. To check the running clearance for the clutch packs, apply approximately 140 kPa (20 psi) air pressure to passage (14) for clutch pack (12).

  5. Piston (13) and the clutch pack (12) should move up. Determine the distance that the piston and the clutch pack has moved from the dial indicator. This is the running clearance for the clutch pack.

Note: Use this same procedure in order to determine the running clearances for the clutch pack for the existing clutch assemblies.

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