Caterpillar Cat 206 EXCAVATOR WHEEL TYPE EXCAVATOR (Prefix 3GC) Service Repair Manual (3GC00001 and up)

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Product EXCAVATOR Model 206 EXCAVATOR
3GC Configuration 206 EXCAVATOR WHEEL TYPE
3GC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
POWER TRAIN Media Number -SENR4322-00 Publication
Date -01/03/1989
Date Updated -11/10/2001
Transmission SMCS - 3009-010 3009-017 Remove
And Install Transmission
NOTE The following steps show the transmission
being removed with the differential carrier. The
transmission may also be removed by using a
suitable transmission jack and leaving the
differential carrier in the excavator. Start
By a. remove transmission/differential
carrier NOTICE Keep all parts clean from
contaminants. Contaminants put into the system
may cause rapid wear and cause shortened
component life.
1. Install tool (A) and remove eight bolts (1).
2

• Lift transmission from transmission/differential
  carrier assembly. The weight of the transmission
  is 30 kg (65 lb).
• NOTE The following steps are to install the
  transmission.
• Position transmission into dropbox of
  transmission/differential carrier assembly and
  secure with eight bolts (1).
• Remove tool (A). End By
• a. install transmission/differential carrier

Disassemble And Assemble Transmission
Start By a. remove transmission
NOTICE
3
Keep all parts clean from contaminants.
Contaminants put into the system may cause rapid
wear and cause shortened component life.
1. Use tool (A) and two blocks (X) to remove
clutch assembly (1) from transmission housing (2).

• Remove three seals (4) and one O-ring seal (3)
  from shaft (5).
• Use tool (B) and remove retaining ring (6).
  Remove gear (7) and shaft (5).
• NOTE On clutch pack removal, maintain the
  correct sequence of disks and plates as there are
  different thicknesses of disks and plates.

4. Remove retaining ring (8) and clutch pack (9).
4
5. Use a shop press and tool (C) to compress
spring washer (10) and remove retaining ring
(11). Release compression and remove plate (12)
and spring washer (10).
6. Remove flange (13) from gear (14) by means of
compressed air in port (Y).
7. Remove retaining ring (15), washer (16) and
O-ring seal (17). Remove gear (14) from guide
(19).
8. With retaining ring pliers remove retaining
ring (20) and gear (18) from guide (19). NOTE
Contact Caterpillar Service Technology Group for
information regarding the type of retaining ring
pliers to use.
5
9. Remove retaining ring (22) and seal (23) from
guide (19). Remove three seals (24) and two O-
ring seals (25).
10. Remove retaining ring (26), seal (27) and two
bearings (28) from gear (18).
11. From gear (18), remove ring (29), retaining
ring (30) and washer (31).
12. Using tool (D), remove bearing (32), washer
(33) and retaining ring (20) from gear (18).
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13. Remove retaining ring (34) and clutch pack
disks and plates (35) from transmission (2).
14. Using a shop press and tool (C), compress
spring seat (37) and remove retaining ring (36).
Release press and remove seat (37) and spring
(38) from transmission housing (2).
15. Remove retaining ring (39) and gear (40).
8

1. Remove washer (41) from gear (40).
2. Turn gear (40) over and apply air pressure to
   port (Z) to remove flange (42).

18. Remove five bolts (43). Under each bolt (43)
is a special seal washer which must be replaced
at assembly with a new seal washer. Using a
plastic mallet from opposite end, drive shaft
assembly (44) out of transmission housing (2).
19. Remove O-ring seal (45) from transmission
housing (2).
20. From shaft assembly (44), remove rotor (46)
and pin (47).
9
21. Remove O-ring seal (49), ring (48) and two
rings (50) from shaft assembly (44).
22. Attach tooling (F) to needle bearing (58)
inside shaft (44). Attach tooling (G) to tooling
(F) and use two spacer blocks (X) to pull two
needle bearings out of shaft (44).
23. Turn shaft assembly (44) over and remove
retaining ring (51) and seal (52). Seal (52) will
be destroyed and must be replaced with a new
seal at assembly.
24. Remove retaining ring (53), spacer (54) and
thrust washer (55) from shaft (44).
10

• Remove retaining ring (56) and use tool (D) and
  tool (E) to remove bearing (57) from shaft (44).
• NOTE The following steps are to assemble the
  transmission
• Heat bearing (57) to 135C (275F), and install
  on shaft (44). Install retaining ring (56).
• Insert shaft assembly (44) into thrust washer
  (55). Install spacer (54) and retaining ring (53).

1. Install seal (52) into shaft assembly (44) with
   tooling (H) and secure with retaining ring (51).
2. Install needle bearing (58) into shaft assembly
   (44). Install two rings (50), ring (48) and
   O-ring seal (49) on shaft assembly (44).
3. Install pin (47). Coat rotor (46) with 5P0960
   Grease and install on shaft assembly (44).
4. Coat O-ring seal (45) with lubricant and install
   in transmission housing (2).
5. Lubricate rings (50) and insert shaft assembly
   (44) into transmission housing (2). Install five
   bolts (43) with new seals on each bolt. torque to
   10 Nm (7.4 lb ft).

33. Place new seal on flange (42) and install
flange into gear (40). Place spring (38) and
spring seat (37) into gear (40). Compress with
tool (C) and install retaining ring (36).
11
34. Install clutch pack (35), beginning with
thick outer plate (59) and ending with pressure
plate (60), and install retaining ring (34).
35. Compress clutch pack (35) with a pressure of
200 Nm (148 lb ft), and measure depth A of
pressure plate (60) with tool (H).
36. Remove clutch pack assembly (35) from press
and apply pressure to pressure plate (60) to
push plate against retaining ring (34) and
measure depth B with tool (H). The difference in
value between measurement A and B should be
2.2mm 1.5mm. If value is not within
specification, adjust with different value
retaining ring (34). See Parts Book for 206 or
212 Excavators.
37. Install washer (41) and retaining ring (39).
12
38. In guide (19) use tool (J) and install new
seal (23). Install retaining ring (22), new
O-ring seals (25) and three seals (24).
39. Place bearing (32) into bore of guide (19)
and install retaining ring (20). Measure distance
between bearing and retaining ring with a feeler
gauge, and select from Parts Book for 206 or 212
Excavators the correct washer (33) to eliminate
any bearing end play. After correct washer has
been selected, remove retaining ring (20) and
bearing (32) from guide (19).
40. Install retaining ring (20) and washer (33)
on gear (18).
41. Press bearing (32) on gear (18) firmly
against shoulder. Install retaining ring (30).
Measure distance between bearing (32) and
retaining ring (30). Select correct washer (31)
from 206 or 212 Excavators Parts Book to remove
any bearing play and remove retaining ring (30).
13
42. Install washer (31) and retaining ring (30).
43. Install ring (29) and gear (18).
44. Install two roller bearings (28), seal (27)
and retaining ring (26) in gear (18).
45. Install gear assembly (18) into guide (19)
and using special retaining ring pliers install
retaining ring (20) into guide (19). NOTE
Contact Caterpillar Service Technology Group for
information regarding the type of retaining ring
pliers to use.
14
46. Install gear (14) on guide (19). Install
O-ring seal (17), washer (16) and retaining ring
(15).

• Replace O-ring seal (61) in flange (13). Install
  flange (13) into gear (14).
• Install spring washer (10) in gear (14). With a
  shop press and tool (C), compress spring washer
• (10) and install plate (12) and retaining ring
  (11).
• 49. Install clutch pack (9) starting with the
  thick outer plate. Alternate with disks and
  plates. Three of the plates are available in
  various thicknesses. These are used to adjust
  proper clutch play. See the 206 or 212
  Excavators Parts Book for these plates. End by
  installing the last plate and the retaining ring
  (8). Check clutch play by measuring distance
  between last plate and retaining ring (8). The
  clutch play should be 1.3mm 1.5, - 0.0mm.

50. Install O-ring seal (3) and three seals (4)
on shaft (5). Install shaft (5) into clutch
assembly.
51. Install tool (L) and align clutch plates with
tool (K).
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52. Align clutch assembly (1) with tool (M) and
apply air pressure in port (Y) to hold clutch
pack in position.
53. Pressurize transmission housing (2) with air
to hold clutch assembly in position and carefully
lower clutch assembly (1) into transmission
housing clutch assembly. Care should be taken to
align port (y) in clutch assembly (1) in proper
position in transmission housing (2). End By a.
install transmission NOTICE Perform Scheduled
Oil Sampling on oil wetted compartments after
performing service work to check for contaminants
left in the compartment following repair.
Contaminants put into the system may cause rapid
wear and shortened component life.
Copyright 1993 - 2021 Caterpillar Inc. All
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Licensees.
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16
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Previous Screen
Product EXCAVATOR Model 206 EXCAVATOR
3GC Configuration 206 EXCAVATOR WHEEL TYPE
3GC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
POWER TRAIN Media Number -SENR4322-00 Publication
Date -01/03/1989
Date Updated -11/10/2001

• Axle Housing (Rear)
• SMCS - 4313-010
• Remove And Install Axle Housing (Rear)
• Start By
• remove rear drive shaft
• remove rear wheels and tires

• Install suitable transmission jack. Remove two
  hydraulic lines (1) and eight bolts (2). Lower
  the rear axle housing and remove it from under
  machine.
• NOTE The following step is to install the rear
  axle housing.
• Position rear axle housing under excavator, raise
  with suitable transmission jack and install
  eight bolts (2) and two hydraulic lines (1).
• End By
• install rear wheels and tires
• install rear drive shaft

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Licensees.
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Shutdown SIS
Previous Screen
Product EXCAVATOR Model 206 EXCAVATOR
3GC Configuration 206 EXCAVATOR WHEEL TYPE
3GC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
POWER TRAIN Media Number -SENR4322-00 Publication
Date -01/03/1989
Date Updated -11/10/2001

• Axle Housing (Front)
• SMCS - 4313-010
• Remove And Install Axle Housing (Front)
• Start By
• remove wheels and tires (front only)
• remove axles (front)
• remove drive shaft (front)

1. Use suitable floor jack and wood block to support
   the front axle housing.
2. Remove pin (1) and lower front axle housing. The
   weight of the front axle housing is 264 kg (580
   lb).

3. Inspect and replace two bushings (2) if
necessary.
18

• NOTE The following steps are to install the
  front axle housing.
• Position front axle housing on suitable floor
  jack.
• Raise front axle housing into position and
  install pin (1).

Copyright 1993 - 2021 Caterpillar Inc. All
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Licensees.
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19
Shutdown SIS
Previous Screen
Product EXCAVATOR Model 206 EXCAVATOR
3GC Configuration 206 EXCAVATOR WHEEL TYPE
3GC00001-UP (MACHINE)
Disassembly and Assembly 206 212 EXCAVATORS
POWER TRAIN Media Number -SENR4322-00 Publication
Date -01/03/1989
Date Updated -11/10/2001
Differential (Front) SMCS - 3258-010 Remove And
Install Differential (Front)
Start By a. remove axle housing
(front) NOTICE Keep all parts clean from
contaminants. Contaminants put into the system
may cause rapid wear and shortened component life.

1. Attach tooling (A) to differential housing (1).
2. Remove twelve bolts (2) and remove differential
   housing. The weight of the differential housing
   is 127 kg (280 lb).

20
NOTE The following steps are to install the
differential (front).

• NOTE Make sure ring gear (3) is in proper
  position to axle housing. If ring gear is
  installed on the wrong side the wheels will turn
  in the opposite direction.
• Install guide bolt (4). Attach tooling (A) to
  differential housing and lower housing into front
  axle housing.
• Install twelve bolts (2).

Disassemble And Assemble Differential (Front)
Start By a. remove front differential
NOTICE Keep all parts clean from contaminants.
Contaminants put into the system may cause rapid
wear and shortened component life.
21

1. Drive two roll pins (1) up so that the two castle
   nuts (2) can be removed.
2. Remove four bolts (3), two bearing caps (4), two
   castle nuts (2) and two cup bearings (5).
3. Remove ring gear shaft assembly (6).

4. Remove eight bolts (7) and four bolts (8) to
remove ring gear (9).
5. Mark top and bottom housings and remove top
housing (10) from ring gear shaft assembly (6).
6. From bottom housing (11), remove thrust washer
(12) and gear (13).
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7. From bottom housing (11), remove spider gear
set (14), gear (15) and thrust washer (16).
8. Place top housing (10) in press. Install
tooling (A) and remove cone bearing (17).
9. Place bottom housing (11) in press. Install
tooling (A) and remove cone bearing (18).
10. From housing (19) remove nut (20), washer
(21) and flange (22).
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11. Place housing (19) in press and remove pinion
shaft assembly (23).

1. From housing (19) remove seal (24) and cup and
   cone bearings (25).
2. Turn housing (19) over and remove cup bearing
   (26) and shim (27) located behind cup bearing
   (26).

14. From pinion shaft assembly (23) remove
bushing (29). Place pinion shaft in press and use
tool (A) to remove bearing (28). NOTE The
following steps are to assemble the front
differential.
24
15. To determine proper shim (27) for pinion gear
tooth contact, install tools (B) and (C) and
bearing caps (4) with bolts (3). Measure distance
with tool (D) from top of tool (C) to face of
bearing bore in housing (18). Dimension Z.
Subtract 1/2 of the diameter of tool (C) from
dimension Z and determine dimension Y.

• Place cup bearing (26) on cone bearing (28) and
  with tool (D) measure thickness. Dimension X.
• Read dimension W off the end of the pinion gear
  (23) and calculate Y - X - W proper shim
• (27) thickness. Select proper shim from the 206
  or 212 Excavators Parts Book.

1. Freeze shim (27) and cup bearing (26) and install
   into housing (19).
2. Heat bearing (28) to 135 (275F), and install on
   pinion gear shaft (23). Install bushing (29) on
   pinion gear shaft (23).
3. Turn housing (19) over and install cup and cone
   bearing (25) and seal (24).

25

• Using press install pinion shaft assembly (23)
  into housing (19).
• Install flange (22), washer (21) and nut (20).
  See Specification Manual for the proper torque
  for nut (20).
• Press bearing (18) onto housing (11).
• Press bearing (17) onto housing (10).
• Install thrust washer (16) and gear (15) into
  housing (11).
• Install four washers and four gears as shown onto
  spider assembly (14) and install spider assembly
  (14) into housing (11).
• Place gear (13) and thrust washer (12) on spider
  assembly (14) in housing (11).
• NOTE The thrust washer tabs on washers (16) and
  (12) must be in the slots in the housings (11)
  and (10).
• Place housing (10) on housing (11) lining up
  reference mark mentioned in Step (5).
• Heat gear (9) to 135 (275F), and install on
  ring gear shaft assembly (6) so that roll pin
  holes and bolt holes line up.
• Install four bolts (8) and eight bolts (7). Apply
  9S3263 Thread Lock to bolts.

1. Install ring gear assembly (6), with two cup
   bearings (5), into differential carrier. Install
   two nuts (2) to hold bearings (5) in place.
2. Install two bearing caps (4) with four bolts (3).
   Make sure roll pins (1) are driven up to allow
   adjusting of nuts (2) to set backlash. Hand
   tighten bolts (3).

26
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• Install tool (E) and adjust nut (2) on bevel gear
  side to obtain a backlash of 0.18 - 0.3mm.
• Screw in nut (2) on opposite end of bevel gear to
  remove all slack in bearing and then turn nut
  two more notches. Check backlash and correct if
  necessary.
• Tighten bolts (3) to 210 Nm (155 lb ft). Check
  ring gear backlash to make sure it has not
  changed. If the back lash is out of tolerance,
  repeat Steps 32, 33, 34 and 35 again.
• After the backlash and differential bearing
  preload have been made, check tooth contact
  between the bevel gear and the pinion as follows
• a. Put a small amount of Prussian Blue, red lead
  or paint on the bevel gear teeth. Turn the pinion
  and inspect the marks made on the bevel gear
  teeth.

Correct Tooth Contact (No Load)
Correct Tooth Contact (With Load) b. With no
load, correct tooth contact will be as shown. The
area of contact starts near the toe of the gear
and moves approximately half way up the length of
the tooth. With this setting, the tooth contact
will be as shown when a load is put on the gear.
29
Short Toe Contact c. If the pinion is too far
away from the bevel gear, short toe contact will
be the result. The teeth on the pinion will make
contact with the surfaces of the teeth that make
a curve toward the outside (convex surfaces) at
the toe ends, and the surfaces of the teeth that
make a curve toward the inside (concave
surfaces) and the heel ends. Short toe contact
must be corrected by an increase to the
thickness of shim between the pinion bearing cage
and the carrier. This will move the pinion in the
direction of the arrow. Check backlash and tooth
contact again. Move the bevel gear in the
direction of the arrow if needed to keep the
correct backlash.
Short Heel Contact d. If the pinion is too near
the center of the bevel gear, short heel contact
will be the result. The teeth on the pinion will
make contact with the concave surfaces of the
teeth at the toe ends, and the convex surfaces
of the teeth at the heel ends. Short heel contact
must be corrected by a decrease in the thickness
of shim between the pinion bearing cage and the
carrier. This will move the pinion in the
direction of the arrow. Check the backlash and
tooth contact again. Move the bevel gear in the
direction of the arrow if needed to keep the
correct backlash. NOTE It is possible that
several adjustments of both the pinion and the
bevel gear will have to be made before the
backlash and tooth contact are correct. Always
remember that any change to the backlash will
also change the tooth contact. The backlash must
be correct before the tooth contact is
checked. e. Remove the Prussian Blue, red lead
or paint from the gears after the correct tooth
contact is made. 37. Drive roll pins (1) down to
lock nuts (2). End By a. install differential
(front) NOTICE
30
Perform Scheduled Oil Sampling on oil wetted
compartments after performing service work to
check for contaminants left in the compartment
following repair. Contaminants put into the
system may cause rapid wear and shortened
component life.
Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Sun Oct 17 102707 UTC0800 2021
31
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