Caterpillar Cat 627G Wheel Tractor (Prefix DBD) Service Repair Manual (DBD00001 and up)

1
Service Repair Manual
Models 627G Wheel Scraper
2
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Product WHEEL TRACTOR Model 627G WHEEL TRACTOR
DBD Configuration 627G Wheel Tractor DBD00001-UP
(MACHINE) POWERED BY C15 Engine
Disassembly and Assembly 627G Wheel Tractor Power
Train Media Number -RENR7498-02 Publication Date
-01/08/2007
Date Updated -16/08/2007
i02301155
Transfer Gears - Disassemble SMCS -
3159-015 Disassembly Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 1
B 8B-7548 Push-Puller Tool Gp 1
B 8B-7551 Bearing Puller Gp 1
B 1P-0498 Drive Plate 1
C 5P-4170 Step Plate 1
C 1P-2321 Combination Puller 1
D 8B-7554 Bearing Cup Puller Gp 1
D 5P-4170 Step Plate 1
D 1P-0518 Drive Plate 1
E 8B-7560 Step Plate 1
E 5F-7345 Screw 1
E 8B-7554 Bearing Cup Puller Gp 1
F - Bolts 3/8" - 16 NC by 3 inch 3
Start By
3

• Remove the transfer gear case. Refer to
  Disassembly and Assembly, "Transfer Gears -
  Remove".
• Remove the transmission oil filter base. Refer to
  Disassembly and Assembly, "Transmission Oil
  Filter Base - Remove and Install".
• Remove the transmission scavenge pump. Refer to
  Disassembly and Assembly, "Transmission Scavenge
  Pump - Remove".
• Remove the transmission oil pump. Refer to
  Disassembly and Assembly, "Transmission Oil Pump
  - Remove".
• NOTICE
• Care must be taken to ensure that fluids are
  contained during performance of inspection,
  maintenance, testing, adjusting, and repair of
  the product. Be prepared to collect the fluid
  with suitable containers before opening any
  compartment or disassembling any component
  containing fluids.
• Refer to Special Publication, NENG2500, "Dealer
  Service Tool Catalog" for tools and supplies
  suitable to collect and contain fluids on Cat
  products.
• Dispose of all fluids according to local
  regulations and mandates.

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.
4

• Illustration 1 g01048669
• Remove the bolts that secure bearing cage (1) to
  the transfer gear case. Use Tooling (F) in order
  to separate bearing cage (1) from the transfer
  gear case.
• Remove bearing cage (1), shims (2), and pump
  drive gear (3) from the transfer gear case.

• Illustration 2 g01102869
• Remove the bolts that secure bearing cage (4) to
  the transfer gear case. Use Tooling (F) in order
  to separate bearing cage (4) from the transfer
  gear case.
• Remove bearing cage (4), shims (5), and gear (6)
  from the transfer gear case.

Illustration 3
g00529211
5
6. Remove bearing cups (7) and (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 4 g01102873
• Remove the bolts that secure bearing cage (9) to
  the transfer gear case. Use Tooling (F) in order
  to separate bearing cage (9) from the transfer
  gear case.
• Remove bearing cage (9), shims (10), and gear
  (11) from the transfer gear case.

Illustration 5 g00529214 9. 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.
6
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• Illustration 6 g00529215
• 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
• and gear (15) separate from the transfer gear
  case. Remove bearing cage (14) and gear
• as a unit from the transfer gear case.

Illustration 7
g00529216
Illustration 8 g00529257 11. Remove retaining
ring (16) from gear (15). Remove bearing (17) and
bearing cage (14) from gear (15).
8
Illustration 9 g01048544 12. Remove bearing (17)
from bearing cage (14).
Illustration 10 g01048548 13. Remove bolts (19)
and separate gear (20) from gear (11). Use
Tooling (B) to remove bearing cone (18) from
gear (11). Repeat the procedure for the bearing
cone on the opposite side of the gear.
Illustration 11 g01048549 14. Use Tooling (C) to
remove bearing cone (21) from gear (6). Repeat
the procedure for the bearing cone on the
opposite side of gear (6).
9
Illustration 12 g01048550 15. Use Tooling (C) to
remove bearing cone (22) from gear (3). Repeat
the procedure for the bearing cone on the
opposite side of gear (3).
Illustration 13 g01048551 16. Use Tooling (D) to
remove bearing cup (23) from bearing cage (4).
Remove O-ring seal (24) from bearing cage (4).
Illustration 14 g01048553 17. Remove bearing cup
(25) from bearing cage (9).
10
Illustration 15 g01048552 18. Use Tooling (E) to
remove bearing cup (26) from bearing cage (1).
Remove O-ring seal (27) from bearing cage (1).
Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Tue May 4 135342 UTC0800 2021
11
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Product WHEEL TRACTOR Model 627G WHEEL TRACTOR
DBD Configuration 627G Wheel Tractor DBD00001-UP
(MACHINE) POWERED BY C15 Engine
Disassembly and Assembly 627G Wheel Tractor Power
Train Media Number -RENR7498-02 Publication Date
-01/08/2007
Date Updated -16/08/2007
i07232119
Transfer Gears - Assemble SMCS -
3159-016 Assembly Procedure Table 1
Required Tools Required Tools Required Tools 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.
12

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 g01048544 3. Install bearing (17)
into bearing cage (14).
Illustration 2 g00529216 4. 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).
13
Illustration 3 g00529215 5. 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 Nm (41 7 lb ft).
Illustration 4 g01048552 6. Install O-ring seal
(27) onto bearing cage (1). Lower the temperature
of bearing cup (26). Install bearing cup (26) to
bearing cage (1). Check that bearing cup (26) is
seated in the bore of bearing cage (1).
Illustration 5 g01048553 7. 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).
14
Illustration 6 g01048551 8. Install O-ring seal
(24) to bearing cage (4). Lower the temperature
of bearing cup (23). Install bearing cup (23) to
bearing cage (4). Check that bearing cup (23) is
seated in the bore of bearing cage (4).
Illustration 7 g01048550 9. Raise the
temperature of bearing cone (22). Install bearing
cone (22) on gear (3). Repeat the procedure for
the bearing cone on the opposite side of gear (3).
Illustration 8
g01048549
15
10. Raise the temperature of bearing cone (21).
Install bearing cone (21) on gear (6). Repeat the
procedure for the bearing cone on the opposite
side of gear (6).

• Illustration 9 g01048548
• 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).
• Position gear (20) on gear (11). Install bolts
  (19). Tighten bolts (19) to a torque of
• 55 10 Nm (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).

Illustration 10 g00529214 13. 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.
16
Illustration 11
g00529695

• Illustration 12 g01048735
• Position gear (11) in the transfer gear case.
  Install bearing cage (9) and shims (10). Install
  bolts (28) that hold bearing cage (9) in
  position. Tighten bolts (28) to a torque of
• 55 10 Nm (41 7 lb ft).
• 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) to
  obtain an end play of 0.15 0.05 mm (0.006
  0.002 inch). Tighten bolts (28) to a torque of
  55 10 Nm (41 7 lb ft).

Illustration 13
g00529211
17
16. Use Tooling (G) to install bearing cups (7)
and (8) to the transfer gear case. Check that
bearing cups (7) and (8) is seated in the bore of
the transfer gear case.
Illustration 14
g00529696

• Illustration 15 g01048736
• Position gear (6) in the transfer gear case with
  the internal snap ring groove facing up. Install
  bearing cage (4) and shims (5). Install the bolts
  (29) that hold bearing cage (4) in position.
  Tighten bolts (29) to a torque of 55 10 Nm (41
  7 lb ft).
• Attach Tooling (A) and a suitable lifting device
  to the transfer gear case. Place the transfer
  gear case on wood blocks, as shown. Position
  Tooling (H) on the transfer gear case, as shown.
  Make sure that the dial indicator is in contact
  with gear (6). Use a pry bar to move gear (6) up
  and down. Adjust shims (5) to obtain an end play
  of 0.15 0.05 mm
• (0.006 0.002 inch). Tighten bolts (29) to a
  torque of 55 10 Nm (41 7 lb ft).

18
Illustration 16
g00529697

• Illustration 17 g01048737
• Position gear (3) in the transfer gear case.
  Install bearing cage (1) and shims (2). Install
  the bolts (30) that hold bearing cage (1) in
  position. Tighten bolts (30) to a torque of
• 55 10 Nm (41 7 lb ft).
• Position Tooling (H) on the transfer gear case,
  as shown. Make sure that the dial indicator is
  in contact with gear (3). Use a pry bar to move
  gear (3) up and down. Adjust shims (2) to obtain
  an end play of 0.15 0.05 mm (0.006 0.002
  inch). Tighten bolts (30) to a torque of 55 10
  Nm (41 7 lb ft).
• End By
• Install the transmission oil pump. Refer to
  Disassembly and Assembly, "Transmission Oil Pump
  - Install".
• Install the transmission scavenge pump. Refer to
  Disassembly and Assembly, "Transmission Scavenge
  Pump - Install".
• Install the transmission oil filter base. Refer
  to Disassembly and Assembly, "Transmission Oil
  Filter Base - Remove and Install".
• Install the transfer gear case. Refer to
  Disassembly and Assembly, "Transfer Gears -
  Install".

19
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Product WHEEL TRACTOR Model 627G WHEEL TRACTOR
DBD Configuration 627G Wheel Tractor DBD00001-UP
(MACHINE) POWERED BY C15 Engine
Disassembly and Assembly 627G Wheel Tractor Power
Train Media Number -RENR7498-02 Publication Date
-01/08/2007
Date Updated -16/08/2007
i02301157
Transfer Gears - Install - Off Chassis SMCS -
3159-012 Installation Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7574 Link Bracket 1
Illustration 1 g01050175 1. Install O-ring seals
(5) to transmission (1). Install O-ring seal (4)
to transfer gear assembly (2) .
20
Illustration 2
g00841290

• Illustration 3 g01050174
• Attach Tooling (A) and a suitable lifting device
  to transfer gear assembly (2), as shown. The
  weight of transfer gear assembly (2) is
  approximately 340 kg (750 lb).
• Connect transfer gear assembly (2) to
  transmission (1) .
• Install the nuts and bolts (3) that hold transfer
  gear assembly (2) to transmission (1). Tighten
  the nuts to a torque of 55 10 Nm (41 7 lb
  ft).
• Remove Tooling (A) from transfer gear assembly
  (2) .
• End By
• Install the speed sensor. Refer to Disassembly
  and Assembly, "Speed Sensor (Transmission)
• - Install".
• Install the transmission, the torque converter
  and the transfer gears. Refer to Disassembly and
  Assembly, "Transmission, Torque Converter and
  Transfer Gears - Install".

Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Tue May 4 135534 UTC0800 2021
21
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Product WHEEL TRACTOR Model 627G WHEEL TRACTOR
DBD Configuration 627G Wheel Tractor DBD00001-UP
(MACHINE) POWERED BY C15 Engine
Disassembly and Assembly 627G Wheel Tractor Power
Train Media Number -RENR7498-02 Publication Date
-01/08/2007
Date Updated -16/08/2007
i02038459
Transfer Gears - Install - In Chassis SMCS -
3159-012 Installation Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 1
C 1/2 - 13 NC by 6 inch Threaded Rod 2

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.
3. Install the O-ring seal to the transfer gear
   case.
4. Install Tooling (C) in the transmission case.

22
Illustration 1 g00841340 5. Use Tooling (A) and
a suitable lifting device to position the
transfer gear case to the transmission.

• Illustration 2 g01048435
• Remove Tooling (C). Install the nuts (not shown)
  and bolts (3) that secure the transfer gear case
  to the transmission case. Tighten the nuts (not
  shown) and bolts (3) to a torque of 105 20 Nm
  (77 15 lb ft).
• Install the piston pump for the cushion-hitch.
  Refer to Machine Systems Disassembly and
  Assembly, "Piston Pump (Cushion-Hitch) -
  Install".
• Install the vane pump for the hydraulic system
  and the steering system. Refer to Machine
  Systems Disassembly and Assembly, "Vane Pump
  (Hydraulic and Steering) - Install".
• Install the drive shaft. Refer to Disassembly and
  Assembly, "Drive Shaft - Remove and Install".
• Install the speed sensor. Refer to Disassembly
  and Assembly, "Speed Sensor (Transmission)
• - Install".

23

• Illustration 3 g00527046
• Install drain plugs (1) and (2). Fill the
  transmission case with oil. Refer to Operation
  and Maintenance Manual for the appropriate oil
  and the procedure to fill the transmission case.
• Install the power train guard. Refer to
  Disassembly and Assembly, "Power Train Guard
  (Transmission) - Remove and Install".

Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Tue May 4 135629 UTC0800 2021
24
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Product WHEEL TRACTOR Model 627G WHEEL TRACTOR
DBD Configuration 627G Wheel Tractor DBD00001-UP
(MACHINE) POWERED BY C15 Engine
Disassembly and Assembly 627G Wheel Tractor Power
Train Media Number -RENR7498-02 Publication Date
-01/08/2007
Date Updated -16/08/2007
i02127894

• Transmission Planetary - Disassemble
• SMCS - 3030-015
• Disassembly Procedure
• Start By
• Separate the transfer gears from the
  transmission. Refer to Disassembly and Assembly,
  "Transmission and Transfer Gears - Separate".
• Remove the transmission hydraulic control valve.
  Refer to Disassembly and Assembly, "Transmission
  Hydraulic Control Valve - Remove".
• Table 1

Required Tools Required Tools Required Tools 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 NC Forcing Screw 4
NOTICE
25
Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting and repair of
the product. Be prepared to collect the fluid
with suitable containers before opening any
compartment or disassembling any component
containing fluids. Refer to Special Publication,
NENG2500, "Caterpillar Tools and Shop Products
Guide" for tools and supplies suitable to collect
and contain fluids on Caterpillar
products. Dispose of all fluids according to
local regulations and mandates.
Illustration 1 g01052880 1. Install Tooling (A)
and a suitable lifting device onto transmission
assembly (1). Position transmission assembly (1)
onto Tooling (F). The weight of the transmission
assembly is approximately 703 kg (1550 lb).
Illustration 2
g00841452
26
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) .
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
27
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 the clutch
housing is approximately 27 kg (60 lb). Remove
Tooling (A) and (B) .
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.
28
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. 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 the clutch housing is approximately 27
kg (60 lb). Remove Tooling (A) and (B) .
29
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) .
30
Illustration 11 g00506953 11. Remove retaining
ring (21) from shaft (22) .
Illustration 12 g01083360 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).
31
Illustration 13 g00506968 13. Remove bolts (24)
and oil slinger (25) from carrier assembly (23).
Remove bearing (26) from carrier assembly (23) .
Illustration 14 g01053892 14. Use a hammer and a
punch in order to push pin (27) into shaft (28) .
Illustration 15 g01083400 15. Remove shaft (28),
thrust discs (29) and planetary gears (30) from
carrier assembly (23). Remove pin (27) from
shaft (28) .
32

• Illustration 16 g01053896
• Remove bearings (31) from planetary gear (30) .
• Repeat Steps 14, 15, and 16 in order to remove
  the remaining three shaft assemblies.

Illustration 17 g01053901 18. Use a hammer and a
punch in order to push pin (32) into shaft (33) .
Illustration 18
g01083401
33
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 19 g00507145
• Remove bearings (37) and spacer (38) from gear
  (35).
• Repeat Steps 18, 19, and 20 in order to remove
  the remaining three shaft assemblies from the
  carrier assembly.

Illustration 20 g01083402 22. Remove bolts (39)
and plates (40) from clutch housing (41). Remove
ring gear (42) from clutch housing (41) .
34
Illustration 21 g00507153 23. Remove bolts (43)
that secure clutch housing (41) to housing
assembly (14) .
Illustration 22 g01083403 24. Use Tooling (B) in
order to hold the piston into clutch housing
(41). Install Tooling (A) and a suitable lifting
device onto clutch housing (41). Remove clutch
housing (41) from housing assembly (14). The
weight of the clutch housing is approximately 27
kg (60 lb). Remove Tooling (A) and (B) .
35
Illustration 23 g00507166 25. Remove piston (44)
from clutch housing (41). Remove seal ring (45)
from piston (44) and from clutch housing (41) .
Illustration 24
g00507206
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.
26. Remove springs (46), friction discs (47), and
clutch plate (48) from housing assembly (14) .
36
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Illustration 25 g00507207 27. Remove ring gear
(49) from housing assembly (14). Remove plate
assembly (50) from housing assembly (14) .
Illustration 26 g00507245 28. Remove retaining
ring (51) from shaft (22). Remove sun gear (52)
and sun gear (53) from shaft (22) .
Illustration 27 g00507350 29. Remove bolts (54)
and the washers in order to remove carrier
assembly (55) from housing assembly (14).
38
Illustration 28 g01083405 30. Install Tooling
(G) and a suitable lifting device onto carrier
assembly (55). Remove carrier assembly (55) from
housing assembly (14). The carrier assembly
weighs approximately 14 kg (30 lb). Remove
Tooling (G) .
Illustration 29 g01053911 31. Use a hammer and a
punch in order to push pin (56) into shaft (57) .
Illustration 30
g00507391
39
32. Remove shaft (57), two thrust discs (58), and
gear (59) from carrier assembly (55). Remove pin
(56) from shaft (57) .
Illustration 31
g00507395

1. Remove bearing (60) from gear (59) .
2. Follow Steps 31, 32, and 33 in order to remove
   the remaining two shaft assemblies from the
   carrier assembly.

Illustration 32
g01083407
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.
40
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Friend! Thank you very much for visiting. Full
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