Caterpillar Cat 639D WHEEL TRACTOR (Prefix 99X) Service Repair Manual (99X00001 and up)

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Product WHEEL TRACTOR Model 639D WHEEL TRACTOR
99X Configuration 639D TRACTOR / POWER SHIFT /
99X00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly 3408E and 3412E Engines
for Caterpillar Built Machines Media Number
-RENR2336-06 Publication Date -01/08/2018
Date Updated -10/08/2018
i01364167
Vibration Damper and Pulley - Remove and
Install SMCS - 1205-010 Removal Procedure Table 1
Tool Part Number Part Description Qty
A - 5/8 inch-NF X 7 inch long guide bolt 2

• Illustration 1 g00719482
• Install a nylon strap and a hoist on pulley (2).
• Remove two bolts (1) and install Tool (A).
• Remove the remainder of the bolts (1).
• Remove pulley (2). Weight of the pulley is 32 kg
  (71 lb).

2
Illustration 2
g00719530
5. Remove vibration damper (3).
Illustration 3
g00719523
6. Remove spacer (4) and adapter
(5). Installation Procedure Table 2
Tool Part Number Part Description Qty
A - 5/8 inch-NF X 7 inch long guide bolt 2
3
Illustration 4
g00719523

1. Install Tool (A) in the crankshaft.
2. Install adapter (5) and spacer (4).

Illustration 5
g00719530
3. Install vibration damper (3).
Illustration 6
g00719482
4. Install pulley (2).
4
5. Lightly lubricate the bolt threads with clean
engine oil. Install four bolts (1). Remove
Tool (A). Install the last two bolts. Tighten
bolts (1) to a torque of 215 40 Nm (159 30
lb ft).
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Product WHEEL TRACTOR Model 639D WHEEL TRACTOR
99X Configuration 639D TRACTOR / POWER SHIFT /
99X00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly 3408E and 3412E Engines
for Caterpillar Built Machines Media Number
-RENR2336-06 Publication Date -01/08/2018
Date Updated -10/08/2018
i01622074
Crankshaft Front Seal - Remove SMCS -
1160-011 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1U-7600 Slide Hammer Puller 1
B (1) 5P-7314 Distorter Ring 1
C (1) 5P-7312 Seal Distorter 1
( 1 ) Part of the 5P-7318 Wear Sleeve Distorter
Group Start By A. Remove the vibration damper
and the pulley. Refer to Disassembly and
Assembly, "Vibration Damper and Pulley - Remove
and Install". NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
Note The front seal and the wear sleeve must be
replaced at the same time. Once the seal and the
wear sleeve are separated, these components can
not be used again. Refer to Special Instruction,
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SMHS8508, "Special Handling Information and
Installation Instructions for Crankshaft Seal
Groups That Have Hydrodynamic Grooves In the
Sealing Lip" before the seal is serviced.
Type 1
Illustration 1
g00829187

• Type 1 seal design.
• Seal
• Wear sleeve

8
Illustration 2
g00582156
Typical example 1. Use a punch or Tool (A) to
puncture a hole in seal (1). Use Tool (A) to
remove seal (1) .
Illustration 3
g00582158

• Typical example
• Place Tool (B) in position. The correct position
  is shown in Illustration 3.
• Install Tool (C) between Tool (B) and the wear
  sleeve. Turn Tool (C), until the edge of the tool
  makes a flat crease in the wear sleeve. Repeat
  this procedure until there are enough creases in
  the wear sleeve in order to allow the wear sleeve
  to be slipped off the end of the crankshaft.
• Remove Tool (B) and the wear sleeve by hand.

Type 2
9
Illustration 4
g00829143

• New seal design
• Seal
• Wear sleeve flange
• Wear sleeve
• Use a hammer and a punch in order to puncture 3
  holes in the wear sleeve (3) on the flange of the
  wear sleeve (2). Use Tool (A) to remove the wear
  sleeve (3) .
• Use a punch or Tool (A) to puncture a hole in
  seal (1). Use Tool (A) to remove seal (1) .

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Product WHEEL TRACTOR Model 639D WHEEL TRACTOR
99X Configuration 639D TRACTOR / POWER SHIFT /
99X00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly 3408E and 3412E Engines
for Caterpillar Built Machines Media Number
-RENR2336-06 Publication Date -01/08/2018
Date Updated -10/08/2018
i01655980
Crankshaft Front Seal - Install SMCS -
1160-012 Installation Procedure Type 1 Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 5P-1733 Seal Locator 1
B 5P-1737 Bolts 3
C 9S-8858 Nut (Seal Installer) 1
D 6V-6142 Front Seal Installer 1
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
Note The front seal and the wear sleeve must be
replaced at the same time. Once the seal and the
wear sleeve are separated, these components
cannot be used again. Refer to Special
Instruction, SMHS8508, "Special Handling
Information and Installation Instructions for
Crankshaft Seal Groups That Have Hydrodynamic
Grooves In the Sealing Lip" before the seal is
serviced.
11

• Note Do not use any type of lubricant during the
  installation of the crankshaft seal and the wear
  sleeve.
• Before installation of the crankshaft seal and
  the wear sleeve, inspect the crankshaft for
  scratches. Also, inspect the crankshaft for any
  distortion on the surface that may lead to an out
  of round condition. Use a polishing cloth in
  order to remove any imperfections on the
  crankshaft.
• Use 4C-9500 Quick Cure Primer to clean the
  outside diameter of the crankshaft and the inside
  diameter of wear sleeve (1).
• Apply 4C-9507 Retaining Compound to the outside
  diameter of the crankshaft. Apply 4C- 9507
  Retaining Compound to the inside diameter of wear
  sleeve (1).

• Illustration 1
• Type 1 seal design.
• Seal
• Wear sleeve

g00829187
12
Illustration 2 Typical example
g00829675
4. Fasten Tool (A) to the crankshaft with Tool
(B). NOTICE The front and rear seals and wear
sleeves have different spiral grooves in the
seal. Because of this type of design, the front
seal group for an engine is different from the
rear seal group. If a seal group is installed on
the wrong end of the engine, oil can actually be
taken out of the engine instead of moving oil
back into the engine.
Illustration 3 g00515623 Note Install the seal
with the arrow that shows the direction of
crankshaft rotation toward the front of the
engine.
13

• Position wear sleeve (2) and seal (1) on Tool
  (A). Install Tool (D) on Tool (A). Lubricate the
  face of the washer on Tool (C). Install Tool (C)
  on Tool (A).
• Tighten Tool (C) until Tool (D) contacts Tool
  (A).
• Remove Tools (A), (B), (C), and (D). Check the
  crankshaft seal and the wear sleeve for the
  correct installation.
• Type 2
• Table 2

Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 5P-1733 Seal Locator 1
B 5P-1737 Bolts 3
C 9S-8858 Nut (Seal Installer) 1
D 6V-6142 Front Seal Installer 1
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.

• Note The front seal and the wear sleeve must be
  replaced at the same time. Once the seal and the
  wear sleeve are separated, these components
  cannot be used again. Refer to Special
  Instruction, SMHS8508, "Special Handling
  Information and Installation Instructions for
  Crankshaft Seal Groups That Have Hydrodynamic
  Grooves In the Sealing Lip" before the seal is
  serviced.
• Note Do not use any type of lubricant during the
  installation of the crankshaft seal and the wear
  sleeve.
• Before installation of the crankshaft seal and
  the wear sleeve, inspect the crankshaft for
  scratches. Also, inspect the crankshaft for any
  distortion on the surface that may lead to an out
  of round condition. Use a polishing cloth in
  order to remove any imperfections on the
  crankshaft.
• Use 4C-9500 Quick Cure Primer to clean the
  outside diameter of the crankshaft.
• Note The type 2 seal comes with the 4C-9507
  Retaining Compound that is already applied to the
  inside diameter of the wear sleeve.

14

• Illustration 4
• Type 2 seal design.
• Seal
• Wear sleeve flange
• Wear sleeve

g00829143
Illustration 5 Typical example
g00829675
3. Fasten Tool (A) to the crankshaft with Tool
(B). NOTICE
15
The front and rear seals and wear sleeves have
different spiral grooves in the seal. Because of
this type of design, the front seal group for an
engine is different from the rear seal group. If
a seal group is installed on the wrong end of the
engine, oil can actually be taken out of
the engine instead of moving oil back into the
engine.

• Illustration 6 g00515623
• Note Install the seal with the arrow that shows
  the direction of crankshaft rotation toward the
  front of the engine.
• Position wear sleeve (2) and seal (1) on Tool
  (A). Install Tool (D) on Tool (A). Lubricate the
  face of the washer on Tool (C). Install Tool (C)
  on Tool (A).
• Tighten Tool (C) until Tool (D) contacts Tool
  (A).
• Remove Tools (A), (B), (C), and (D). Check the
  crankshaft seal and the wear sleeve for the
  correct installation.
• End By
• a. Install the vibration damper and the pulley.
  Refer to Disassembly and Assembly, "Vibration
  Damper and Pulley - Remove and Install".

Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Sun Oct 10 235446 UTC0800 2021
16
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Previous Screen
Product WHEEL TRACTOR Model 639D WHEEL TRACTOR
99X Configuration 639D TRACTOR / POWER SHIFT /
99X00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly 3408E and 3412E Engines
for Caterpillar Built Machines Media Number
-RENR2336-06 Publication Date -01/08/2018
Date Updated -10/08/2018
i02160179
Gear Group (Front) - Remove SMCS -
1206-011 Removal Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1
Start By a. Remove the camshaft. Refer to
Disassembly and Assembly, "Camshaft -
Remove". NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
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.
17
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.

• Illustration 1 g00577213
• Align the timing mark on the idler gear with the
  timing mark on the crankshaft gear.
• Remove bolts (1) and plate (2).
• Remove idler gear (3).

Illustration 2 g00577286 4. Remove the bearing
from idler gear (3) with Tooling (A) and a
suitable press.
18
Illustration 3 g00577251 5. Remove thrust washer
(6). Remove bolts (4) and shaft (5).
Illustration 4 g00577274 6. Drilled passage (7)
and drilled passage (8) in the shaft must be free
of obstructions.
Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Sun Oct 10 235542 UTC0800 2021
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Product WHEEL TRACTOR Model 639D WHEEL TRACTOR
99X Configuration 639D TRACTOR / POWER SHIFT /
99X00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly 3408E and 3412E Engines
for Caterpillar Built Machines Media Number
-RENR2336-06 Publication Date -01/08/2018
Date Updated -10/08/2018
i02151029
Gear Group (Front) - Install SMCS -
1206-012 Installation Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
20
Illustration 1
g00577251

• Illustration 2 g00537659
• Place shaft (5) in position on the cylinder block
  and install bolts (4). Tighten bolts (4) to a
  torque of 55 10 Nm (41 7 lb ft).
• Tighten bolts (4) for the shaft in the following
  sequence. See Illustration 2 for the numbering of
  the bolts. ... 1,3,4,5,2,1,2,3,4,5,1
• Install thrust washer (6) with the oil groove
  side toward the idler gear.

Illustration 3 g00577286 3. Lower the
temperature of the bearing. Install the bearing
in idler gear (3) with Tooling (A) and a suitable
press. Install the bearing to a depth of 0.38
0.25 mm (0.015 0.010 inch).
21
Illustration 4 g00577213 4. Apply clean engine
oil to the shaft and to the inside diameter of
idler gear (3). Install idler gear (3) on the
shaft. Install plate (2) and bolts (1). End
By a. Install the camshaft. Refer to Disassembly
and Assembly, "Camshaft - Install".
Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Sun Oct 10 235638 UTC0800 2021
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Product WHEEL TRACTOR Model 639D WHEEL TRACTOR
99X Configuration 639D TRACTOR / POWER SHIFT /
99X00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly 3408E and 3412E Engines
for Caterpillar Built Machines Media Number
-RENR2336-06 Publication Date -01/08/2018
Date Updated -10/08/2018
i02389879
Housing (Front) - Remove SMCS - 1151-011 Removal
Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1

• Start By
• Remove the engine oil pan. Refer to Disassembly
  and Assembly, "Engine Oil Pan - Remove and
  Install".
• Remove the water pump. Refer to Disassembly and
  Assembly, "Water Pump - Remove".
• Remove the crankshaft front seal. Refer to
  Disassembly and Assembly, "Crankshaft Front Seal
  - Remove".
• Remove the front cover. Refer to Disassembly and
  Assembly, "Front Cover - Remove".
• Remove the speed/timing sensors. Refer to
  Disassembly and Assembly, "Speed/Timing Sensor -
  Remove and Install".
• NOTICE
• Keep all parts clean from contaminants.
• Contaminants may cause rapid wear and shortened
  component life.

23
Illustration 1
g00553958

1. Remove bolts (2) and retainer plate (3).
2. Remove gear (1).

• Illustration 2 g00553982
• Attach Tooling (A) and a suitable lifting device
  to front housing (4). The weight of front housing
  (4) is approximately 34 kg (75 lb).
• Remove nut (6).
• Remove bolts (5).
• Remove front housing (4) and the gasket.

Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
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Product WHEEL TRACTOR Model 639D WHEEL TRACTOR
99X Configuration 639D TRACTOR / POWER SHIFT /
99X00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly 3408E and 3412E Engines
for Caterpillar Built Machines Media Number
-RENR2336-06 Publication Date -01/08/2018
Date Updated -10/08/2018
i02389888
Housing (Front) - Install SMCS -
1151-012 Installation Procedure Table 1
Required Tools Required Tools Required Tools Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1
B 8T-9022 Silicone Gasket -
NOTICE Keep all parts clean from
contaminants. Contaminants may cause rapid wear
and shortened component life.
25

• Illustration 1 g00553982
• The rear of front housing (4) and the front of
  the cylinder block should be thoroughly cleaned
  before you install the front housing.
• Install a new gasket on the cylinder block.
• Apply Tooling (B) to the common junction of the
  cylinder block, the front housing and the oil
  pan.
• Attach Tooling (A) and a suitable lifting device
  to front housing (4). The weight of front housing
  (4) is approximately 34 kg (75 lb).
• Install front housing (4) on the cylinder block.
• Install bolts (5).
• Install nut (6).
• Remove Tooling (A) from front housing (4).

Illustration 2
g00553958
26
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• Illustration 3 g00555906
• Note With the number one piston of the engine at
  top center, the timing marks on the front gear
  group can be aligned. Align the timing marks on
  gear (1) with the marks on the camshaft gear. The
  alignment of the timing marks is shown in
  Illustration 3.
• Install gear (1) and retainer plate (3).
• Install bolts (2). Tighten the bolts to a torque
  of 135 20 Nm (100 15 lb ft).
• End By
• Install the speed/timing sensors. Refer to
  Disassembly and Assembly, "Speed/Timing Sensor -
  Remove and Install".
• Install the front cover. Refer to Disassembly and
  Assembly, "Front Cover - Install".
• Install the crankshaft front seal. Refer to
  Disassembly and Assembly, "Crankshaft Front Seal
  - Install".
• Install the water pump. Refer to Disassembly and
  Assembly, "Water Pump - Install".
• Install the engine oil pan. Refer to Disassembly
  and Assembly, "Engine Oil Pan - Remove and
  Install".

Copyright 1993 - 2021 Caterpillar Inc. All Rights
Reserved. Private Network For SIS Licensees.
Sun Oct 10 235829 UTC0800 2021
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Product WHEEL TRACTOR Model 639D WHEEL TRACTOR
99X Configuration 639D TRACTOR / POWER SHIFT /
99X00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly 3408E and 3412E Engines
for Caterpillar Built Machines Media Number
-RENR2336-06 Publication Date -01/08/2018
Date Updated -10/08/2018
i02389917
Valve Mechanism Cover - Remove and Install SMCS -
1107-010 Removal Procedure NOTICE Keep all parts
clean from contaminants. Contaminants may cause
rapid wear and shortened component life.
Illustration 1
g01095551
30

1. Remove bolts (2).
2. Remove cover (1).

Installation Procedure NOTICE Keep all parts
clean from contaminants. Contaminants may cause
rapid wear and shortened component life.
Illustration 2
g01095551

1. Install cover (1).
2. Install bolts (2).

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Sun Oct 10 235925 UTC0800 2021
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