Caterpillar Cat 651E Wheel Tractor (Prefix 4YR) Service Repair Manual (4YR00001 and up)

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Service Repair Manual
Models 651E WHEEL SCRAPER
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Shutdown SIS
Previous Screen
Product WHEEL TRACTOR Model 651E WHEEL TRACTOR
4YR Configuration 651E Wheel Tractor 4YR00001-UP
(MACHINE) POWERED BY 3412E Engine
Disassembly and Assembly 651E 657E TRACTOR
POWER TRAIN Media Number -SENR9096-02 Publication
Date -01/10/2004
Date Updated -11/06/2015
SENR90960018
Transmission Transfer Gears SMCS - 3159-011
3159-012 3159-015 3159-016 Remove Transmission
Transfer Gears

• Start By
• remove cushion hitch pump
• remove electronic speed sensor
• See machine systems DISASSEMBLY AND ASSEMBLY
  section.

1. Turn the tractor 90 degrees to the scraper. Drain
   the oil from the sump in the transmission.
2. Disconnect hose (1) from bearing cage (2). Cap
   and plug the fittings to keep out dirt and
   debris.
3. Remove bolts (3). Use two 3/8 in - 16 NC Forcing
   Screws to remove cage (2) from the transfer
   gears. Remove two bolts (4).

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4. Remove gear (5) and coupling (6) from the
drive shaft as a unit.
5. Disconnect wiring harness (7) from the light.
Remove the four bolts that hold the light
bracket (8) in position on the transfer
gears. 6. Remove the bolt and clip (9) that
holds the transmission electronic speed sensor
wiring harness in position.

1. Put a block in position between the tube and the
   transmission case to give support to the tube
   when the transfer gears are removed.
2. Remove four bolts (10) that hold the tube in
   position against the rear of the transfer gears.

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9. Fasten Tooling (A) and a hoist to the transfer
gears. Remove bolts (11). Use two 1/2 in - 13 NC
Forcing Screws to remove transfer gears (12) from
the machine. The weight of the transfer gears is
approximately 188 kg (415 lb).
10. Remove O-ring seals (13).
Install Transmission Transfer Gears
1. Install O-ring seals (1) on the machine. Put
clean oil on each O-ring seal.

1. Install two 1/2 in - 13 NC Guide Bolts in the
   transmission case. Make sure the O-ring seal is
   in position on the transfer gears. Put clean oil
   on the O-ring seal.
2. Fasten Tool (A) and a hoist to the transfer
   gears. Install transfer gears (2) on the
   transmission. The weight of the transfer gears
   is approximately 188 kg (415 lb).
3. Install the bolts and washers that hold the
   transfer gears in position.

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1. Istall two bolts (3).
2. Connect tube (4) to the rear of the transfer
   gears. Install the four bolts that hold it in
   place. Remove the support block that was placed
   between the tube and transmission case.

1. Install the light bracket (5) and light. Install
   clips (6) and the bolts that hold the light
   bracket in position. Connect the wiring harness
   to the light.
2. Install clip (7) that holds the transmission
   electronic speed sensor wiring harness in
   position.

9. Make sure coupling (8) is in position in gear
(9). Install gear (9) on the drive shaft.
10. Install two 3/8 in - 16 NC Guide Bolts in the
transfer gears as shown. Make sure the O-ring
seal is in position on the cage. Put clean oil on
the O-ring seal. 10. Install the original shims
(10) and cage (11).
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• 11. Fill the transmission with oil to the correct
  level. See Operation And Maintenance Manual.
• End By
• install electronic speed sensor
• install cushion hitch pump
• See machine systems DISASSEMBLY AND ASSEMBLY
  section.

Disassemble Transmission Transfer Gears

• Start By
• remove transmission transfer gears
• remove transmission oil filter
• remove transmission pump

1. Remove coupling (1) from gear (2). NOTE Gear
(2) was removed when the transmission transfer
gears were removed from the transmission.
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NOTE On later models, it will be necessary to
remove the spiral snap ring in the bore of the
gear before the coupling can be removed from the
gear.
2. Remove ring (3) from gear (2).
3. Use Tooling (A) to remove the bearing cones
from gear (2).
4. Use Tooling (B) to remove the bearing cup from
cage (4). NOTE Cage (4) was removed when the
transmission transfer gears were removed from the
transmission.
5. Remove the bolts and light (5) from the
transfer gear case.
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1. Turn the transfer gear case over. Remove bolts
   (6). Use two 3/8 in - 16 NC Forcing Screws to
   remove cage (7). Remove the shims that are under
   the cage.
2. Use Tooling (C) to remove the bearing cup from
   the cage.

8. Remove the bolts that hold gear (9) in
position. Use two 3/8 in - 16 NC Forcing Screws
(8) to remove gear (9).
9. Remove gear (10).
10. Use Tooling (D) to remove two bearing cones
(11) from gear (10).
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11. Use Tooling (C) to remove bearing cup (12)
from the transfer gear case.
12. Turn the transfer gear case over. Use Tooling
(C) to remove bearing cup (13) from the transfer
gear case.
13. Remove three bolts (14) and gear (15).
14. Remove spiral ring (16) from gear (15).
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15. Use three 3/8 in - 16 NC Forcing Screws (17)
to remove cage (18) and bearing (19) from the
gear.

1. Use Tooling (E) to remove bearing (19) from cage
   (18).
2. Use Tool (F) to remove ring (20) from the bearing.

18. Remove the bolts that hold shaft (22) in
position. Use two 3/8 in - 16 NC Forcing
Screws (21) to remove shaft (22) from the
transfer gear case. 19. Remove the shims and the
O-ring seal from the shaft.
20. Give support to the bearing cone on the
bottom of gear (23). Remove gear (23) from the
transfer gear case.
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21. Remove bearing cones (24) and spacer (25)
from gear (23).
22. Use a hammer and a punch to remove bearing
cup (26) from gear (23).

1. Use Tooling (E) and a press to remove spacer (28)
   and the bearing cup behind the spacer.
2. Remove spiral ring (27).

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Assemble Transmission Transfer Gears
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1. Install spiral ring (1) in gear (2). Check
dimension (X) on both sides of the gear. Put a
mark on the side of the gear with the larger
dimension.

• NOTE Spacer (3) must be installed on the side of
  the gear that has the greater dimension from the
  spiral ring to the face on the gear (see Step 1).
  Groove (4) in the spacer must be toward the
  spiral ring as shown.
• Install spacer (3) in the gear so it is against
  the spiral ring.
• Use Tooling (A) and a press to install bearing
  cup (5). Install the bearing cup so it is against
  the spacer.
• Turn the gear over and use Tooling (A) and a
  press to install the other bearing cup.

5. Install spacer (7) and two bearing cones (6)
in gear (2).
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6. Give support to the lower bearing cone in gear
(2). Install gear (2) in the transfer gear case.

• Install shaft (8) without the shims and without
  the O-ring seal. Use a feeler gauge to measure
  the gap between the bottom of the shaft and the
  transfer gear case.
• NOTE Check the gap in four places around the
  shaft.
• Remove shaft (8).

1. Install O-ring seal (9) on shaft (10). Install
   enough shims (10) that are equal in thickness to
   the average gap from Step (7) minus 0.50
   0.05 mm (.020 .002 in).
2. Install shaft (8) in the transfer gear case.
   Install the bolts and washers that hold the shaft
   in position.

• Use Tool (B) to install snap ring (11) on bearing
  (12).
• Use Tooling (A) to install bearing (12) in cage
  (13).
• NOTE Make sure the bearing is installed in the
  cage so that snap ring (11) is in the counterbore
  of the cage. Make sure the end of the bearing
  that is nearest the snap ring is up when
  installed in the cage.

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13. Use Tooling (C) and a press to install the
bearing and cage (13) on gear (14). NOTE
Install cage (13) so that the side of the cage
that has the snap ring on the bearing is away
from gear (14).
14. Install spiral ring (15).
15. Install gear (14) in the transfer gear case.
Install the three bolts that hold the gear in
position. Tighten the three bolts to a torque of
50 3 Nm (37 2 lb ft).
16. Lower the temperature of bearing cup (16).
Install the bearing cone in the transfer gear
case. Use Tooling (A) to make sure the bearing
is against its seat in the transfer gear case.
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17. Lower the temperature of bearing cup (17).
Install the bearing cup (17) in the transfer gear
case. Use Tooling (A) to make sure the bearing
is against its seat in the transfer gear case.
18. Heat bearing cones (18) to a temperature of
135C (275F). Install the bearing cones on gear
(19).
19. Install gear (19) in the transfer gear case.
Make sure the side of the gear with holes (20)
are up as shown.
20. Install gear (21) on gear (19). Install the
bolts that hold it in position. Tighten the bolts
to a torque of 50 3 Nm (37 2 lb ft).
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1. Lower the temperature of the bearing cup for cage
   (22). Install the bearing cup in the cage. Use
   Tooling (A) to make sure the bearing cup is
   against its seat in the cage.
2. Install the shims and cage (22) on the transfer
   gear case. Install bolts (23). Tighten bolts (23)
   to a torque of 50 3 Nm (37 2 lb ft).
3. Use Tooling (D) to check the bearing end play.
   Add or subtract shims under cage (22) until the
   bearing end play is 0.15 0.05 mm (.006 .002
   in).

24. Install light (24) on the transfer gear case.
25. Lower the temperature of bearing cup (25).
Install the bearing cup in cage (26). Use
Tooling (A) to make sure the bearing cup is
against the seat in the cage.
26. Heat bearing cones (27) to a temperature of
135C (275F). Install the bearing on gear (28).
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27. Install spiral ring (29) in the gear.

• Install gear (28), the original shims and cage
  (26) in the transfer gear case.
• NOTE Make sure the O-ring seal on the cage is
  removed before the cage is installed.
• Use Tooling (D) to check the bearing end play. It
  will be necessary to add or subtract shims until
  the bearing end play is 0.15 0.05 mm (.006
  .002 in).
• Remove cage (26) and gear (28). Put the O-ring
  seal on the cage.
• NOTE Gear (28) and cage (26) will be installed
  in the transfer gear case after the transfer gear
  case is installed on the transmission.

31. Install coupling (30) in gear (28).
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• NOTE On later models, install the other spiral
  ring that is in the middle of gear (28).
• End By
• install transmission pump
• install transmission oil filter
• install transmission transfer gears

Copyright 1993 - 2021 Caterpillar Inc. All
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Licensees.
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Shutdown SIS
Previous Screen
Product WHEEL TRACTOR Model 651E WHEEL TRACTOR
4YR Configuration 651E Wheel Tractor 4YR00001-UP
(MACHINE) POWERED BY 3412E Engine
Disassembly and Assembly 651E 657E TRACTOR
POWER TRAIN Media Number -SENR9096-02 Publication
Date -01/10/2004
Date Updated -11/06/2015
SENR90960019

• Transmission Transfer Gears
• SMCS - 3002-011 3002-012 3030-015 3030-016
• Remove Transmission Transfer Gears
• Start By
• a. remove cushion hitch pump
• Turn the tractor 90 degrees to the scraper.
  Remove the oil from the bevel gear case for the
  transmission and from the transmission sump.
• Remove the cushion hitch pump. See REMOVE CUSHION
  HITCH PUMP in machine systems DISASSEMBLY AND
  ASSEMBLY section.

1. Remove the bolts that hold clip (1) in position
   on top of the transmission. Move the clip and the
   oil line connected to the clip away from the
   transmission.
2. Disconnect wire harness (2) at the connector on
   top of the transmission. Move the tractor end of
   the harness away from the transmission..
3. Disconnect wire harness (3) at the connector
   beside the cushion hitch. Clip or tie the
   transmission portion of the wiring harness to the
   transmission.
4. Remove bracket (4) that support the transmission
   oil lines.

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1. Disconnect hose (5).
2. Remove bolts (6) that hold the cage in position
   on the transfer gears. Use two 3/8 in - 16 NC
   Forcing Screws to remove cage (7), and the shims
   from the transfer gears.

9. Remove gear (8) from the drive shaft.
10. Pull drive shaft (9) part way out of the
transmission. Fasten a strap and a hoist to the
drive shaft and remove it from the transmission.
The weight of the drive shaft is approximately 32
kg (70 lb).

1. Fasten a strap (10) to one of the oil lines above
   the transmission and to tube (11). Remove the
   four bolts that hold the tube against the rear of
   the transfer gear case.
2. Remove two bolts (12).

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1. Remove the eight bolts that hold oil lines (13)
   in position on the adapter on the side of the
   transmission.
2. Fasten a chain and a hoist to the three lifting
   eyes on the transmission.

15. Remove guard (14).
16. Remove bolts (15) and nuts (16) that hold the
transmission to the differential carrier. Do
not remove nuts (17) that hold the differential
carrier to the bevel gear case.
17. Use 5/8 in - 11 NC Forcing Screws to move the
transmission away from the differential carrier.
Remove transmission and transfer gears (18) from
the machine. The weight of the transmission and
transfer gears is approximately 1586 kg (3500 lb).
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Install Transmission Transfer Gears

1. Make sure two O-ring seals (2) are in position on
   the differential carrier. Put clean oil on the O-
   ring seals. Make sure the O-ring seal is in
   position on the end of the transmission.
2. Install transmission and transfer gears (1) on
   the machine. The weight of the transmission and
   transfer gears is approximately 1586 kg (3500 lb).

3. Install the nuts (3) and bolts (4) that hold
the transmission in position against the
differential carrier.
4. Install the guard and the bolts that hold
guard (5) in position on the machine.
5. Install the bolts that hold oil lines (6) in
position on the adapter on the side of the
transmission.
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6. Install clamp (7) that supports the oil lines.

1. Make sure the O-ring seal is in position on the
   end of tube (9). Install the four bolts that hold
   tube (9) against the rear of the transfer gear
   case. Remove strap (8).
2. Install two bolts (10).

9. Use a strap and a hoist to install drive shaft
(11). The weight of the drive shaft is
approximately 32 kg (70 lb).
10. Install gear (12) on the drive shaft. Use a
punch to turn the idler gear, if necessary, to
put the teeth on gear (12) in alignment with the
teeth on the idler gear in the transfer gear case.
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11. Install two 3/8 in - 16 NC Guide Bolts in the
transfer gears as shown. Make sure the O-ring
seal is in position on the cage. Put clean oil on
the O-ring seal. Make sure the O-ring seal is in
position on cage (13). Put clean oil on the seal.
Install cage (13) and shims (14) on the transfer
gear case.
12. Connect oil line (15) to the cage.

• Connect transmission wire harness (16) to the
  wiring harness from the tractor.
• Connect wiring harness (17) to the connector
  beside the cushion hitch.
• Install bolt (18) and clip for the oil line.
• Fill the bevel gear case with transmission oil to
  the correct level. End By
• a. install cushion hitch pump
• See machine systems DISASSEMBLY AND ASSEMBLY
  section.

Disassemble Transmission
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• Start By
• remove transmission and transfer gears
• remove hydraulic control valves

1. Remove transfer gears from transmission (see
REMOVE TRANSFER GEARS) and put transmission case
(1) in position on Tool (A) as shown.

1. Fasten Tool (B) and a hoist on No. 7 clutch
   housing (3).
2. Remove bolts (2) and the No. 3 through No. 7
   clutch housings from transmission case (1). The
   weight of the No. 3 through No. 7 clutch housings
   is 522 kg (1150 lb).

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1. Put the No. 3 through No. 7 clutch housings in
   position on Tool (C).
2. Use Tool (D) to hold the piston in No. 7 clutch
   housing (3).
3. Fasten Tool (B) and a hoist on No. 7 clutch
   housing (3) as shown.
4. Remove bolts (4) and No. 7 clutch housing (3)
   from the No. 6 clutch housing. The weight of the
   No. 7 clutch housing is 41 kg (90 lb).

1. Remove piston (5) from the No. 7 clutch housing.
2. Remove ring (6) from piston (5).

10. Remove ring (7) from No. 7 clutch housing (3).
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11. Remove springs (9), five discs (8), four
plates (12), separator springs (11) and pins (10)
for the No. 7 clutch.

1. Remove ring (14) and adapter (13) from the
   carrier.
2. Remove gear (15) from the No. 6 clutch housing.

14. Fasten Tool (B) and a hoist on No. 6 clutch
housing (16) and remove it from the No. 5 clutch
housing. The weight of the clutch housing is 63
kg (140 lb).

1. Remove piston (17) from the No. 6 clutch housing.
2. Remove ring (18) from piston (17).

17. Remove ring (19) from No. 6 clutch housing
(16).
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18. Put the No. 6 clutch housing on its opposite
side and if necessary remove the dowels.
19. Remove springs (21), four discs (20), three
plates (22) and the pins for the No. 6 clutch.
20. Use Tool (E) and remove snap ring (23) from
the shaft assembly.
21. Fasten Tool (B) and a hoist on carrier (24)
and remove it from the gear. The weight of the
carrier is 61 kg (135 lb).

1. Remove bearing (25) from the carrier.
2. Use a hammer and punch to push pins (26) in the
   outer shafts so the shafts can be removed.

31
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24. Remove shafts (28) from the carrier and
remove gears (27), washers (30) and bearings
(29). After shafts (28) are removed, remove pins
(26) from the shafts.
25. Use a hammer and punch to push pins (32) in
inner shafts (31) so the shafts can be removed.
26. Remove shafts (31) from the carrier and
remove inner gears (35), washers (33) and
bearings (34). After shafts (31) are removed,
remove pins (32) from the shafts.
27. Remove spiral ring (37) and gears (36) and
(38) from the shaft assembly.
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1. Bend the locks away from bolts (40) and remove
   bolts (40), the locks and plate (39) from the
   carrier.
2. Remove gear (41) from the No. 5 clutch housing.

1. Remove the two bolts that hold No. 5 clutch
   housing to the plate.
2. Fasten Tool (B) and a hoist on No. 5 clutch
   housing (42) as shown.
3. Use Tool (D) to hold the piston in No. 5 clutch
   housing (42) and remove the No. 5 clutch housing
   from the plate. The weight of the clutch housing
   is 41 kg (90 lb).

1. Remove piston (43) from the No. 5 clutch housing.
2. Remove ring (44) from piston (43).

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1. Remove ring (45) from No. 5 clutch housing (42).
2. If necessary, put the No. 5 clutch housing on its
   opposite side and remove the dowels.

1. Remove the springs, three discs (46), the four
   plates and the pins for the No. 5 clutch.
2. Remove gear (47) from the carrier.

39. Use two 3/8 in - 16 NC Forcing Screws as
shown and remove plate assembly (48) from the
housing assembly. If necessary the dowels from
the plate assembly.
40. Remove spiral ring (49) from the retainer
assembly.
41. Fasten Tooling (B) and a hoist on carrier
(50) and remove the bolts and the carrier from
the No. 4 clutch housing. The weight of the
carrier is 29 kg (65 lb).
35
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