Caterpillar Cat D6R TRACK-TYPE TRACTOR (Prefix 4FM) Service Repair Manual (4FM00001 and up).pdf

Service Repair Manual
Models
D6R TRACK-TYPE TRACTOR

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D6R TRACK-TYPE TRACTOR 4FM
Configuration: D6R Track-Type Tractor Differential Steering 4FM00001-UP (MACHINE) POWERED BY 3306 Engine
Disassembly and Assembly
D6R TRACK-TYPE TRACTOR POWER TRAIN
Media Number -SENR9496-02 Publication Date -01/11/2004 Date Updated -23/07/2018
SENR94960017
Final Drives
SMCS - 4050-012; 4050-015; 4050-016; 4050-011
Remove Final Drives
Start By:
a. separate track
NOTE: The final drive planetary carriers can be removed in chassis. See topic, Remove Final
Drive Planetary Carriers (In Chassis).
1. Turn the final drive until drain plug (1) is on the bottom as shown. Remove drain plug (1) and
drain approximately 13.2 liters (3.4 U.S. gal.) of oil from the final drive.
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2. Remove the cover from the final drive and remove the O-ring seal from the cover.
3. Install Tooling (A) and remove the outer axle.
4. Adjust the top bracket on Tooling (B) so that dimension (X) is 213 mm (8.4 in). The lower
mounting bracket must be installed with the spacers outward as shown.
5. Remove two of the bolts from the sprocket segments. Fasten a hoist and install Tooling (B) on
the final drive.
NOTICE
Bolts (4) hold the steering clutch and brake to the main case and frame.
Do not remove bolts (4).
2/12
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6. Remove bolts (2) that hold the final drive to the main case and frame.
7. The weight of the final drive is 490 kg (1075 lb). Remove four bolts (3) that hold the final drive
and steering clutch and brake together.
8. Use Tooling (B) and remove the final drive from the machine.
9. Remove the O-ring seal from either the face of the steering clutch or the final drive hub.
Install Final Drives
1. Inspect the condition of O-ring seals and replace if necessary.
2. Put the O-ring seal in position on the face of the steering clutch.
3. Fasten a hoist and install Tooling (B) on the final drive. Adjust Tooling (B) if necessary to put
the final drive in a level position.
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4. Put the final drive in position on the frame and install four bolts (3) that hold the final drive to
the steering clutch and brake.
5. Install bolts (2) that hold the final drive and steering clutch and brake to the main case and
frame. Remove Tooling (B).
6. Put SAE 30 oil on the threads of the segment bolts. Install the bolts and nuts with the nuts and
washers against the final drive. Tighten the nuts to a torque of 175 ± 40 N·m (130 ± 30 lb ft).
Tighten the nuts 1/3 of a turn more.
7. Install Tool (A) on the outer axle and install the axle in the final drive.
8. Install the O-ring seal on the cover and install the cover on the final drive.
9. Rotate the final drive so drain plug (1) is toward the bottom. Fill the drive with oil to the bottom
of the fill plug hole. See the Operation And Maintenance Guide for the type of oil and capacity.
End By:
a. connect track
Disassemble Final Drives
Start By:
a. remove final drives
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1. Install Tooling (A) on the planetary carrier and attach a hoist.
2. The weight of the planetary carrier is 137 kg (301 lb). Remove bolts (1) that hold the planetary
carrier to the hub. Remove planetary carrier (3) and the two O-ring seals from the hub.
3. Remove three retainers (2).
4. Support planetary carrier (3), from underneath, to prevent damage. Use Tooling (B) and a press
and remove the three planetary gear shafts.
5. Remove three planetary gears (4) from carrier (3).
6. Remove bearing cones (5) from each of the gears (4).
7. Remove the bearing cups from each side of the gears.
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8. Remove ten bolts (6) and retainer (7).
9. The weight of the hub and ring gear (8) is 68 kg (150 lb). Use nylon straps and a hoist and
remove the hub and ring gear (8).
10. Turn hub (9) and ring gear (8) over. Remove retaining ring (10). The weight of hub (9) is 37
kg (82 lb). The weight of ring gear (8) is 32 kg (71 lb). Use nylon straps and a hoist and remove
hub (9).
11. Install Tooling (C) on hub (12).
NOTICE
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Do not lift hub (12) high enough to make contact with the fitting on the
hydraulic cylinder, [part of Tooling (C)].
12. Use Tooling (C) and loosen hub (12) from spindle (13). Remove Tooling (C).
13. Remove bearing cone (11).
14. The weight of hub (12) is 180 kg (395 lb). Install Tooling (D) and attach a hoist. Remove hub
(12) from spindle (13).
15. Turn hub (12) over and remove Duo-Cone Seal (15). Use a hammer and a punch and remove
bearing cup (16).
16. Turn the hub over and remove bearing cup (14) from the hub.
NOTE: If the Duo-Cone Seals are to be used again, put identification marks on the seals so they
can be assembled and installed in their original position.
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NOTICE
Bearing cone (18) may be damaged if it is removed from spindle (13).
17. Remove Duo-Cone Seal (19) from spindle (13).
18. If necessary, remove bearing cone (18) from the spindle.
19. Remove lip seal (17) from spindle (13).
Assemble Final Drives
1. Put clean oil on all of the parts during assembly.
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2. Use Tooling (B) and install lip seal (17) in spindle (13). Put clean oil on the lip of the seal.
3. Heat bearing cone (18) to a maximum temperature of 135° C (275° F). Install bearing cone (18)
on spindle (13).
NOTE: Before installing any of the Duo-Cone Seals, see Installation Of the Duo-Cone Floating
Seals in this module.
4. Use Tool (E) and install the Duo-Cone Seal on spindle (13).
5. Lower the temperature of bearing cups (14) and (16) and install them in hub (12).
6. Use Tool (E) and install the Duo-Cone Seal in hub (12).
7. Install Tooling (D) on hub (12) and attach a hoist. Carefully, put hub (12) in position on spindle
(13).
8. Heat bearing cone (11) to a maximum temperature of 135° C (275° F). Install bearing cone (11)
on spindle (13).
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9. Use nylon straps and a hoist and put hub (9) in position in gear (8) and install retaining ring
(10).
10. Turn the hub and gear (8) over and install nylon straps. Attach a hoist to the nylon straps and
put the hub and the gear in position in hub (12).
11. Put retainer (7) in position and install ten bolts (6), while slowly rotating the hub. Tighten bolts
(6) evenly to a torque of 135 ± 15 N·m (100 ± 11 lb ft). The retainer must be in contact with the
end of spindle (13) after bolts (6) have been tightened.
12. Lower the temperature of bearing cups (20) and (21) and install them in three planetary gears
(4).
10/12
D6R Track-Type Tractor Differential Steering 4FM00001-UP (MACHINE) POWE...
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13. Put the planetary carrier in position in a press. Planetary shaft retainer (2) should be in position
and supported so as to act as a positive stop for the shaft when it is installed.
NOTICE
Shaft (22) must be installed correctly or bearing pre-load will be
incorrect and damage will result.
14. Put planetary gear (4) in position in the planetary carrier.
15. Lower the temperature of shaft (22) and use a press to install it in the planetary carrier. The
end of shaft (22) must be installed flush with the retainer surface of the planetary carrier for
correct bearing preload. Make sure the gear will rotate by hand after it has been installed. If it will
not rotate by hand, the problem should be found and corrected. Repeat the procedure for three
shafts.
16. Install three retainers (2) on shafts (22).
11/12
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17. Install Tooling (A) and attach a hoist. Install the two O-ring seals on the planetary carrier.
Align the drain hole in the carrier with the drain hole in the hub.
18. Put the planetary carrier in position on the hub.
19. Install the bolts that hold the planetary carrier to the hub. Remove Tooling (A).
End By:
a. install final drives
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Apr 26 18:29:30 UTC+0800 2020
12/12
2020/4/26

Shutdown SIS
Previous Screen
SENR94960018
Power Train Oil Filter
SMCS - 3004-017; 3004-010
Remove & Install Power Train Oil Filter
1. Remove plug (1) under the right platform and drain the oil from the filter.
2. Remove the seat, arm rest and the right side console cover.
3. Disconnect two wires (2) at the sender, disconnect two tube assemblies (3). Remove four bolts
and washers (5) and panel (4).
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4. Remove two bolts and washers (7) and loosen clamp (6).
5. Install Tooling (A) and a hoist to oil filter (8) and remove the filter from the machine.
NOTE: Install the power train oil filter in the reverse order.
Disassemble & Assemble Power Train Oil Filter
Start By:
a. remove power train oil filter
1. Remove switch (1), O-ring seal (2), plunger (3), and spring (5) from housing assembly (7).
2. Remove plug (6) from the cover assembly.
3. Remove five bolts (8) that hold cover assembly (4) to the filter housing assembly.
4. Remove plug (9) from the housing assembly.
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5. Remove locknut (13), retainer and O-ring seal (10), element (11), stud (14), and two O-ring
seals (12) from cover assembly (4).
6. Inspect O-ring seals and replace if necessary. Thoroughly clean all of the parts.
NOTE: The following Steps are for the assembly of the power train oil filter.
7. Install stud (14) into cover assembly (4). Put element (11), retainer and O-ring seal (10), and
locknut (13) in position on the stud. Tighten locknut (13) to a torque of 13.6 ± 2.7 N·m (122 ± 24
lb in).
8. Install two O-ring seals (12) onto cover assembly (4).
9. Put cover assembly (4) into position in housing assembly (7) and install five bolts (8).
10. Install plug (6) into cover assembly.
11. Install plug (9) into housing assembly.
12. Install spring (5), plunger (3), O-ring seal (2), and switch (1) into housing assembly (7).
End By:
a. install power train oil filter
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Apr 26 18:30:19 UTC+0800 2020
3/3
2020/4/26

Shutdown SIS
Previous Screen
SENR94960019
Power Train Oil Pump
SMCS - 3066-016; 3066-010; 3066-015
Remove & Install Power Train Oil Pump
Start By:
a. remove seat
1. Disconnect four hose assemblies (1) from the implement control valve and position out of the
way.
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2. Disconnect hose (2) and hose assemblies (3) and (4).
3. Disconnect hose assembly (5) from the steering implement pump.
4. Remove two bolts and washers (6) from flange (8). Disconnect electrical connector (7).
5. Attach Tooling (A) and a strap to pump (9). Remove four bolts (10) and two nuts (11) and
remove power train oil pump. The weight of the power train oil pump is 39 kg (85 lb).
2/11
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End By:
a. install seat
Disassemble Power Train Oil Pump
Start By:
a. remove power train oil pump
NOTE: The power train oil pump used on the power shift machine is a three section pump. A four
section pump is used on the direct drive machine. The four section pump has been illustrated here,
but the disassembly and assembly procedures are similar for both pumps.
To clarify any differences and for identification of the individual pump sections, see the
Specification module, Form No. SSENR3239.
1. Remove switch (3). Remove four bolts (2) and flange (1) with the cage from the pump.
2. Remove two bolts (4).
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3. Remove O-ring seal (5) from cage (6). Remove spiral snap (8) from flange (1).
4. Use Tooling (A) and a press, and remove flange (1) from cage (6). If necessary, remove plug
(7) from the flange.
5. Use Tooling (B), and remove the baring and lip seal from cage (6).
NOTICE
Put identification mark on the pump gears. If the pump gears are
reused, they should be installed in their original position.
6. Turn the pump over, and support it with wood blocks as shown.
7. Remove the four O-ring seals and four bolts (10) from cover (9). Remove the cover. Turn cover
(9) over, and remove the two O-ring seals.
8. Remove two gears (12). Remove the key from gear assembly (11).
9. Remove the two O-ring seals and body assembly (13). Turn body assembly (13) over, and
remove the three O-ring seals and the two dowels.
4/11
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10. Remove two gears (14). Remove the key from gear assembly (11).
11. Remove body assembly (15). Turn body assembly (15) over, and remove the O-ring seal. Use
Tooling (B), and remove the two bearings.
12. Remove gear assembly (16).
13. Turn the pump over, and support with wood blocks as shown. Remove cover assembly (17).
14. Turn cover assembly (17) over, and remove the O-ring seal. Use Tooling (B), and remove the
two bearings.
15. Remove two gears (18) and (19). Remove the key from gear assembly (11).
16. Remove body assembly (20) and gear assembly (11) from body assembly (21).
17. Turn body assembly (20) over, and remove the O-ring seal. Use Tooling (B), and remove the
O-ring seal. Use Tooling (B), and remove the two bearings.
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18. Remove the dowels from body assemblies (20) and (21).
Assemble Power Train Oil Pump
1. Make sure all parts are clean and free of foreign material. Inspect all parts for wear or damage,
and replace if necessary. Put clean oil on all parts at assembly.
2. Install four dowels (2), two on each side, in body assembly (1). The dowels should be 5.0 ± 0.5
mm (.200 ± .020 in) above the surface of body assembly (1).
NOTICE
Install bearings (3) with the joint in both bearings in the correct
location in the body assembly. The location of the joint is at an angle 30
± 15 degrees from the centerline of the two bearings bores in the
direction of the groove on the pressure side of the pump.
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3. Us Tooling (A) and a press, and install two bearings (4) in body assembly (6). The bearings
must be 1.5 ± 0.25 mm (.059 ± .020 in) below the surface of the body.
4. Install O-ring seal (5) on body assembly (6).
5. Position body assembly (1) on wood blocks as shown. Align the dowels, and put body assembly
(6) in position on body assembly (1).
6. Install two dowels (9) in body assembly (6). The dowels should be 5.0 ± 0.5 mm (.200 ± .020
in) above the surface of body assembly (6).
7. Install gear assembly (7) in body assemblies with the splined end of the shaft up as shown. Put
the key in position, and install two gears (8).
NOTICE
Install two bearings (11) with the joint in both bearings in the correct
location. The location of the joint is at an angle 30 ± 15 degrees from
the centerline of the two bearing bores in the direction of the groove on
the pressure side of the pump. See illustration C2910P1.
7/11
2020/4/26

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8. Use Tooling (A) and a press, and install two bearings (11) in body assembly (10). The bearings
must be 1.5 ± 0.25 mm (.059 ± .020 in) below the surface of the body.
10. Turn body assembly (10) over, and put it in position on body assembly (6). make sure O-ring
seal (12) stays in position when the body is turned over.
11. Turn the pump assembly over, and install gear assembly (13).
NOTICE
Install two bearings (15) with the joint in both bearings in the correct
location. The location of the joint is at an angle 30 ± 15 degrees from
the centerline of the two bearing bores in the direction of the groove on
the pressure side of the pump. See illustration C2910P1.
12. Use Tooling (A) and a press, and install two bearings (15) in body assembly (14). The
bearings must be 1.5 ± 0.25 mm (.059 ± .020 in) below the surface of the body.
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14. Turn body assembly (14) over, and put it in position on body assembly (1). Make sure O-ring
seal (16) stays in position when the body is turned over.
15. Put the key in position in the groove on gear assembly (7). Install two gears (17).
16. Install two dowels (19) in body assembly (18). The dowels should be 5.0 ± 0.5 mm (.200
± .020 in) above the surface of body assembly (18).
17. Install three O-ring seals (20) on body assembly (18).
18. Turn body assembly (18) over, and install it on body assembly (14). Make sure three O-ring
seals (20) stay in position.
19. Put the key in the groove in gear assembly (7). Install two gears (22).
20. Install two O-ring seals (21).
21. Install two O-ring seals (24) in cover (23).
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22. Turn cover (23) over, and install it on body assembly (18). Install four bolts and washers (25).
23. Install the four O-ring seals on cover (23).
24. Put 7M-7260 Liquid Gasket Material on the outer diameter of the lip seal. Use Tool (A) and a
press, and install the lip seal in cage (26). Put clean oil on the lip of the seal.
25. Use Tool (A) and a press, and install the bearing in cage (26).
26. Clean the outer diameter of the plug that goes in flange (27), and put 7M-7260 Liquid Gasket
Material on it. Use Tool (A), and install the plug until it is 1.25 ± 0.25 mm (.05 ± .010 in) below
the surface of the flange.
27. Use Tool (A) and a press, and install flange (27) in cage (26).
28. Install spiral snap ring (29) and O-ring seal (28) on the cage assembly.
10/11
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