Caterpillar Cat D6R TRACK-TYPE TRACTOR (Prefix DMP) Service Repair Manual (DMP00001 and up).pdf

Service Repair Manual
Models
D6R TRACK-TYPE TRACTOR

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D6R TRACK-TYPE TRACTOR DMP
Configuration: D6R Track-Type Tractor XW Differential Steering DMP00001-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
SENR94960030
Transmission (Power Shift)
SMCS - 3150-016; 3150-015
Disassemble Transmission (Power Shift)
NOTE: The Transmission Modulating Valves need to be recalibrated when any of the following
is performed:
Transmission Modulating Valve and/or Solenoid is replaced
Transmission is serviced or replaced
ECM is replaced
1/30
D6R Track-Type Tractor XW Differential Steering DMP00001-UP (MACHINE) PO...
2021/1/4
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

NOTE: For Calibration procedure reference Power Train Electronic Control System Manual
SENR8367
Start By:
a. separate transmission and bevel gear
1. Put transmission in position on Tooling (A). Put alignment marks on all of the housings for
assembly purposes.
2. Remove four small O-ring seals (1) and large O-ring seal (2) from the transmission cover.
3. Remove two plugs and fitting (5).
4. Remove three bolts and retainers (4).
5. Remove three tubes (3) and the seals from the tubes.
2/30
2021/1/4

6. Remove locknut (6) and push connector (7) out of the case.
7. Disconnect electrical connector (8).
8. Remove four 9/16 in Headed Bolts (9) and control valve (10).
9. Remove bolt (11) and tube assembly (12).
10. Remove the O-ring seal from tube assembly (12).
11. The weight of the planetary group is 341 kg (750 lb). Install Tooling (B), and attach a hoist as
shown.
12. Remove 21 bolts (13) that hold the planetary group to the transmission cover. Remove the
planetary group.
3/30
2021/1/4

13. The weight of transmission cover (15) is 100 kg (220 lb). Install Tooling (B) to the
transmission cover, and fasten a hoist. Remove the transmission cover from Tooling (A).
14. Remove suction screen cover (14) and the O-ring seal from the transmission cover.
15. Remove the suction screen from transmission cover (14).
16. Put transmission planetary group (16) in position on Tooling (A). Use four bolts and nuts (17)
to fasten the planetary group to Tooling (A).
17. Remove four electrical connectors (20) from the clips on the back side of plate assembly (19).
Remove three bolts and washers (18) and plate assembly (19) from the planetary group (16).
18. Remove guard and bracket (21) with four sensors (22) from the planetary group.
4/30
2021/1/4

19. Using Tool (C) remove retaining ring (23) and rotor (24).
20. Remove ring (25) and rotor (26).
21. Using Tool (C) remove retaining ring (27). Remove 10 bolts and washers (28) from manifold
(29).
22. Install Tooling (B) and a hoist and remove manifold (29). The weight of manifold (29) is 22
kg (50 lb).
5/30
2021/1/4

23. Use Tool (D) and remove bearing (30) from manifold (29).
24. Remove bearing (31) from manifold (29).
25. The weight of first gear clutch gear (31) and housing assembly is 31 kg (68 lb). Remove first
speed clutch gear and housing assembly (31).
26. Remove ten springs (32) and five dowels (34).
NOTICE
The discs and plates used in the individual clutches must be kept in
order and with their original clutch housing. Different friction material
is used for different clutches, so the discs and plates must not be mixed
from one clutch to another.
27. Remove the two discs and one plate (33) that make up the second speed clutch.
28. Remove retaining ring (34), and remove housing assembly (35) from first speed clutch gear
(31).
29. Remove the four discs and the three plates from first speed clutch gear (31).
6/30
2021/1/4

There is spring pressure under plate (36). To prevent possible personal
injury, a press should be used to remove retainer ring (37) and to
release the spring pressure slowly.
30. Put housing assembly (35) in a press as shown. Compress springs under plate (36), and
remove retainer ring (37). Release spring pressure slowly, and remove plate (36) and the three
spring plates under plate (36).
31. Remove piston (39) from housing assembly (35). Remove ring (40) and seal (38) from the
piston.
32. Turn the housing over, and remove two seal rings (41) from carrier (42).
NOTE: Carrier (42) will be destroyed if it is removed from the housing assembly.
7/30
2021/1/4

33. If carrier (42) is to be removed, use a hammer and chisel to break the carrier, and remove it.
After the carrier is removed, remove the dowel that holds the carrier in position.
34. Use Tooling (E) to hold the two pistons in clutch housing assembly (43).
35. The weight of clutch housing assembly (43) with the piston is 46 kg (101 lb). Use Tooling (F),
and fasten a hoist as shown. Remove clutch housing assembly (43).
36. Remove pistons (45) and (47) from clutch housing (43).
37. Remove Teflon seal rings (44) and (46) from pistons (45) and (47).
38. Remove ten springs (48).
39. Remove three discs (49) and the two plates.
40. Use Tool (C), and remove retaining ring (50).
8/30
2021/1/4

41. Remove gear (51) and planet carrier (52).
42. Use a hammer and a punch, and push pins (56) in shafts (53).
43. Remove shafts (53), gears (54), and thrust washers (55) and (58) from planet carrier (52).
Remove bearings (57) from gears (54).
44. Remove pins (56) from shafts (53).
45. Install small screwdrivers in the teeth around planet carrier, location (X), to compress the
retaining ring. Remove gear (59) from planet carrier (52).
46. Put wood blocks under reverse clutch housing (62).
47. Remove two bolts (60). Use Tool (G) to hold the piston in forward clutch housing (61).
48. The weight of piston and forward clutch housing (61) is 26 kg (57 lb). Use Tooling (H), and
attach a hoist as shown. Remove the piston and forward clutch housing (61).
49. Remove piston (63) from forward clutch housing (61).
50. Remove Teflon seal rings (64) and (65) from piston (63).
9/30
2021/1/4

51. Remove five dowels (68) and ten springs (70).
52. Remove four discs (67), the three plates, ring gear (66) and plate assembly (69).
53. Remove four discs (71) and the three plates from reverse clutch housing assembly (62).
54. Use Tool (C), and remove retaining ring (72) that holds the shaft and planetary to reverse
clutch housing assembly (62).
55. The weight of output shaft (73) and the planetary assembly is 70 kg (154 lb). Use a strap and a
hoist, and remove the shaft and planetary from reverse clutch housing assembly (62).
10/30
D6R Track-Type Tractor XW Differential Steering DMP00001-UP (MACHINE) P...
2021/1/4

56. Remove piston (74) from reverse clutch housing assembly (62).
57. Remove Teflon seals (75) and (76) from the piston.
58. The weight of the reverse clutch housing assembly is 42 kg (92 lb). Turn the reverse clutch
housing assembly over, and use Tool (D) to remove snap ring (77).
59. Remove bearing (78).
60. Remove seal (80) and three seal rings (79) and (81) from the shaft and planetary assembly.
61. Turn the output shaft, planet carriers and gears over, and position them on wood blocks as
shown.
11/30
2021/1/4

62. Remove seal (82) from output shaft (73).
63. Remove seal ring (84) from the planetary carrier.
64. Remove retaining ring (83) that holds the output shaft (73) to the planetary carrier.
65. Remove output shaft (73) from the input shaft and the planetary carrier.
66. Use Tool (C), and remove retaining ring (85) from output shaft assembly (83). Remove gear
(86) and bearing (87) from the output shaft assembly.
67. Remove bearing (88) from output shaft (73).
68. Use Tool (C), and remove retainer ring (92) that holds gear (91) in position on input shaft (90).
Remove gear (91).
69. The weight of the planet carrier is 26 kg (58 lb). Remove planet carrier (89) from the input
shaft.
12/30
2021/1/4

70. Use Tooling (J) to compress retaining ring (93). Remove gear (94) from the planet carrier.
71. Remove retaining ring (95), and remove bearing (97) and the gear as a unit from the planet
carrier.
72. Remove bearing (97) from gear (96).
73. Use a hammer and a punch, and push pins (98) in the planet gear shafts.
74. Remove planet gear shafts (102), gears (99) and (101), and thrust washers (103) from the
planet carrier.
75. Remove bearings (100) from gears (99) and (101).
76. Remove pins (104) from planet gear shafts (102).
77. Remove planet carrier (105) from input shaft (90).
13/30
2021/1/4

78. Use Tool (D), and remove retaining ring (106). Remove bearing (107).
79. Use a hammer and a punch, and push pins (108) in the planet gear shafts.
80. Remove planet gear shafts (109), gears (110), and thrust washers (112).
81. Remove bearings (111) from gears (110).
82. Remove pins (113) from the planet gear shafts.
83. Remove O-ring seal (115) from input shaft (90).
NOTICE
Carrier (114) will be damaged if it is removed.
84. If it is necessary, remove carrier (114) from input shaft (90).
Assemble Transmission (Power Shift)
14/30
2021/1/4

1. Inspect all of the parts for wear or damage, and replace if necessary. Put clean oil on the parts
during assembly. Make sure all of the oil passages in the shafts and housings are clean.
2. If seal carrier (4) was removed from input shaft (3), use the following steps for assembly.
a. Heat carrier (4) to a temperature of 127°C to 166°C (260°F to 330°F) for a maximum of ten
minutes.
b. Align one of the holes in the carrier with the hole in input shaft (3), and install the carrier on the
shaft.
c. Install pin (1) in the carrier and the input shaft. Make sure pin (1) is installed so it is below the
outer diameter of carrier (4).
3. Install O-ring seal (2) on input shaft (3).
15/30
2021/1/4

4. Install bearing (8) in gear (7).
5. Install gear (7) in planet carrier (5) with one thrust washer (9) on each side of the gear.
6. Install planet gear shaft (6) that holds the gear in planet carrier (5).
NOTICE
The rubber in pin (10) must not be damaged. If the rubber is damaged,
the pin must be replaced.
7. Align the holes in the planet gear shaft and the planet carrier, and install pin (10). Repeat this
procedure for all of the planet gears.
8. Install bearing (11) in planet carrier (5). Use Tool (A), and install retaining ring (12) to hold the
bearing in position.
9. Put oil on O-ring seal (2) immediately before planet carrier (5) is installed. Put planet carrier (5)
in position on input shaft (3).
16/30
2021/1/4

10. Install bearings (13) in gears (15).
11. Install gears (15) in planet carrier (17) with thrust washers (14) on each side of the gears.
12. Install planet gear shaft (16) that holds the gear in position in planet carrier (17).
NOTICE
13. Align the hole in planet gear shaft (16) in the hole in the planet carrier, and install pin (18).
Repeat the procedure for all of the planet gears.
14. Install the seal on gear (19).
15. Put oil on the seal immediately before assembly. Install bearing (20) on gear (19).
17/30
2021/1/4

16. Install gear (19) in planet carrier (17). Install retaining ring (21) to hold the gear and bearing in
position in the planet carrier.
17. Install retaining ring (22) on planet carrier (17). Use Tooling (B), and compress the retaining
ring as the planet carrier is installed in gear (23). Remove Tooling (B). Tap the retaining ring to
make sure it is seated in the groove in gear (23).
18. Put planet carrier (17) and gear (23) in position on input shaft (3).
19. Install gear (24). Use Tool (C), and install retaining ring (25).
18/30
2021/1/4

20. Use Tooling (D), and install bearing (27) in the end of output shaft (26). Install the bearing to a
depth of 2.0 ± 0.5 mm (.079 ± .020 in). The inner bearing diameter after assembly should be
50.809 ± 0.049 mm (2.000 ± .002 in).
21. Use Tooling (D), and install bearing (28) in the end of output shaft (26). Install the bearing to a
depth of 13.0 ± 0.5 mm (.519 ± .020 in). The bearing inner diameter after assembly should be
56.650 ± 0.061 mm (2.230 ± .002 in).
22. Put gear (30) in position on output shaft (26). Use Tool (C), and install retaining ring (29).
23. Put output shaft (26) over input shaft (3). Engage gear (30) with the planet gears.
24. Install retaining ring (31) in the planet carrier to hold the bearing and output shaft (26) in
position.
25. Install seal ring (33) on the planet carrier.
26. Install O-ring seal (32) on output shaft (26).
19/30
2021/1/4

27. Turn the shaft and planet carrier assembly over. Install O-ring seal (34) on input shaft (3).
28. Install seal ring (36) on planet carrier (17).
Figure 1. Correct Method To Make (Non-Metal) New Seal Rings Ready For Installation.
Figure 2. Wrong Method To Make (Non-Metal) New Seal Rings Ready For Installation.
NOTICE
New seal rings must be preloaded before they are installed to prevent
them from being damaged or broken when the clutch housing is
installed. There is a correct method to preload new seal rings prior to
installation. Place your hands on each end of the seal ring. and pull
(wind) the ends several inches past each other or until they almost
make contact. See Figure 1. Use care to keep the ring shaped like a
circle. This will make an even bend (or ring "set") all around the ring.
When the seal ring is in the groove of carrier (6), the ends must butt
together lightly. Do not bend the seal ring as shown in Figure 2. This
does not make and even bend all the way around the ring.
Do not attempt to use this method to preload a used seal ring. Also, do
not use this procedure for cast iron seal rings. This will cause used or
cast iron seal rings to break.
20/30
2021/1/4

29. Install two seal rings (35) on the seal carrier.
30. Install bearing (38) in reverse clutch housing (37).
31. Use Tool (A), and install retaining ring (39).
32. Install Teflon seal rings (41) and (42) on pistons (40). The lips of the Teflon seal rings should
be toward the housing. Make sure to put clean oil on the lip of the Teflon seal rings.
33. Install piston (40) in reverse clutch housing (37).
34. Put reverse clutch housing (37) in position on Tooling (E), and use wood blocks under it.
35. Install coupling (43) in the reverse clutch housing.
36. Put oil on O-ring seal (34) immediately before assembly. Loosen the shafts and planet carrier
(17) in reverse clutch housing (37).
21/30
2021/1/4

37. Use Tool (C), and install retaining ring (44) on input shaft (3).
38. Install four discs (45) and three plates (46). Start and stop with a disc.
39. Install plate assembly (47). Install ten springs (50) and five dowels (48).
40. Install four discs (49) and the three plates. Start and stop with a disc.
41. Install Teflon seal rings (52) and (54) on piston (51). The lip of the Teflon seal rings should be
toward the clutch housing. Put clean oil on the lip of the Teflon seal rings.
42. Install piston (51) in forward clutch housing (53).
22/30
2021/1/4

43. Use Tooling (F) to hold piston (51) in the forward clutch housing. Install Tooling (G), and
attach a hoist. Turn the forward clutch housing over, and put it in position, and align the holes for
two bolts (55).
44. Install two bolts (55).
45. Install the bearing in gear (59).
46. Install gear (59) in planet carrier (56) with a thrust washer on each side of the gear.
NOTICE
47. Align the hole in the planet gear shaft with the hole in the planet carrier, and install planet gear
shaft (57).
48. Install pin (61). Repeat the procedure for all of the planet gears.
49. Install retaining ring (58) on planet carrier (56). Use small screwdrivers, and compress the
retaining ring as the planet carrier is installed in gear (60). Remove the screwdrivers, and tap the
retaining ring to make sure it is seated in the groove in gear (60).
23/30
2021/1/4

50. Put planet carrier (56) in position on the output shaft. Engage gear (60) with the planet gears.
51. Install hub (62) on the output shaft. Use Tool (C), and install retaining ring (63).
52. Install three discs (65) and the two plates. Start and stop with a disc.
53. Install ten springs (64).
54. Install Teflon seal rings (67) and (68) on pistons (66) and (69). The lip of the Teflon seal rings
should be toward the center clutch housing. Put clean oil on the lip of the seals.
55. Install pistons (66) and (69) in second and third speed clutch housing (70). Use Tooling (H) to
hold piston (66) and piston (69) in piston.
24/30
2021/1/4

56. Install Tooling (J), and attach a hoist. Lower second and third speed clutch housing (70) with
pistons (66) and (69) on the shaft.
57. Remove Tooling (H) and Tooling (J).
58. Install two discs (72) and one plate (73) in second and third speed clutch housing (70).
59. Install five dowels (71).
60. Install ring gear (74).
61. Install four discs (75) and the three plates. Start and stop with a disc.
62. If seal carrier (76) was removed from housing (77), use the following steps for assembly.
a. Heat carrier (76) to a temperature of 127° C to 166° C (260° F to 330° F) for a maximum of ten
minutes.
b. Align one of the holes in the carrier with the hole in housing (77), and install the carrier on the
housing.
c. Install pin (78) in the carrier and the housing. Make sure pin (78) is installed so it is below the
outer diameter of carrier (76).
63. Install two seal rings (79) on carrier (76).
25/30
2021/1/4

64. Install Teflon seal rings (80) and (82) on piston (81). The lip of the Teflon seal rings should be
toward the housing. Put clean oil on the lip of the seals.
65. Install piston (81) in housing (77).
66. Install three springs (85) in housing (77) as follows:
a. Install the first spring with the outside diameter of the spring so it contacts the housing.
b. Install the next two springs with the outside diameter of the springs in contact with each other.
c. Install ring (84) on top of the springs, and put it in a press.
67. Compress springs (85) until retaining ring (83) can be installed. Install retaining ring (83).
Make sure the retaining ring is seated in the groove in housing (77), and slowly release the
pressure from the press. Remove the housing from the press.
68. Install housing (77) in gear (74). Install retaining ring (86).
69. Install ten springs (87).
26/30
2021/1/4

NOTICE
The notch at location (X) must be installed down as shown.
70. Use Tooling (A), and install bearing (90) in manifold (88) with the notch at location (X) down.
71. Use Tool (A), and install retaining ring (89).
NOTICE
The notch in bearing (90) at location (X) must be aligned at the
locating dowel in housing (77).
72. Install Tooling (K), and attach a hoist. Align the notch at location (X) in bearing (90) with the
locating dowel in housing (77). Install manifold (88). Remove Tooling (K).
73. Install 10 bolts (92), and tighten to a torque of 115 ± 7 N·m (85 ± 5 lb ft).
74. Use Tool (C), and install retaining ring (91).
27/30
2021/1/4

75. Install rotor (94) and ring (93).
76. Install rotor (96) and using Tooling (C) and install retaining ring (95).
77. Install guard and bracket (97) with four sensors (98). Align sensors (98) with the center of the
rotor and screw sensor in until it contacts rotor and back out 1/4 turn. Gap setting will be .35.
78. Install plate assembly (100) with three bolts and washers (99). Install four electrical connectors
(101) in the clips on the back side of plate assembly (100).
79. Install the transmission suction screen in cover (103). Put the O-ring seal and cover (102) in
position, and install the four bolts.
28/30
2021/1/4

Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
GET MORE OTHER MANUALS https://www.aservicemanualpdf.com/
GET MORE OTHER MANUALS https://www.aservicemanualpdf.com/

80. Install Tooling (K), and attach a hoist. Remove the planetary group from Tooling (E). Put
transmission cover (103) in position on Tooling (E). Put the planetary in position on cover (103),
and install 22 bolts (104).
81. Install the O-ring seal on tube (105). Put tube (105) in position, and install bolt (106).
82. Put transmission control valve (107) in place and install four 9/16 in headed bolts (108).
83. Connect electrical connector (109).
29/30
2021/1/4

84. Install connector (111) in the case and install locknut (110).
85. Install three tubes (113) and the seals on the tubes.
86. Install three bolts and retainers (112).
87. Install two plugs (114) and fitting (115).
88. Install four small O-rings (116) and one large O-ring (117).
End By:
a. connect transmission and bevel gear
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Jan 4 16:57:54 UTC+0800 2021
30/30
2021/1/4

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D6R TRACK-TYPE TRACTOR DMP
Configuration: D6R Track-Type Tractor XW Differential Steering DMP00001-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
SENR94960031
Final Drive, Differential And Brake (Left Side)
SMCS - 4050; 4131-010
Remove And Install Left Final Drive, Differential And Brake
Start By:
a. separate track (left side)
1/6
2021/1/4

Caterpillar Cat D6R TRACK-TYPE TRACTOR (Prefix DMP) Service Repair Manual (DMP00001 and up).pdf

Recommended

Recommended

More Related Content

Similar to Caterpillar Cat D6R TRACK-TYPE TRACTOR (Prefix DMP) Service Repair Manual (DMP00001 and up).pdf

Similar to Caterpillar Cat D6R TRACK-TYPE TRACTOR (Prefix DMP) Service Repair Manual (DMP00001 and up).pdf (6)

More from hdjsjndndnd

More from hdjsjndndnd (20)

Recently uploaded

Recently uploaded (8)

Caterpillar Cat D6R TRACK-TYPE TRACTOR (Prefix DMP) Service Repair Manual (DMP00001 and up).pdf