Caterpillar Cat D7R II TRACK-TYPE TRACTOR (Prefix ACS) Service Repair Manual (ACS00001 and up).pdf

Service Repair Manual
Models
D7R II TRACK-TYPE TRACTOR

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D7R II TRACK-TYPE TRACTOR ACS
Configuration: D7R Track-Type Tractor ACS00001-UP (MACHINE) POWERED BY 3176C Engine
Disassembly and Assembly
D7R and D7R Series II
Track-Type Tractors
Power Train
Media Number -RENR3657-02 Publication Date -01/02/2009 Date Updated -18/02/2009
i02529031
Final Drive - Disassemble
SMCS - 4050-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 3
B 1P-0510 Driver Group 1
C
8B-7548 Puller Assembly 1
8H-0684 Ratchet Box Wrench 1
8B-7554 Bearing Cup Puller Attachment 1
D 138-7573 Link Bracket 2
E 1P-0520 Driver Group 1
F 138-7573 Link Bracket 3
G 1P-0520 Driver Group 1
6V-3160 Cylinder 1
1D-4620 Bolt 3/4 inch -10 × 7 inch long 4
FT-1934 Beam 1
5P-8248 Washers 4
4C-4865 Pump 1
1/9
D7R Track-Type Tractor ACS00001-UP (MACHINE) POWERED BY 3176C Engine...
2021/4/12
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H 138-7574 Link Bracket 2
Start By:
a. Remove the final drives. Refer to Disassembly and Assembly, "Final Drive - Remove".
Illustration 1 g01265376
1. Attach Tooling (A) and a suitable lifting device to planetary carrier (2). The weight of
planetary carrier (2) is approximately 105 kg (231 lb).
2. Remove bolts (3) and planetary carrier (2).
3. Remove bolts (1) and the O-ring seal from each of the plates.
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4. Use Tooling (B) and a suitable press in order to remove shafts (4).
5. Remove gears (5).
6. Remove bearing cones (6) from each side of gears (5).
7. Use Tooling (C) in order to remove the bearing cups from each side of gears (5).
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NOTICE
There is a second sun gear that is shown in Step 15 in the center of the
planetary carrier. The sun gear is free to fall if the gear stays with the
planetary carrier.
8. Install Tooling (D) and a suitable lifting device to planetary carrier (8). The weight of
planetary carrier (8) and sun gear (7) is approximately 46 kg (101 lb). Remove planetary
carrier (8) and sun gear (7) as a unit.
9. Invert planetary carrier (8) and remove spiral ring (9) from sun gear (7).
10. Use a suitable lifting device in order to remove planetary carrier (8) from sun gear (7). The
weight of planetary carrier (8) is approximately 32 kg (70 lb).
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11. Use a suitable punch in order to drive roll pins (11) in the planetary gear shafts (10).
12. Use a suitable press in order to remove shafts (10) from gears (12). Remove roll pins (11)
from planetary gear shafts (10).
13. Remove gears (12).
14. Remove bearings (13) from each side of gears (12).
15. Remove ring (14) and sun gear (15) from the hub.
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16. Remove the bolts and retainer (16). If ring (17) and retainer (16) need to be replaced, use
Tooling (E) and a suitable press, and remove ring (17) from retainer (16).
17. Use a magnet, and remove pins (18) from the hub.
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18. Install Tooling (F) and a suitable lifting device to hub (19) and ring gear (20). The weight of
hub (19) and ring gear (20) is approximately 73 kg (161 lb). Remove hub (19) and ring gear
(20).
19. Invert hub (19) and ring gear (20). Remove retainer ring (21).
20. Remove hub (19) from ring gear (20). The weight of hub (19) is approximately 22 kg
(48 lb).
21. Install Tooling (G) on hub (23), as shown.
NOTICE
Do not lift the hub high enough to make contact with the fitting on the
hydraulic cylinder which is part of Tooling (G).
22. Use Tooling (G), and loosen hub (23) from hub (24).
23. Remove Tooling (G). Remove bearing cone (22) from the hub.
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24. Install Tooling (H) on hub (23).
25. Attach a suitable lifting device to Tooling (H) and remove hub (23) from hub (24). The
weight of hub (23) is approximately 260 kg (573 lb).
26. Invert the hub and remove Duo-Cone seal (26). Remove bearing cup (27) with a hammer
and a punch.
27. Turn over the hub and remove bearing cup (25) from the hub with a hammer and a punch.
Note: In order to reuse the Duo-Cone seals, place identification marks on the seals.
28. Remove Duo-Cone seal (28).
NOTICE
Bearing cone (30) may become damaged if it is removed from the hub
29. Remove bearing cone (30) from hub (24).
8/9
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30. Remove lip seal (29) from the hub.
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All Rights Reserved.
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Mon Apr 12 14:11:40 UTC+0800 2021
9/9
2021/4/12

Shutdown SIS
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Track-Type Tractors
Power Train
i02529261
Final Drive - Assemble
SMCS - 4050-016
Assembly Procedure
Table 1
Required Tooling
A 138-7575 Link Bracket 3
D 138-7573 Link Bracket 2
E 1P-0520 Driver Group 1
F 138-7573 Link Bracket 3
H 138-7574 Link Bracket 2
J 1U-6437 Seal Installer 1
K 6V-7030 Micrometer Depth Gauge Group 1
L 8T-2827 Spacer 1
1/8
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1. Use Tooling (A), and install lip seal (29). Place clean oil on the lip of the seal.
2. Raise the temperature of bearing cone (30). Install bearing cone (30).
3. Use Tooling (J) in order to install the Duo-Cone seal (28). Refer to Disassembly And
Assembly, "Duo-Cone Floating Seals - Install".
4. Lower the temperature of bearing cups (25) and (27). Install the bearing cups (25) and (27).
2/8
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5. Use Tooling (J) in order to install the Duo-Cone seal (26).
6. Attach Tooling (H) and a suitable lifting device to hub (23). The weight of hub (23) is
approximately 260 kg (573 lb). Place hub (23) in position on hub (24).
7. Raise the temperature of bearing cone (22). Install bearing cone (6) on the hub.
8. Place Tooling (L) in position on bearing cone (22). Install retainer (16). Turn the hub while
you are tightening the bolts that hold retainer (16) to a torque of 135 ± 15 N·m
(100 ± 11 lb ft). Allow bearing cone (22) to return to room temperature before retainer (16)
and Tooling (L) are removed. Remove retainer (16) and Tooling (D).
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9. Place hub (19) in position in gear (20). Install retainer ring (21).
10. Invert hub (19) and gear (20) and install Tooling (E). Attach a suitable lifting device to
Tooling (E) and install hub (19) and gear (20). The weight of hub (19) and gear (20) is
approximately 73 kg (161 lb).
4/8
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11. Install pins (18). Use Tooling (E) in order to install ring (17) in retainer (16).
12. Install retainer (16) and the bolts. There must be metal to metal contact between the hub and
retainer (16).
13. Measure the distance between retainer (16) and pins (18). There must be a clearance of
0.08 ± 0.05 mm (0.003 ± 0.002 inch) between retainer (16) and pins (18).
14. Place bearings (13) in position in each of the three gears (12).
15. Install gears (12) and bearings (13).
16. Lower the temperature of shaft (10). Align hole (X) in shaft (10) with hole (X) in the
planetary carrier. Use a suitable press in order to install shaft (10). Install roll pin (11) in
hole (X) in order to retain shaft (10).
5/8
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17. Use a suitable lifting device in order to lower carrier (8) in position on sun gear (7).
18. Install spiral ring (9).
19. Install sun gear (15) and ring (14). Install Tooling (D) and a suitable lifting device to
planetary carrier (8). The weight of planetary carrier (8) is approximately 46 kg (101 lb).
6/8
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20. Align the gears in planetary carrier (8) with gear (20), and sun gear (15). Lower planetary
carrier (8) into position. Be sure that sun gear (15) engages the gears of planetary carrier (8).
Be sure that ring (14) stays in the correct position.
21. Lower the temperature of the two bearing cups and install the bearing cups in gears (5).
22. Place two bearing cones (6) and gears (5) in position in carrier (2).
7/8
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23. Lower the temperature of shafts (4). Use a suitable press in order to install shafts (4) in
carrier (2).
24. Invert carrier (2). Use Tooling (K) in order to measure the distance between the end of
shafts (4) and the machined surface of carrier (2). The distance must be 0.08 ± 0.05 mm
(0.003 ± 0.002 inch).
25. Install Tooling (A) and a suitable lifting device to planetary carrier (2). The weight of
planetary carrier (2) is approximately 105 kg (231 lb).
26. Install planetary carrier (2) and the O-ring seals. Install the plates and bolts (1).
27. Install bolts (3). Tighten bolts (3) to a torque of 475 ± 50 N·m (350 ± 37 lb ft). Remove
Tooling (A).
End By:
a. Install the final drives. Refer to Disassembly and Assembly, "Final Drive - Install".
Mon Apr 12 14:12:36 UTC+0800 2021
8/8
2021/4/12

Shutdown SIS
Previous Screen
Track-Type Tractors
Power Train
i01602153
Final Drive - Install
SMCS - 4050-012
Installation Procedure
Table 1
Required Tools
A 8T-3045 Adapter 1
B
8T-3207 Lifting Bracket 1
5P-8622 Shackle 1
1D-4615 Bolt 3/4 inch - 10 × 5 1/2 inch long 2
1B-4331 Nut 2
5P-8248 Washer 4
Note: Inspect O-ring seal (11) for wear or damage. If necessary, replace the seal.
1/5
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1. Adjust the top bracket of Tooling (B) until Dimension (X) is 38 mm (1.5 inch). Adjust the
lower plate so that the spacers are oriented away from the vertical leg of the tool.
2. Lubricate O-ring seal (11). Position the seal on the face of the steering clutch.
2/5
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3. Use a hoist and Tooling (B) to install the final drive. The weight of the final drive is
approximately 625 kg (1377 lb).
4. Install bolts (10) that hold the final drive and the steering clutch and brake to the frame. Do
not tighten the bolts.
Note: Bolts (9) hold the steering clutch and brake to the frame.
5. Install bolts (8) that hold the final drive and the steering clutch and brake together.
6. Tighten bolts (10) to a torque of 750 ± 90 N·m (550 ± 65 lb ft). Remove Tooling (B) .
7. Place SAE 30W oil on the threads of bolts (7) for the segment. Install the bolts and the nuts
with the head of the bolts and the washers against the final drive. Tighten the nuts to a
torque of 300 ± 50 N·m (221 ± 37 lb ft). Tighten the nuts 1/3 turn more. The final torque
must be a minimum of 570 N·m (420 lb ft).
3/5
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8. Install Tool (A) on the outer axle, and install outer axle (6) in the final drive. Be sure that
the thrust button that is located between the inner axle and the outer axle is installed in the
end of the outer axle.
9. Install retainer (5) in the sun gear of the final drive. Install O-ring seal (4) in the cover.
4/5
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10. Install cover (3) on the final drive. Install bolts (2) .
11. Drain plug (1) must be toward the bottom of the final drive. Fill the final drive with oil until
the oil is to the bottom of the filler hole. Refer to Operation and Maintenance Manual,
"Lubricant Viscosities and Refill Capacities".
End By: Connect the track. Refer to Disassembly and Assembly, "Track - Connect".
Mon Apr 12 14:13:32 UTC+0800 2021
5/5
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Shutdown SIS
Previous Screen
Track-Type Tractors
Power Train
i01515235
Power Train Oil Filter - Remove
SMCS - 3067-011-FI
Removal Procedure
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, "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.
1/3
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1. Open access cover (1) .
2. Remove bolts (2). Remove cover assembly (3) from filter housing (4) .
3. Remove O-ring seals (5) from the housing.
2/3
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Mon Apr 12 14:14:27 UTC+0800 2021
3/3
2021/4/12

Shutdown SIS
Previous Screen
Track-Type Tractors
Power Train
i01515364
Power Train Oil Filter - Disassemble
SMCS - 3067-015
Disassembly Procedure
Start By:
A. Remove the power train oil filter. Refer to Disassembly and Assembly, "Power Train Oil
Filter - Remove".
NOTICE
performance of inspection, maintenance, testing, adjusting and repair
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.
1/2
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1. Remove nut (1) and retainer (2). Remove O-ring seal (3) from the retainer. Remove filter
element (4). Remove stud (5) .
Mon Apr 12 14:15:23 UTC+0800 2021
2/2
2021/4/12

Shutdown SIS
Previous Screen
Track-Type Tractors
Power Train
i01515458
Power Train Oil Filter - Assemble
SMCS - 3067-016-FI
Assembly Procedure
Note: Check the O-ring seals for wear and damage and replace the seals, if necessary.
1. Install stud (5) to the cover. Install filter element (4). Install O-ring seal (3) in retainer (2)
and install the retainer. Install nut (1) on stud (5). Tighten nut (1) to a torque of 30 ± 5.4
N·m (22 ± 4 lb ft).
Mon Apr 12 14:16:19 UTC+0800 2021
1/1
2021/4/12

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Shutdown SIS
Previous Screen
Track-Type Tractors
Power Train
i01515069
Power Train Oil Filter - Install
SMCS - 3067-012-FI
Installation Procedure
Note: Check the O-ring seals for wear and damage and replace the seals, if necessary.
1. Install O-ring seals (5) .
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2. Install cover assembly (3) into filter housing (4). Install bolts (2) .
3. Close access cover (1) .
Mon Apr 12 14:17:15 UTC+0800 2021
2/2
2021/4/12

Shutdown SIS
Previous Screen
Track-Type Tractors
Power Train
i04266769
Power Train Oil Pump - Remove
SMCS - 3066-011
Removal Procedure
Start By:
A. Remove the bottom guards. Refer to Disassembly and Assembly, "Bottom Guard -
Remove".
B. Remove the drive shaft from the pump. Refer to Disassembly and Assembly, "Drive Shaft
(Pump Coupling) - Remove and Install".
NOTICE
performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
1. Drain the transmission and bevel gear case.
2. Remove the floorplate from the machine.
1/3
2021/4/12

Caterpillar Cat D7R II TRACK-TYPE TRACTOR (Prefix ACS) Service Repair Manual (ACS00001 and up).pdf

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Caterpillar Cat D7R II TRACK-TYPE TRACTOR (Prefix ACS) Service Repair Manual (ACS00001 and up).pdf