Caterpillar cat d6 r track type tractor (prefix 4tr) service repair manual (4tr00001 and up)

Service Repair Manual
Models
D6R TRACK-TYPE TRACTOR

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Product: TRACK-TYPE TRACTOR
Model: D6R TRACK-TYPE TRACTOR 4TR
Configuration: D6R TRACTORS / POWERSHIFT / 4TR00001-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
SENR94960025
Torque Divider
SMCS - 3113-016; 3113-010; 3113-015
Remove And Install Torque Divider
Start By:
a. remove torque converter outlet relief valve
b. remove drive shaft (main)
1. Remove the floor plate.
2. Loosen the flange bolts on hose (3) and drain the oil from the torque divider. Disconnect hose
(3) from the torque divider when the oil has drained.
3. Disconnect hose assemblies (1) and (2) from the torque divider.
1/17D6R TRACTORS / POWERSHIFT / 4TR00001-UP (MACHINE) POWERED BY 33...
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4. Remove elbow (5) from the bottom of the flywheel housing. Remove the O-ring seal from
elbow (5).
5. Remove sleeve (4). Remove the two O-ring seals from sleeve (4).
6. Loosen the hose clamp, and remove hose (7) from tube assembly (6).
7. Disconnect hose assemblies (8) from the steering and implement pump.
8. Remove guard assembly (9).
9. Install Tooling (A) on the top of the torque divider housing. Fasten a hoist to Tooling (B).
10. Remove the remaining ten bolts that hold the torque divider to the flywheel housing.
11. Install two 3/8 in - 16 NC forcing screws in the torque divider housing. Tighten the forcing
screws evenly, and remove the torque divider from the flywheel housing. The weight of the torque
divider is 145 Kg (320 lb.).
12. Lower the torque divider to the ground, and remove it from under the machine.
13. Remove the O-ring seal from the torque divider housing.
NOTE: The following steps are for installation of the torque divider.
14. Install the O-ring seal on the torque divider housing. Put clean oil on the O-ring seal.

15. Put the torque divider in position under the machine. Fasten a hoist and Tooling (A) to the
torque divider.
16. Put the torque divider in position on the flywheel housing, and install guard assembly (9) and
the bolts that hold the torque divider in place.
17. Connect hose assemblies (8) to the steering and implement pump.
18. Install hose (7) on tube assembly (6), and tighten the hose clamp.
19. Install the O-ring seals on sleeve (4) and elbow (5). Install the sleeve and elbow on the bottom
of the torque divider.
20. Connect hose assemblies (1) and (2) and hose (3) to the torque divider.
21. Install the floor plate.
22. Check the power train oil level, and add as necessary. See the Operation And Maintenance
Manual.
End By:
a. install drive shaft (main)
b. install torque converter outlet relief valve
Disassemble Torque Divider
Start By:
a. remove torque divider
NOTICE
When a torque converter or divider has a failure, the complete oil
system for the torque converter, torque divider and transmission must
be thoroughly cleaned. Any foreign material which is not removed

from the oil system for the torque converter will move through the
hydraulic system for the transmission.
1. Use Tool (A), and remove retaining ring (1) from the shaft.
2. Remove planetary carrier (2).
3. Remove retainer (4) and retaining ring (3) from the planetary carrier (2).
4. Use a hammer and a punch to push pin (8) in shafts (7).
5. Remove shaft (7), two washers (9) and gear (6).
6. Remove bearings (5) from the gear.
7. Remove the pin from shaft (7).

8. Remove the bolt, retainer, O-ring seal and yoke.
9. Put wood blocks under the converter group, as shown, so the cover can be removed.
10. Remove eight bolts (10).
11. The weight of the cover (12) is 68 kg (150 lb.). Install Tooling (B), and attach a hoist. Install
two 3/8 in - 16 NC forcing screws (11) in the cover. Tighten the forcing screws evenly, and
remove cover (12).
12. Remove O-ring seal (14) and lip seal (13).

13. Remove two bolts (15) and washers 180° apart from each other. Drain the oil from the
converter.
14. Use Tool (C), and remove retaining ring (17).
15. Remove shaft assembly (16) and the bearing.
16. Remove seal ring (21) from shaft assembly (19).
17. Remove bearing (20) from the shaft assembly.
NOTE: Race (18) will be destroyed if it is removed from the shaft assembly.
18. Remove race (18) from the shaft assembly if necessary.
19. Remove the remaining thirty-four bolts (15) and washers. Install two 3/8 in - 16 NC forcing
screws (23) in impeller wheel (22).
20. The weight of impeller wheel (22) and the carrier assembly is 30 kg (66 lb.) Install Tooling
(D), and attach a hoist. Tighten two forcing screws (23) evenly, and remove the impeller wheel
and a carrier assembly.
NOTICE
Use care to avoid causing damage to the stator when it is removed.

21. Remove eight bolts (24), and remove stator assembly (25).
22. Support the wheel and carrier assembly as close to the center as possible with wood blocks.
Use Tooling (E) on the inside diameter of pins (26), and remove carrier assembly (28).
23. Remove six pins (26) and sleeve (29) from carrier assembly (28).
24. Remove seal ring (30) from carrier (27).
25. Heat carrier assembly (28) to a maximum temperature of 135° C (275° F), and use two pry
bars to remove carrier (27) from carrier assembly (28).
26. Remove the eight bolts that fasten retainer (31) to the impeller wheel. Use two 3/8 in - 24 NF
forcing screws, and remove retainer (31).
27. Use Tool (F), and remove carrier (32) and the bearing.
28. Use Tool (F), and remove bearing (33) from carrier (32).

29. Use Tool (G), and remove retaining ring (35) from the flange.
30. Remove turbine wheel (34) from housing (36) and the flange assembly. Remove the spacer
that is under turbine wheel (34).
31. The weight of housing (36) with the gear and flange assembly is 35.5 kg (78 lb.) Turn the
housing over, and remove two stop pins (37).
32. Compress the retaining ring, and remove gear (38). Remove the retaining ring.
33. Install two 3/8 in - 16 NC forcing screws in flange assembly (39). Tighten the forcing screws
evenly, and remove flange assembly (39) from the housing.
34. Remove seal ring (42) from carrier (41) on flange assembly (39).
NOTE: Carrier (41) will be destroyed if it is removed from the flange assembly.
35. If carrier (41) is to be removed, use a chisel to break the carrier, and remove it.

36. Use Tooling (E), and remove two bearings (40) from flange assembly (39).
37. Remove six bolts (43) and retainer (44) from the housing.
38. Use Tooling (F), and remove bearing (45) from housing (36).
Assemble Torque Divider
NOTE: Before the torque divider is assembled, measurements of certain clearances must be made
if the torque divider is to operate with efficiency.
1. Check the clearance between the turbine wheel and stator as follows:

a. Put stator (25) in position in turbine wheel (34). Hold the stator against one side of the turbine
wheel, and use a feeler gauge (46) to find the clearance between the stator and the turbine wheel.
b. The clearance across the diameters between the stator and the turbine wheel must be 1.76 to
1.94 mm (0.069 to 0.076 inch). Check the clearance at four points on the turbine wheel. The
maximum permissible clearance across the diameters is 2.15 mm (0.085 inch).
2. Check the clearance between the impeller wheel and stator as follows.
a. Use an outside diameter micrometer (47) and make a measurement of the diameter of the stator
flange at four points on stator. Make a record of the lowest reading.
b. Use an inside diameter micrometer (48) and make a measurement of the inside diameter of
outer edge of flange on impeller wheel (22) at four points. Make a record of the highest reading.
c. The clearance across the diameters between the impeller and stator is the difference between the
highest reading on the impeller and the lowest reading on the stator. The clearance must be 1.17 to
1.32 mm (0.046 to 0.052 inch). The maximum permissible clearance across the diameters is 1.54
mm (0.061 inch).
10/17D6R TRACTORS / POWERSHIFT / 4TR00001-UP (MACHINE) POWERED BY ...

3. Use Tooling (F) and install bearing (44) in housing (36).
4. Put retainer (44) in position on the housing, and install six bolts (43). Tighten bolts (43) to a
torque of 50 ± 7 N*m (37 ± 5 lb.ft.).
5. Use Tooling (E), and install bearings (40) in flange assembly (39).
a. Bearing (40a) should be installed to a depth of 25.4 mm (1.0 in.) below the surface of flange
assembly (39).
b. Bearing (40b) should be installed flush with the surface of flange assembly (39).
c. Bearings (40) should have an inside diameter of 44.501 to 0.013 mm (1.7520 to .0005 in.) after
installation.
6. If carrier (41) was removed from flange assembly (39), heat the carrier to a temperature of 138°
C to 166° C (280° F to 330° F) for a maximum time of ten minutes. Install carrier (41) on flange
assembly (39). Install seal ring (42) on carrier (41).

NOTICE
When the flange assembly is installed in the housing, use care to avoid
causing damage to seal ring (15).
7. Put SAE 30 oil on seal ring (42). Pull the ends of the seal ring together, and install flange
assembly (39) in housing (36).
8. Put retaining ring (49) in position in the groove on flange assembly (39). Compress the ring,
and install gear (38). Make sure retaining ring (49) engages the slot in gear (38) to hold it in
position.
9. Install two pins (37) to hold the retaining ring in position.
10. Hold gear (38) and flange assembly (39) to prevent them from sliding, and turn housing (36)
over. Put spacer (50) in position on the flange assembly.
11. Install turbine wheel (34) on the flange assembly.
12. Use Tool (G), and install retaining ring (35) on the flange assembly.
13. Use Tooling (F), and install bearing (33) in carrier (32).

14. Use two 3/8 in - 24 NF guide bolts, and put carrier (32) in position in impeller wheel (22). Use
Tooling (F), and install carrier (32).
15. Turn impeller wheel (22) over, and put retainer (31) in position. Install eight bolts (51), and
tighten to a torque of 50 ± 7 N*m (37 ± 5 lb.ft.).
16. Heat carrier (27) to a maximum temperature of 135° C (275° F), and install carrier (27) on
carrier assembly (28).
17. Install seal ring (30) on carrier (27).
18. Install six pins (26) in carrier assembly (28).
19. Position sleeve (29) in carrier assembly (28). The cutout sleeve (29) must line up with the oil
passage in carrier assembly (28) as shown. Stake sleeve (29) in one place only, at location (X).
After staking, the sleeve must be 1.1 ± 0.4 mm (.04 ± .016 in.) below the surface of the carrier
assembly, at location (X) only.

NOTICE
When the carrier assembly is installed in the impeller wheel, use care
to avoid causing damage to seal ring (30).
20. Put SAE 30W oil on seal ring (30). Pull the ends of the seal ring together, and put carrier
assembly (28) in position on impeller wheel (22).
21. Use Tooling (F), and install carrier assembly (28) in impeller wheel (22).
22. Turn the impeller wheel over, and install two 3/8 in guide bolts. Position stator assembly (25)
in impeller wheel (22), and install the eight bolts. Tighten the bolts to a to a torque of 30 ± 5 N*m
(22 ± 4 lb.ft.).
23. Turn the impeller wheel over. Install Tooling (D) on impeller wheel (22) and the carrier, and
attach a hoist. Put the impeller wheel and carrier in position on housing (36). Remove Tooling
(D), and install the thirty-six bolts. Tighten the thirty-six bolts to a torque of 30 ± 5 N*m (22 ± 4
lb.ft.).
24. Heat race (18) to a temperature of 135° C (275° F) for a maximum time of ten minutes, and
install the race on shaft assembly (19).
25. Install seal ring (21) on the shaft assembly.

26. Heat bearing (20) to a temperature of 135° C (275° F) for a maximum time of ten minutes.
Install bearing (20) on the shaft assembly.
NOTICE
When the shaft assembly is installed in the converter group, use care to
avoid causing damage to seal ring (21).
27. Put SAE 30W oil on seal ring (21). Pull the ends of the seal ring together, and install shaft
assembly (19) and the bearing in the converter group.
28. Use Tool (C), and install retaining ring (17).
29. Install O-ring seal (14) in the carrier assembly (28). Put SAE 30W oil on the O-ring seal.
30. Install lip seal (13) in the carrier assembly with the lip of the seal toward the bearing. Put SAE
30W oil on the lip of the seal.
31. Install Tooling (B) on cover (12), and attach a hoist.
32. Use two 3/8 in - 24 NF guide bolts, and install cover (12) on the converter group. Make sure O
-ring seal (14) stays in position when the cover is installed.

33. Install eight bolts (10), and tighten to a to a torque of 54 ± 3 N*m (40 ± 2 lb.ft.).
34. Install yoke (55). Put O-ring seal (54) in position on yoke (55). Install retainer (53) and bolt
(52). Tighten bolt (52) to a torque of 122 ± 7 N*m (90 ± 5 lb.ft.).
35. Put bearing (5) in gear (6). Put gear (6) and one disc (9) on each side of the gear in position in
the carrier, and install shaft (7).
36. Align the hole in shaft (7) with the hole in the carrier, and install pin (8) flush with the surface
of the carrier.
37. Install spiral ring (3) in the inner diameter of carrier (2). Put retainer (4) in position next to the
spiral ring.
38. Put planetary carrier (2) with gears in position in gear (38) and on shaft assembly (19). Make
sure retainer (4) stays in position.
39. Use Tool (A), and install retaining ring (1).

End By:
a. install torque divider
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri May 1 13:22:07 UTC+0800 2020

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SENR94960026
Transmission Planetary (Power Shift)
SMCS - 3176-010
Remove & Install Transmission Planetary (Power Shift)
NOTE: This method for removing the transmission planetary is the least recommended procedure
to follow because:
a. More extensive Tooling is required.
b. It requires more effort to counterbalance the weight of the planetary during removal.
c. The bevel and transfer gears cannot be removed if it becomes necessary once the planetary has
been removed.
d. It is difficult to align the splines between the planetary and the transfer gears during assembly.
This procedure does not require the axle shafts to be removed, but the disadvantages listed above
should be considered before proceeding.
Start By:

a. remove main drive shaft
1. Remove the plug in the bottom of the transmission and bevel gear case, and drain the power
train oil. Loosen the bolts that hold the transmission suction screen cover in place, and drain the
oil from the transmission case. Approximately 159 liter (33 U.S. gal.) of oil will be drained. Install
the plug, and tighten the suction screen cover bolts.
2. Remove the yoke. Remove four bolts (1) and retainer (2) and the O-ring seal from the
transmission and bevel gear case.
3. Remove 17 bolts and washers (4), guard (3) and cover (5).
4. Disconnect electrical connector (6).
5. Disconnect tube assembly (7).

6. Attach FT1977 Adapter to the 5P7279 Adjustable Hook [both are parts of Tooling (A)].
7. Put a piece of plywood or similar material in position over the rear glass of the cab for
protection.
8. Adjust the top hanger [dimension (X)] to 25.4 cm (10 in). Adjust the lower hanger as far in as
possible.
9. Use a hoist, and attach Tooling (A) to the transmission cover.
10. Remove the small round cover, and install Tooling (B) on the transmission cover.
11. Remove four bolts (9) and 22 bolts (8) from the transmission cover. The axle shafts will
prevent the bevel gear case from moving out of the tractor case and frame.
12. The weight of the transmission planetary is 375 kg (825 lb). Put a long bar in Tooling (B), and
remove the transmission planetary from the tractor case and frame.
NOTE: The following steps are for installation of the transmission planetary.
13. Install Tooling (A) and (B) on the transmission planetary. Put O-ring seal (11) in position on
the transmission cover.
14. Put the transmission planetary in position in the tractor case and frame. Use a long bar to
counterbalance the planetary as it is installed. Align the splines of transmission output shaft (10)
with the transfer gears, and install the planetary. Install four bolts (9) and twenty-two bolts (8).

15. Remove Tooling (B), and install the round cover. Remove Tooling (A).
16. Install tube (7), connect electrical connector (6), install guard (3), cover (5) and 17 bolts and
washers (4).
17. Install retainer (2) and the yoke.
18. Fill the transmission and bevel gear case with oil. See the Operation And Maintenance Guide
for the proper type of oil and capacity.
End By:
a. install main drive shaft
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri May 1 13:22:56 UTC+0800 2020

Shutdown SIS
Previous Screen
SENR94960027
Transmission & Bevel Gears (Power Shift)
SMCS - 3159-029; 3176-012; 3176-011; 3256
Remove Transmission & Bevel Gears (Power Shift)
NOTE: Two methods exist to remove the power shift transmission planetary:
a. The method described here is; remove the transmission and bevel gears from the tractor, and
then separate the bevel gears from the planetary. This is the easiest and most preferred method,
since it allows the weight of the transmission and bevel gears to be supported by the rollers that
are attached to the bevel gear case.
b. The method described on Page 165 is the least recommended procedure, due to the additional
Tooling that is necessary, and the higher degree of difficulty.
Start By:
a. remove main drive shaft

NOTE: Approximately 129 liters (33 U.S. Gal) of power train oil will be drained in Steps 1 and 2.
1. Remove plug (4) and drain the power train oil from the main case and frame. Install plug (4)
after all of the oil has been drained.
2. Loosen the bolts that hold suction screen cover (5) in place and drain the remainder of the oil
from the transmission. Tighten the bolts after all of the oil has been drained.
3. Remove 17 bolts (2), guard (1) and cover (3).
4. Disconnect wire harness (4).
5. Disconnect tube assembly (5).
6. Remove yoke (6).
7. Remove four bolts (7). Remove the retainer and O-ring seal (8).

8.a. Remove the final drive cover.
b. Insert Tool (A) in to the left final drive by approximately 940 mm (37 inch). Rotate Tool (A) by
180 degrees in order to engage the sliding carrier. Then pull out Tool (A) by approximately 25
mm (1 inch), until the sliding carrier is off the bevel gear shaft. Rotate Tool (A) backward by 180
degrees in order to disengage the Tool from the carrier. Remove the Tool from the final drive.
NOTE: The distance for insertion may require an adjustment.
9. Remove the small cover on the transmission and install Tooling (B). Attach a hoist to Tooling
(B).
NOTICE
Four bolts (12) hold the transmission cover and the bevel gear case
together. Do not remove four bolts (12).
10. Remove twenty two bolts (11).

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11. The weight of the transmission and bevel gears is 864 kg (1900 lb). Use forcing bolts and
separate the transmission from the transmission and bevel gear case. Use the hoist and slowly pull
the transmission and bevel gears from the case. The transmission and bevel gears will roll out on
the tube assemblies.
The transmission and bevel gears must be supported when the hoist is
moved from the rear tube adapter [Tooling (B)] to the link brackets on
top of the transmission [Tooling (C)]. To prevent possible personal
injury, make sure the support is on a solid footing so the transmission
and bevel gears will not fall when the hoist is removed from Tooling (B).
12. Install Tooling (C) on the top of the transmission case. Put a floor jack or wood blocks in
position to support the transmission.
13. Remove the hoist from Tooling (B). Attach the hoist to Tooling (C) and remove the
transmission and bevel gears from the tube assemblies.
14. Remove large diameter O-ring seal (14) from the outer diameter of the transmission case.
Remove four O-ring seals (13) and (15) from the transmission and bevel gear case.
Install Transmission & Bevel Gears (Power Shift)

1. Put clean oil on the O-ring seals.
2. Install O-ring seal (14) on the transmission case. Install four O-ring seals (13) and (15) on the
transmission and bevel gear case.
3. Install Tooling (C) on top of the transmission case and attach a hoist.
4. Put the transmission and bevel gears in position so the rollers are on the tube assemblies.
The transmission and bevel gears must be supported when the hoist is
moved from the link brackets on top of the transmission [Tooling (C)]
to the rear tube adapter [Tooling (B)]. To prevent possible personal
injury, make sure the support is on a solid footing so the transmission
and bevel gears will not fall when the hoist is removed from Tooling (C).
5. Put a floor jack or wood blocks in position to support the transmission.
6. Install Tooling (B) on the transmission cover.
7. Remove the hoist from Tooling (C). Attach the hoist to Tooling (B).
8. Remove Tooling (C) from the top of the transmission.

9. Keep the transmission level with the hoist and push it evenly in the case.
10. Install twenty two bolts (11) that hold the transmission and bevel gears in the case.
11. Remove Tooling (B) and install the cover and gasket.
12. Install tube assembly (5).
13. Connect electrical connector.
14. Install cover (3), guard (1) and 17 bolts and washers (2).

Caterpillar cat d6 r track type tractor (prefix 4tr) service repair manual (4tr00001 and up)

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