Caterpillar cat d6 r track tractor (prefix 7gr) service repair manual (7gr00001 and up)

Service Repair Manual
Models
D6R TRACK TRACTOR

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Product: TRACK-TYPE TRACTOR
Model: D6R TRACK-TYPE TRACTOR 7GR
Configuration: D6R Track-Type Tractor Differential Steering 7GR00001-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
SENR94960032
Final Drive, Planetary And Brake (Right Side)
SMCS - 4132-010
Remove And Install Right Final Drive, Planetary And Brake
Start By:
a. separate track (right side)
Before doing any service work which requires separating a track, a
thorough inspection of the front track roller frame must be made. See
Special Instruction, Form No. SMHS8273-02.
1. Remove the drain plug from the transmission and bevel gear case, and drain the power train oil.
Install the drain plug.
1/4D6R Track-Type Tractor Differential Steering 7GR00001-UP (MACHINE) POWERE...
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2. Turn the final drive until drain plug (2) is on the bottom as shown. Remove drain plug (2), and
drain the oil from the final drive. Install the drain plug.
3. Remove the three bolts and cover (1) from the final drive. Remove the O-ring seal from the
cover.
4. Install Tooling (A) and remove outer axle (3).
5. Adjust the top bracket on Tooling (B) so that dimension (X) is 165 mm (6.5 in.). The lower
mounting bracket must be installed with the spacers outward as shown.

6. Remove two of the bolts from the sprocket segment. Fasten a hoist and Tooling (B) on the final
drive.
NOTICE
Do not remove two bolts (5) that hold the final drive to the planetary
and brake.
7. Remove twenty six bolts (4) that hold the final drive, planetary and brake to the frame.
8. Remove two bolts (6) that hold the planetary and brake to the frame.
9. Using Tooling (B) and hoist, remove the final drive, planetary and brake as a unit. The weight
of the final drive, planetary and brake assembly is 577 kg (1270 lb.).
10. Remove O-ring seals (7) and (8) from the planetary and brake housing.
NOTE: The following steps are for installation of the right final drive, planetary and brake.
11. Install O-ring seals (7) and (8) on the planetary and brake housing. Put clean oil on the O-ring
seals.
12. Fasten a hoist and Tooling (B) on the final drive. Make an adjustment to Tooling (B) if
needed, to level the final drive, planetary and brake.
13. Put the final drive, planetary and brake in position on the tractor.
14. Install two bolts (6) that hold the planetary and brake in position on the frame.

15. Install twenty six bolts (4), and remove the hoist and Tooling (B).
16. Put SAE 30W oil on the threads of the two segment bolts, and install the two bolts, washers
and nuts. Tighten the nuts to a torque of 175 ± 40 N·m (130 ± 30 lb.ft.). Tighten the nuts 1/3 of a
turn more.
17. Using Tooling (A), install outer axle (3).
18. Install the O-ring seal on cover (1). Put cover (1) in position on the final drive, and install the
three bolts.
19. Fill the final drive with oil to the correct level. See the Operation And Maintenance Manual.
20. Fill the transmission and bevel gear case with oil to the correct level. See the Operation And
Maintenance Manual.
End By:
a. connect track (right side)
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All Rights Reserved.
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Sun Sep 1 15:13:23 UTC+0800 2019

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D6R TRACK-TYPE TRACTOR POWER TRAIN
SENR94960033
Right Planetary And Brake
SMCS - 4132-015; 4132-016
Disassemble Right Planetary And Brake
Start By:
a. remove final drive, planetary and brake (right side)
1. Position the right final drive, planetary and brake as shown.
2. Remove the two forcing screws and nuts that fasten right planetary and brake (1) to final drive
(2). The two forcing screws and nuts were installed during the removal of the right final drive,
planetary and brake.
3. Attach Tooling (A) and a hoist to right planetary and brake (1). Install three 3/8 in - 16 NC
forcing screws in the final drive hub. Tighten the forcing screws evenly, and remove right
planetary and brake (1) from final drive (2). The weight of the right planetary and brake is 136 kg
(300 lb.).

NOTICE
Remove bolts (3) evenly to relieve the spring pressure behind gear (4).
4. Remove bolts (3), and remove gear (4) from housing (5).
5. Remove four discs (6) and the three plates from the housing.
NOTICE
Do not let planetary carrier (10) fall when it is pressed from housing
(5).

6. Remove bolts (7) and plate (8). Use a press and Tooling (B) to remove planetary carrier (10)
from housing (5).
7. Remove bearing cone (9) from the housing.
8. Remove ring (14) from carrier (11).
9. Remove bolts (13), and remove slinger (12) from the carrier.
NOTICE
Bearing cone (15) must be destroyed to remove it from the carrier.
10. If necessary, remove bearing cone (15) from carrier (11).
11. Use a hammer and punch to push pin (17) in shaft (16).
12. Remove shaft (16), gear (19), two discs (20) and two bearings (21) from carrier (11).
13. Remove pin (17) from shaft (16).

14. Remove the remaining two gears.
15. Remove gear assembly (18) from carrier (11).
NOTICE
Remove bolts (22) evenly to relieve the spring pressure behind retainer
(23).
16. Remove bolts (22), and remove retainer (23) from piston (24).
17. If necessary, remove bearing cups (25) from retainer (23).
18. Remove seal ring (26) from the retainers.
19. Remove piston (24) and O-ring seal (27) from the housing.

20. Remove seal ring (28) from piston (24).
21. If necessary, remove ring (29) from piston (24).
22. Remove spring (30) and ring (31) from housing (5).
Assemble Right Planetary And Brake
1. Put ring (31) and spring (30) in position in housing (5). Spring (30) must be installed with the
convex side up.

2. Install ring (29) on piston (24).
3. Install seal ring (28) in piston (24). Install seal ring (28) with the lip of the seal ring as shown.
Put clean oil on the seal ring.
4. Install piston (24) and O-ring seal (27) in the housing.
5. If bearing cups (25) were removed, lower the temperature of the bearing cups, and install them
in retainer (23).
6. Install seal ring (26) in retainer (23). Install seal ring with the lip of the seal ring as shown. Put
clean oil on the seal ring.
7. Position retainer (23) on piston (24). Make sure the oil passage in retainer (23) is aligned with
the oil passage and O-ring seal in the housing. Install bolts (22) that hold retainer (23) in place.

8. Position gear assembly (18) in carrier (11).
9. Install two bearings (21) in gear (19).
10. Put discs (20) and gear (19) in position in carrier (11), and install shaft (16).
NOTE: Make sure the rubbers in pin (17) is not damaged. If the rubber in the pin is damaged,
replace the pin.
11. Align the hole in shaft (16) with the hole in carrier (11), and install pin (17). Install the pin
until it is even with the surface of the carrier.
12. Install the remaining two gears in the carrier.
NOTE: If bearing cone (15) was removed from carrier (11), a new bearing must be installed.
13. Heat bearing cone (15) to a maximum temperature of 135° C (275° F). Install the bearing cone
or carrier (11). Make sure the bearing cone is seated on the carrier.
14. Coat the flange of slinger (12) which contacts carrier (11) with 8C8422 sealant. Put slinger
(12) in position on carrier (11), and install bolts (13).
15. Install ring (14) in carrier (11).
16. Position housing (5) on carrier (11).

17. Heat bearing cone (9) to a maximum temperature of 135° C (275° F), and install, the bearing
cone on carrier (11).
18. Position plate (8) on the carrier, and install bolts (7).
19. Start with a disc, and install four discs (6) and the three plates. Alternate the discs and plates.
20. Position gear (4) on housing (5), and install bolts (3).
21. Use a hoist and Tooling (A) to position right planetary and brake (1) on final drive (2). Install
the two bolts that fasten the right planetary and brake on the final drive.
End By:
a. install final drive, planetary and brake (right side)
Sun Sep 1 15:14:08 UTC+0800 2019

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D6R Track-Type Tractor Machine Systems
i01007311
Bulldozer Blade - Remove and Install
SMCS - 6060-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-9759 Stand (pair) 1
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
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.
Note: Mark all components for correct installation. When you disconnect the hoses, cap the
connections in order to keep the system clean.
Illustration 1 g00596992
1. Disconnect hose assemblies (2) from manifold (1) .
2. Remove the following components from the lift cylinders: bolts (3), cap (5) and shims (4).
Retract the lift cylinders.

3. Remove the following components from the stabilizer link: bolts (8), cap (6) and shims (7) .
4. Install Tooling (A) under each push arm (9), as shown.

5. Remove the following components from each push arm: bolts (12), cap (11) and shims
(10) .
6. Secure stabilizer link (14) to bulldozer blade (13). Move the machine away from the
bulldozer blade.
Installation Procedure
Table 2
Required Tools
A 1U-9759 Stand (pair) 1
Reference: Refer to Specifications, "Push Arm" in the Service Manual for your machine.

1. Move the machine to bulldozer blade (13), as shown.
2. Connect each push arm to the trunnion on the track roller frame by installing the following
components: shims (10), cap (11) and bolts (12). Tighten the bolts to a torque of 1800 ± 200
N·m (1300 ± 150 lb ft).
3. Connect the stabilizer link to the trunnion on the machine by installing the following
components: shims (7), cap (6) and bolts (8). Tighten the bolts to a torque of 430 ± 60 N·m
(320 ± 45 lb ft).

4. Extend the lift cylinders to the trunnion on the bulldozer blade. Connect each lift cylinder to
a trunnion on the bulldozer blade by installing the following components: shims (4), cap (5)
and bolts (3). Tighten the bolts to a torque of 430 ± 60 N·m (320 ± 45 lb ft).
5. Connect hose assemblies (2) to manifold (1). Tighten the bolts on the half flanges to a
torque of 50 ± 10 N·m (37 ± 7 lb ft).
6. Operate the lift cylinders for several cycles in order to purge air from the system. Fill the
hydraulic tank.
Reference: Refer to the Operation and Maintenance Manual, "Lubricant Viscosities and
Refill Capacities" for your machine.
Sun Sep 1 16:51:02 UTC+0800 2019

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i01007322
Bulldozer Lift Cylinder - Remove
SMCS - 5102-011
Removal Procedure
Table 1
Required Tools
A 138-7573 Link Bracket 2
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered, oil is cool before
removing any components or lines. Remove the oil filler cap only when
the engine is stopped, and the filler cap is cool enough to touch with
your bare hand.
NOTICE

containing fluids.
Note: Mark all components for correct installation. When you disconnect the hoses, cap the
connections in order to keep the system clean.
1. Remove bolts (1) with the nuts. Remove cap (3) with the shims from the cylinder rod.
2. Move the cylinder rod into the lift cylinder and away from bulldozer blade trunnion (2) .
3. Place cap (3) with the shims on the cylinder rod. Loosely install bolts (1) with the nuts.

4. Attach Tooling (A) on lift cylinder (4). Attach a hoist.
5. Disconnect hoses (5) from quick-drop valve (6) .
6. Remove bolts (7) and caps (8) that hold the lift cylinder to yoke (9). Remove the lift
cylinder from the machine. The lift cylinder weighs approximately 200 kg (440 lb).
Sun Sep 1 16:51:49 UTC+0800 2019

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i01007329
Bulldozer Lift Cylinder - Disassemble
SMCS - 5102-015
Disassembly Procedure
Table 1
Required Tools
A
1U-9901 Hydraulic Cylinder Repair Stand 1
3S-6224 Hydraulic Pump 1
B 1U-8792 Chain Wrench 1
C
8T-5245 Torque Multiplier 1
1P-0851 Spline Adapter 1
1P-0852 Male Adapter 1
5P-1748 Impact Socket 1
Start By:
A. Remove the bulldozer lift cylinder. See the procedure in Disassembly and Assembly, "Bulldozer Lift
Cylinder - Remove" in this module.
Reference: Refer to Specifications, "Bulldozer Lift Cylinder" in the Service Manual for your machine.

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1. Remove the guard from lift cylinder (1) .
NOTICE
containing fluids.
2. Mark hose assembly (2) and hose assembly (4) for installation. Disconnect the hose assemblies from
the lift cylinder.
3. Remove hose assembly (4) and tube assembly (3) from lift cylinder (1) .
4. Remove hose assembly (2) from lift cylinder (1) .

5. If necessary, remove bearings (5) from the lift cylinder.
6. Place the lift cylinder on Tooling (A). The lift cylinder weighs approximately 200 kg (440 lb).
7. Use Tooling (B) in order to remove head (9) from lift cylinder (7) .
8. Support cylinder rod (8) with Tooling (A) .
9. Use Tooling (A) in order to separate the hydraulic cylinder from cylinder rod (8) .
10. Use Tooling (C) in order to loosen the bolt on the end of cylinder rod (8). Remove Tooling (C) and
the bolt.
11. Remove piston (10) from cylinder rod (8) .
12. If necessary, use Tooling (A) in order to remove head (9) from cylinder rod (8) by the procedure in
Steps 12.a through 12.d:
a. Position the hydraulic cylinder on cylinder rod (8) and on head (9) .
b. Rotate head (9) in order to install the head on the hydraulic cylinder.
c. Use Tooling (A) in order to separate head (9) from cylinder rod (8) .
d. Rotate head (9) in order to remove the head from the hydraulic cylinder.
13. Remove wear ring (12) and seal (13) from piston (10) .
14. If necessary, use a press in order to push plungers (11) with the inserts out of piston (10). Then,
remove the spacers under the plungers.
15. Remove O-ring seal (16) and backup ring (15) from head (9) .
16. Remove seals (17), (14), and (18) from the head.
Sun Sep 1 16:52:37 UTC+0800 2019

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i01007335
Bulldozer Lift Cylinder - Assemble
SMCS - 5102-016
Assembly Procedure
Table 1
Required Tools
A
1U-9901 Hydraulic Cylinder Repair Stand 1
3S-6224 Hydraulic Pump 1
B 1U-8792 Chain Wrench 1
C
8T-5245 Torque Multiplier 1
1P-0851 Spline Adapter 1
1P-0852 Male Adapter 1
5P-1748 Impact Socket 1
D 1P-0510 Driver 1
Reference: Refer to Specifications, "Bulldozer Lift Cylinder" in the Service Manual for your machine.
1. Inspect the components for wear and for damage. Replace the components with new components, if
necessary. Make sure that the components are clean. Apply clean oil to the surfaces of the
components during assembly.

2. Install seal (14) and seal (18) in head (9). The lip of seal (14) must be oriented toward seal (18) .
3. Use Tooling (D) in order to install seal (17) in the head.
4. Align the hydraulic cylinder and cylinder rod (8) on Tooling (A) .
5. Position head (9) in the hydraulic cylinder.
6. Apply clean oil to the seals in head (9). Make sure that the cylinder rod is aligned with the seals in
head (9). Use Tooling (A) in order to connect cylinder rod (8) with the cylinder and with the head.
7. Use Tooling (A) in order to separate the cylinder from head (9) and from cylinder rod (8) .
8. Install the spacers under plungers (11) .
Note: Align the flat sides of two inserts (19) across the piston, as shown. See Illustration 1.
9. Install plungers (11) and inserts (19) in piston (10) .
10. Install backup ring (15) and O-ring seal (16) on head (9). O-ring seal (16) must be oriented toward
the cylinder during installation.
11. Position piston (10) on cylinder rod (8) .
12. Install the rubber expansion ring on piston (10). Install seal (13) over the rubber expansion ring.
13. Install wear ring (12) on the piston.
14. Apply clean oil to the threads of bolt (20). Install bolt (20) with the washer in the end of cylinder rod
(8) .
15. Use Tooling (C) in order to tighten bolt (20) to a torque of 3600 ± 400 N·m (2700 ± 300 lb ft).
Remove Tooling (C) .
16. Apply clean oil to the seals of the piston and of the head. Use Tooling (A) in order to connect the
cylinder to the cylinder rod and to the head.
Note: Position the cylinder rod in contact with the piston during the installation of the head.
17. Install the head on cylinder (7). Tighten the head to a torque of 600 ± 130 N·m (440 ± 95 lb ft).

18. Heat bearings (5) to a maximum temperature of 135 °C (275 °F). Install one bearing on each side of
the lift cylinder. The bearings must not extend beyond the ends of the trunnion. The correct outside
diameter of the bearings after installation is 63.089 ± 0.058 mm (2.484 ± 0.002 inch).
19. Install the O-ring seal in hose assembly (2). Install hose assembly (2) on lift cylinder (1) .
20. Install the O-ring seals in tube assembly (3). Install tube assembly (3) and hose assembly (4) on lift
cylinder (1) .
21. Install the guard on lift cylinder (1) .
End By: Install the bulldozer lift cylinder. See the procedure in Disassembly and Assembly, "Bulldozer
Lift Cylinder - Install" in this module.
Sun Sep 1 16:53:24 UTC+0800 2019

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i02603536
Bulldozer Lift Cylinder - Install
SMCS - 5102-012
Installation Procedure
ReferenceRefer to Specifications, "Cylinder Mounting" in the Service Manual for your machine.
1. Attach Tooling (A) on lift cylinder (4) . Attach a hoist. The lift cylinder weighs
approximately 200 kg (440 lb).

2. Position the lift cylinder on yoke (9) . Install caps (8) and bolts (7) that hold the lift cylinder
to the yoke.
3. Remove the cap with the shims from the cylinder rod. Position the cylinder rod for
installation on the bulldozer blade trunnion (2) .
4. Install cap (3) with the shims on the cylinder rod. Install bolts (1) with the nuts. Tighten the
nuts to a torque of 430 ± 60 N·m (315 ± 45 lb ft).

5. Connect hoses (5) to quick-drop valve (6) . Tighten the eight bolts that fasten the half
flanges to a torque of 50 ± 10 N·m (37 ± 7 lb ft).
6. Remove the hoist and Tooling (A) .
7. Operate the lift cylinders for several cycles in order to purge air from the system. Fill the
hydraulic tank.
ReferenceRefer to the Operation and Maintenance Manual, "Lubricant Viscosities and
Refill Capacities" for your machine.
Sun Sep 1 16:54:11 UTC+0800 2019

Caterpillar cat d6 r track tractor (prefix 7gr) service repair manual (7gr00001 and up)

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