Repair D7R Tractor Transmission

Service Repair Manual
Models
D7R TRACK-TYPE TRACTOR

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Product: TRACK-TYPE TRACTOR
Model: D7R TRACK-TYPE TRACTOR 3ZR
Configuration: D7R TRACTORS / POWERSHIFT / 3ZR00001-UP (MACHINE) POWERED BY 3306 ENGINE
Disassembly and Assembly
D7R Track-Type Tractor Power Train
Media Number -SENR8342-03 Publication Date -01/06/2010 Date Updated -28/06/2010
i01569561
Steering Clutch and Brake - Disassemble
SMCS - 4100-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 3
Start By:
A. Separate the final drive from the steering clutch and from the brake. Refer to Disassembly
and Assembly, "Final Drive, Steering Clutch, and Brake - Separate".
Illustration 1 g00620422
1. Remove bolts (1) and plate (2) .
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2. Remove sleeve bearings (3) from plate (2) .
3. Remove input hub (4) .
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4. Remove clutch plates (5) and friction discs (6) from hub (7) .
5. Remove piston (8) from hub (7) .
6. Remove sleeve bearing (9) .
7. Remove seals (10) and (11) from piston (8) .
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8. Turn over the brake assembly.
9. Remove ring (12) from hub (7) .
10. Fasten a hoist and Tooling (A) to housing (13). Remove the brake assembly from hub (7).
The weight of the brake assembly is 86 kg (190 lb).
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11. Remove bearing (14) from housing (13) .
12. Remove three rings (15) from hub (7) .
13. Remove bearing (16) from the hub.
Note: Bolts (19) hold a spring under compression behind the piston. Bolts (17) must be
removed before bolts (19).
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
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14. Remove bolts (17) and remove plate (18) from housing (13) .
15. Remove brake plates (20) and friction discs (21) from the housing.
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
Note: Bolts (19) hold a spring under compression. Carefully loosen bolts (19).
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16. Remove bolts (19) and manifold assembly (22) from housing (13) .
17. Remove seals (23) and (24) from manifold assembly (22) .
18. Remove piston (25) from housing (13) .
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Note: Note the direction of spring (26) before the spring is removed.
19. Remove spring (26) from housing (13) .
20. Remove O-ring seals (27) and (28) .
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Apr 8 19:54:13 UTC+0800 2021
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i01569580
Steering Clutch and Brake - Assemble
SMCS - 4100-016
Assembly Procedure
Table 1
Required Tools
B 1P-0510 Driver Group 1
1. Clean all the parts. Inspect all the parts for wear or for damage. If necessary, replace any
parts that are worn or damaged.
2. Install spring (26) in housing (13) .
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
3. Install O-ring seals (27) and (28) .
4. Position piston (25) in housing (13) .
5. Install seals (23) and (24) on manifold assembly (22). Install the seals on the manifold
assembly with the lip of the seals in the position that is shown. Put clean oil on the lip of the
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seals. Preload the seal rings before the installation procedure. This will prevent the seal
rings from being damaged. Use the following method to preload the new seal rings.
a. Place your hands on each end of the seal ring. Pull the ends past each other by several
inches. The ends should almost make contact. Be careful to maintain the circular
shape of the ring. This will make an even bend around the ring.
b. When the seal ring is in the groove of the hub, the ends should lightly make contact.
Do not bend the seal ring. This will make an uneven bend around the ring.
Note: Do not use this procedure to preload a used seal ring. Do not use this procedure
for cast iron seal rings. This procedure will cause used seal rings or cast iron seal
rings to break.
6. Align the oil holes in manifold assembly (22) with the holes in housing (13). Install the
manifold assembly and install bolts (19) .
7. Heat bearing (16) to a maximum temperature of 120 °C (248 °F). Use Tool (B) to install the
bearing on hub (7). Be certain that the bearing is squarely seated on the hub after the bearing
has cooled.
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8. Install three rings (15) on hub (7) .
9. Install bearing (14) in housing (13) .
10. Fasten a hoist and fasten Tooling (A) to housing (13). Lower the housing into the correct
position on hub (7) .
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11. Install ring (12) on hub (7) .
12. Install brake plate (20). Install friction disc (21). Install the remaining brake plates and
friction discs in an alternating fashion.
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13. Install plate (18) and bolts (17) on housing (13) .
14. Install sleeve bearing (9) in hub (7) .
15. Install seals (10) and (11) in piston (8) .
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16. Put clean oil on the seals. Install piston (8) in hub (7) .
17. Install input hub (4) .
18. Install clutch plate (5). Install friction disc (6). Install the remaining clutch plates and
friction discs in an alternating fashion.
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19. Install sleeve bearing (3) in plate (2) .
20. Position plate (2) on the housing. Install bolts (1) .
End By: Connect the final drive to the steering clutch and to the brake. Refer to Disassembly and
Assembly, "Final Drive, Steering Clutch, and Brake - Connect" in this module.
Thu Apr 8 19:55:09 UTC+0800 2021
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i01008366
Transmission and Bevel Gears - Separate
SMCS - 3010-076
Procedure to Separate the Transmission and Bevel Gears
Table 1
Required Tools
Tool Part Number Description Qty
A 1P-2420 Repair Stand for Transmissions 1
B 138-7575 Link Bracket 3
Start By:
A. Remove the transmission and bevel gears. See the procedure in Disassembly and Assembly,
"Transmission and Bevel Gears - Remove" in this module.
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Note: The transmission and bevel gears weigh 860 kg (1900 lb).
1. Install Tooling (A) on the bevel gear case. Attach a hoist.
2. Position the transmission and bevel gears on Tooling (B) .
3. Remove the four bolts that hold the transfer and bevel gears (1) to transmission (2) .
Note: The transfer and bevel gears weigh 380 kg (850 lb).
4. Separate the transfer and the bevel gears from transmission (2) .
Thu Apr 8 19:56:05 UTC+0800 2021
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Shutdown SIS
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i01008367
Transmission and Bevel Gears - Connect
SMCS - 3010-077
Procedure to Connect the Transmission and Bevel Gears
Table 1
Required Tools
Tool Part Number Description Qty
A 1P-2420 Repair Stand for Transmissions 1
1. Inspect the O-ring seals. Replace any seals that are damaged or worn. Install the O-ring
seals on the transmission.
Note: The transfer and bevel gears weigh 380 kg (850 lb).
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2. Install Tooling (A) on the bevel gear case. Attach a hoist.
3. Position the transfer and bevel gears (1) on transmission (2) .
4. Install the four bolts that hold the transfer and bevel gears (1) to transmission (2) .
Note: The transmission and bevel gears weigh 860 kg (1900 lb).
5. Remove the transmission and bevel gears from Tooling (B) .
6. Remove the hoist. Remove Tooling (A) from the bevel gear case.
End By: Install the transmission and bevel gears. See the procedure in Disassembly and
Assembly, "Transmission and Bevel Gears - Install" in this module.
Thu Apr 8 19:57:00 UTC+0800 2021
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Shutdown SIS
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i07141397
Bevel and Transfer Gears - Disassemble
SMCS - 3011-015
Disassembly Procedure
Table 1
Required Tools
C 8H-0663 Bearing Puller 1
D 8T-2839 Spanner 1
E 1P-1863 Retaining Ring Pliers 1
F
1P-2321 Puller Assembly 1
5P-4170 Step Plate 1
G Forcing Screw (1/2 inch by 13) 2
H Bolt (1/4 inch by 20) 1
Start By:
a. Separate the transmission and bevel gears.
Note: Put identifying marks on all of the shims as the shims are removed. The identifying marks
will ensure correct installation at assembly.
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1. Remove bolts (1) and roller brackets (2) from each side of the transfer gear case.
2. Remove bolts (4) that hold transfer gear case (3) to the bevel gear case.
3. Install Tooling (A) and attach a hoist to Tooling (A). Remove transfer gear case (3) from the
bevel gear case. The weight of the transfer gear case is approximately 101 kg (223 lb).
4. Remove bolts (5) that hold cage (6) to transfer gear case (3).
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5. Install Tooling (G). Tighten Tooling (G) evenly. Remove the cage and the shims from the
transfer gear case.
6. Remove lip seal (7) and O-ring seal (8) from cage (7).
Note: The bearing cup and the bearing will be damaged if the bearing cups are removed.
7. Remove bearing cup (9) and bearing (10) from cage (6), if necessary.
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8. Remove transfer gear (11) from transfer gear case (3).
Note: The bearing cones will be damaged if the bearing cones are removed from the
transfer gear.
9. Remove bearing cones (12) from transfer gear (11), if necessary.
10. Remove the bolts, and install Tooling (G) in cage (13). Tighten Tooling (G) evenly, and
remove cage (13) and the shims from transfer gear case (3).
11. Remove bearing cup (14) from cage (13).
12. Remove bearing cup (15) from transfer gear case (3).
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13. Remove the bolt and the retainer from pinion gear assembly (17).
14. Install Tooling (B) and attach a hoist. Remove pinion gear assembly (17) from the bevel
gear case. The weight of the pinion gear assembly is approximately 33 kg (73 lb).
15. Remove the bearing cup for the pinion gear assembly from the bevel gear case.
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16. Put the pinion gear assembly in a press. Remove transfer gear (19) and bearing cone (18)
from pinion gear (20).
17. Use Tooling (C) and a press to remove bearing cone (21) from pinion gear (20).
18. Bend the locking tab away from spanner nut (23).
19. Place a pry bar between the bolt heads on the bevel gear. The prybar will prevent rotation of
the bevel gear shaft.
20. Use Tooling (D) to remove spanner nut (23). Remove lockwasher (22) and the tongue
washer.
21. Use nylon straps and a hoist for support of the bevel gear and of the shaft to remove the
bearings. The weight of the bevel gear and the shaft (24) is approximately 55 kg (121 lb).
22. If necessary, remove tube assemble (24A).
Note: Note the orientation of tube assembly (24A) for installation purposes.
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23. Remove the bolts and install Tooling (G). Tighten Tooling (G) evenly and remove cage
(25), bearing cone (27), spacer (28), and bearing cone (27). Remove shims (26) from the
bevel gear case.
24. Remove the following components from cage (25): bearing cup (29), center ring (30) and
bearing cup (29).
25. Remove the bolts and Tooling (G). Tighten Tooling (G) evenly and remove cage (31) and
the bearing from the bevel gear case.
26. Use a hoist and remove bevel gear and shaft (24) from the bevel gear case.
27. Install Tooling (H), and remove dowel (33) from cage (31). Remove race and roller
assembly (32).
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28. Use Tooling (E) and remove the retaining ring from bevel gear shaft (24).
29. Use Tooling (F) and remove bearing race (35) from the bevel gear shaft.
30. Remove bolts (34) and the nuts. Install Tooling (H) in bevel gear (36). Tighten Tooling (H)
evenly, and remove the bevel gear from the bevel gear shaft.
31. Remove the tube assemblies from the bevel gear housing.
Thu Apr 8 19:57:56 UTC+0800 2021
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