Caterpillar cat d6 r track type tractor (prefix 6hr) service repair manual (6hr00001 and up)

Service Repair Manual
Models
D6R Track-Type Tractor

Shutdown SIS
Previous Screen
Product: TRACK-TYPE TRACTOR
Model: D6R TRACK-TYPE TRACTOR 6HR
Configuration: D6R XR & D6R LGP TRACTORS / POWERSHIFT / 6HR00001-UP (MACHINE) POWERED BY 3306 ENGINE
Disassembly and Assembly
D6R TRACK-TYPE TRACTOR POWER TRAIN
Media Number -SENR8357-02 Publication Date -01/05/2005 Date Updated -03/06/2014
SENR83570007
Front Track Roller Frames
SMCS - 4151-011; 4151-012
Remove Front Track Roller Frames
Start By:
a. Separate track
NOTE: The track roller frame does not have an oil drain plug. To avoid an oil spill when the front
track roller frame is removed from the rear track roller frame, use a vacuum pump in the opening,
near the track adjuster valve, to remove the oil. If a vacuum pump is not available, the oil will
drain when the front track roller frame is removed from the rear track roller frame.
1. Remove six bolts (1) and guide assembly (2) from each side of the rear track roller frame.
Remove the O-ring seal from each end of the guide assemblies.
1/6
D6R XR & D6R LGP TRACTORS / POWERSHIFT / 6HR00001-UP (MACHINE) P...
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2. Remove one bolt from each side of the front idlers and install Tooling (A).
3. Attach one end of Tooling (B) to Tooling (A). Attach the other end of the Tooling (B) to a
stationary object. Use Tooling (B) to pull the front track roller frame out of the rear track roller
frame until the bearing is free from the seal. Remove Tooling (B).
4. The weight of the front track roller frame is 546 kg (1200 lb). Put a nylon strap (3) around the
front track roller frame and attach a hoist. Adjust the strap so the front track roller frame will be
level and remove it from the rear track roller frame.
5. Put the front track roller frame on blocks as shown. Use a torch and remove bearing (4) from
the front track roller frame if necessary.
6. Remove seal assembly (5), ring (6), and bearing (7) from the rear track roller frame.
Install Front Track Roller Frame
2/6
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1. If it is necessary to replace bearing (1), remove the track adjuster from the front track roller
frame. See Remove and Install Track Adjuster in this module for the proper procedure.
2. Put dry ice in the front track roller frame tube to lower the temperature of the tube. Heat bearing
(1) to a maximum temperature of 175° C (350° F). Install bearing (1) onto the front track roller
frame. Install the bearing so that it is a maximum of 1 mm (.039 in) away from the plate at the
front of the roller frame.
3. Install the track adjuster into the front track roller frame. See Remove And Install Track
Adjuster in this module for the proper procedure.
4. Install bearing (2) and ring (3) into the rear track roller frame.
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NOTICE
Make sure Tooling (A) and Tooling (B) put pressure on the outer ring
of seal assembly (4) when they are used to install the seal assembly into
the rear track roller frame.
5. Put 7M7456 Bearing Mount on the outer diameter of seal assembly (4). Put seal assembly (4)
and Tooling (A) in position in the rear track roller frame as shown.
6. Tighten two nuts [part of Tooling (A)] evenly and pull seal assembly (4) in until it is even with
the front surface of the rear track roller frame.
7. Use Tool (B) and install seal assembly (4) to the bottom of the counterbore in the rear track
roller frame.
8. Put seal guard [Tooling (C)] in position on the inner diameter of seal assembly (4).
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NOTICE
Use care to avoid causing damage to seal assembly (4) and bearing (2)
when the front track roller frame is installed.
9. Put SAE 30 oil on the outer diameter of the front track roller frame bearing (1).
10. Put a nylon strap around the front track roller frame. Adjust the nylon strap so the front track
roller frame is level. Put the front track roller frame into the rear track roller frame and allow
enough room to remove Tooling (C). Remove Tooling (C).
11. Install Tooling (D) onto the rear track roller frame. Install Tooling (E) onto the front track
roller frame. Attach the ratchet pullers [part of Tooling (D)] to Tooling (E).
12. Evenly, pull the front track roller frame into the rear track roller frame using Tooling (D) and
(E). Make sure the grooves in the front track roller frame are aligned with the guide locations.
Remove Tooling (D) and (E).
13. Install the bolts that hold the front idler caps and tighten them to a torque of 475 ± 50 N·m
(350 ± 37 lb ft).
NOTE: Install guide (5) on the inside of the rear track roller frame first for easier installation.
14. Make sure the guide slots are aligned. Put the O-ring seals in position on the guides. Put
guides (5) into the track roller frame and install the six bolts that hold each one.
NOTE: The tracks must be installed and the correct track adjustment made before the oil level can
be checked in the recoil spring compartment.
15. Fill the recoil spring compartment with oil to the correct level See the Operation And
Maintenance Guide for the type and capacity of oil to be used.
End By:
5/6
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a. connect track
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun May 10 13:11:22 UTC+0800 2020
6/6
2020/5/10

Shutdown SIS
Previous Screen
SENR83570008
Recoil Springs
SMCS - 4158-011; 4158-012
Remove Recoil Springs
NOTE: All part numbers in this operation are part of Tooling (A), (B), (C), or (D).
Start By:
1/11
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a. remove track adjusters
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. SMHS8273-01.
1. Put the front track roller frame on wood blocks so it is level (horizontal). Remove the bolts and
locks that hold retainer (7) in position.
NOTICE
The procedure that follows must not be used unless stop plates (16)
have been welded on each of the four openings (slots) in the 6V2168
Plate. These plates make proper alignment with the 6V2168 Plate on
the studs and prevent movement of the studs from the openings (slots).
The dimensions of the stop plates are 25.4 mm (1.00 in) x 50.8 mm (2.00
in) x 9.6 mm (.38 in).
The recoil spring retainer must never be more than 12.7 mm (.50 in)
away from the recoil spring while the recoil spring is removed. Make
sure the pressure on the pressure gauge of Tooling (A) and (B)
gradually decreases during all the steps of the next operations. If there
is a sudden decrease of pressure before the recoil spring retainer is
approximately 146 mm (5.75 in) outside the roller frame, the spring and
guide assembly has not released correctly. Do not remove the recoil
spring retainer at this time. Personal injury can be the result. Contact
Caterpillar for the nearest Caterpillar Dealer for further instructions.
Use only the Tooling and cylinder listed in this procedure. Do not use
other cylinders because they can cause enough force to break the
tension rods. This can result in personal injury or death.
2/11
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NOTE: Mark the position of retainer (7) for assembly purposes.
2. Install Tooling (A) as follows to remove the recoil spring:
a. Install four 5P9605 Studs (2) into the roller frame.
b. Put 6V2168 Plate (1) in position on the studs. Put two FT1408 spacers [modified to be 51 mm
(2.0) in long] on each of the studs. Put one 5P8249 washer, one 5P8247 washer, and one 7B6683
nut (8) on each stud.
c. Put 5P5214 sleeve (4), FT1395 Adapter Plate (hidden) 1P1842 Puller Adapter (3) and 6V3175
Cylinder (6), in position. Put 5P4184 stud (5) through the center holes to hold everything on
position.
Make sure the 6V9061 Hand Pump Group pressure line from the head
end of the cylinder group is connected through a 1S8937 Valve so the
pressure can be controlled to gradually release the recoil spring.
d. Connect the 6V9061 Hand Pump Group to the 6V3175 Cylinder Group (6) until the rod is
extended 44 mm (1.75 in)
e. Make sure the 5P9605 studs are parallel and equal distance from stop plates (10) on 6V2168
Plate (1).
f. Position the FT1395 Adapter Plate in the center of the recoil spring retainer. Center adapter (3),
sleeve (4) and cylinder (6) and tighten four 6B6683 Nuts (8) to hold the assembly in correct
alignment.
g. Measure and adjust nuts (8) so that all four corners of plate (1) are the same distance from the
face of the roller frame.
h. Use only enough pressure to extend the rod of the cylinder enough to compress the recoil spring
so the recoil spring retainer can be turned. Close the 1S8937 Valve and turn the pump group valve
to the "RETRACT CYLINDER ROD" position.
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i. Use a piece of 12.7 mm x 50.8 mm x 609.6 mm (.50 in x 2 in x 24 in) bar stock [part of
Tooling (A)] and turn recoil spring retainer counterclockwise to move it out of the roller frame
12.7 mm (.50 in). Slowly release the cylinder pressure through the 1S8937 Valve to let the recoil
spring extend 12.7 mm (.50in) (as measured on the cylinder rod). When the cylinder rod retracts
12.7 mm (.50 in), close the 1S8937 Valve.
j. Turn recoil spring retainer (7) out 12.7 mm (.50 in). Slowly, release the cylinder pressure
through the 1S8937 Valve to retract the cylinder rod the same distance. Close the 1S8937 Valve.
k. Repeat Step 2j.
To prevent possible personal injury, make sure the recoil spring is
against recoil spring retainer before a Tooling change is made.
l. Slowly release the cylinder pressure through the 1S8937 Valve to retract the cylinder rod and
allow the recoil spring to be against recoil spring retainer.
NOTE: Tooling (A) and (B) are identical except for FT1408 Spacers (11) and FT1409 Spacers (9)
[modified to 50.8 mm (2 in) long].
3. Install Tooling (B) as follows to remove the recoil spring:
a. Remove nuts (8) and the washers. Remove spacers (9).
b. Extend the 6V3175 Cylinder Group until the rod is extended 44 mm (1.75 in).
c. Install four FT1408 Spacers (11) on four studs (2). Install the washers and four nuts (8).
Measure and adjust the four nuts so all four corners of 6V2168 Plate (1) are the same distance
from the face of the roller frame.
4/11
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d. Use only enough pressure to extend the rod of the cylinder enough to compress the recoil spring
so the recoil spring retainer can be turned. Close the 1S8937 Valve, and turn the pump group
valve to the "Retract Cylinder Rod" position.
e. Turn recoil spring retainer (7) out and retract the cylinder rod in increments of 12.7 mm (.50
in).
NOTE: Tooling (B) and (C) are identical except for FT1408 Spacers (11) and FT1409 Spacers
(12).
4. Install Tooling (C) to remove the recoil spring as follows:
a. Remove nuts (8) and the washers. Remove four spacers (11) from studs (2).
c. Install four FT1409 Spacers (12) on four studs (2). Install the washers and four nuts (8).
Measure and adjust the four nuts (8) so all four corners of 6V2168 Plate (1) are the same distance
from the face of the roller frame.
e. Turn recoil spring retainer (7) out and retract the cylinder rod in increments of 12.7 mm (.50
in).
To prevent possible personal injury, make sure the recoil spring is
against recoil spring retainer before a Tooling change is made.
f. Slowly release the cylinder pressure through the 1S8937 Valve to retract the cylinder rod and
allow the recoil spring to be against recoil spring retainer.
5/11
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NOTE: Tooling (C) and (D) are identical except for FT1409 Spacers (12).
5. Install Tooling (D), as follows to remove the recoil spring:
a. Remove nuts (8) and the washers. Remove four spacers (12) from studs (2).
c. Install the washers and four nuts (8). Measure and adjust the four nuts (8) so all four corners of
6V2168 Plate (1) are the same distance from the face of the roller frame.
e. Turn recoil spring retainer (7) out and retract the cylinder rod in 12.7 mm (.50 in) increments,
until the force of the recoil spring is completely released. The total distance to release the recoil
spring tension should be 146 mm (5.75 in).
6. Remove Tooling (D).
6/11
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7. The weight of retainer (7) is 24.5 kg (54 lb). Use a nylon strap and a hoist and remove retainer
(7) and the plate behind it from the track roller frame.
8. The weight of recoil spring (B) is 68 kg (150 lb). Put a bar in position in the recoil spring. Use a
nylon strap on the bar next to the spring and attach a hoist. Counterbalance the recoil spring at the
opposite end of the bar. Use the hoist and remove recoil spring (13) from the track roller frame.
Install Recoil Springs
7/11
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1. Put a bar into recoil spring (13). Put a nylon strap on the bar and attach a hoist.
2. Counterbalance the recoil spring at the opposite end of the bar. Use the hoist and put recoil
spring (13) into the front track roller frame. Slide the recoil spring into the roller frame as far as it
will go and remove the bar.
3. Put plate (14) into position in the track roller frame against the recoil spring.
4. Put retainer (7) into position in the front track roller frame. Use the bar stock [part of Tooling
(D)] and install retainer (7) as far as possible.
NOTE: For correct assembly of Tooling (A), (B), (C) and (D), see "Remove Recoil Springs." All
part numbers in this story are part of Tooling (A), (B), (C) or (D).
5. Install Tooling (D) on the front track roller frame as shown. Install the recoil spring as follows:
a. Measure and adjust 6B6683 Nuts (8) so that all four corners of the 6V2168 Plate (1) are the
same distance from the face of the roller frame.
8/11
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To prevent possible personal injury from flying parts, there must never
be more than 12.7 mm (.50 in) distance between the recoil spring and
the recoil spring retainer during installation of the recoil spring.
b. Slowly extend the cylinder rod to compress the recoil spring while recoil spring retainer (7) is
installed with bar.
c. When the fall cylinder stroke has been used, hold the recoil spring in position with the recoil
spring retainer. Retract the cylinder rod.
d. Remove 6B6683 Nuts (8), the 5P8247 Washers, and the 5P8249 Washers.
NOTE: Tooling (C) and (D) are identical except for the FT1409 Spacers (12).
6. Install Tooling (C) as follows to install the recoil spring and retainer.
a. Install FT1409 Spacers (12) on 5P9605 Studs (2). Install the washers and nuts (8).
b. Measure and adjust 6B6683 Nuts (8) so that all four corners of 6V2168 plate (1) are the same
distance from the face of the roller frame.
c. Slowly extend the cylinder rod to compress the recoil spring while recoil spring retainer (7) is
installed with bar [part of Tooling (C)].
d. When the full cylinder stroke has been used, hold the recoil spring in position with the recoil
spring retainer (7). Retract the cylinder rod.
e. Remove 6B6683 Nuts (8), the Washers, and FT1409 Spacers (12).
9/11
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NOTE: Tooling (B) and (C) are identical except for the FT1408 Spacers (11) and FT1409 Spacers
(12).
7. Install Tooling (B) as follows to install the recoil spring and retainer.
a. Install four FT1408 Spacers (11), the washers and nuts (8) onto 5P9605 Studs (2).
installed with bar [part of Tooling (B)].
d. When the full cylinder stroke has been used, hold the recoil spring in position with the recoil
spring retainer (7). Retract the cylinder rod.
e. Remove 6B6683 Nuts (8), the washers, and FT1408 Spacers (11).
NOTE: Tooling (A) and (B) are identical except for the FT1408 Spacers (11) and the FT1408
Spacers (9) that have been modified to be 50.8 mm (2 in) long.
8. Install Tooling (A) as follows:
a. Install eight FT1408 Spacers (9) [modified to 50.8 mm (2 in) long]. Install 5P8249 Washers, the
5P8247 Washers and 6B6683 Nuts (8) onto 5P9605 Studs (2).
installed with bar [part of Tooling (A)].
d. Install the recoil spring retainer until the end of the retainer is 7 ± 2 mm (.275 ± .079 in) away
from the end surface of the track roller frame.
e. Make sure the notches in retainer (7) are aligned so that the locks can be installed after Tooling
(A) has been removed.
10/11
D6R XR & D6R LGP TRACTORS / POWERSHIFT / 6HR00001-UP (MACHINE)...
2020/5/10

f. Remove Tooling (A)
9. Put the locks in position and install the bolts that hold the locks in place.
End By:
a. install track adjusters
Sun May 10 13:12:11 UTC+0800 2020
11/11
D6R XR & D6R LGP TRACTORS / POWERSHIFT / 6HR00001-UP (MACHINE)...
2020/5/10

Shutdown SIS
Previous Screen
SENR83570009
Track Adjuster
SMCS - 4157-017; 4157-010
Remove & Install Track Adjuster
Start By:
a. remove front track roller frame
1. Pull the track adjuster out of the front track roller frame until it hits on the stops. Remove four
bolts (1) and the two locks (2).
2. The weight of the track adjuster is 32 kg (71 lb). Put a nylon strap around the track adjuster and
attach a hoist. Remove the track adjuster.
NOTE: The following steps are for installation of the track adjuster.
3. Use a hoist and install the track adjuster into the front track roller frame.
4. Put the locks (2) into position with the lock tang in the track adjuster slot.
5. Install four bolts (1).
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End By:
a. install front track roller frame
Disassemble & Assemble Track Adjuster
Start By:
a. remove track adjusters
1. Remove plate (3) and two valves (1). Remove plug (2) and the O-ring seal.
2. Install Tooling (A) and remove piston (5) from cylinder (4).
3. Remove the lip-type seal from the cylinder.
NOTE: The following steps are for assembly of the track adjuster.
4. Put clean oil on the parts and seals during assembly.
2/3
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5. Install lip-type seal (6) in the cylinder. The lip at the seal should be toward the inside of
cylinder (4). Install piston (5) into the cylinder.
6. Put the O-ring seal on plug (2). Install plug (2) and tighten it to a torque of 320 ± 30 N·m (240
± 22 lb ft).
7. Install two valves (1) and tighten both to a torque of 35 ± 7 N·m (26 ± 5 lb ft).
8. Install plate (3).
End By:
a. install track adjuster
Sun May 10 13:13:00 UTC+0800 2020
3/3
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Shutdown SIS
Previous Screen
SENR83570010
Track Roller Frames
SMCS - 4151-012; 4151-011
Remove Track Roller Frames
1/10
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Before doing any service work that requires separating a track, a
thorough inspection of the front track roller frame should be made. See
Special Instruction, Form No. SMHS8273-02.
Start By:
a. separate track
The tractor could fall off the supports when the track roller frames are
removed if it is on a slope or soft footing. To prevent possible personal
2/10
2020/5/10

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injury, the tractor must be on a level, hard surface before the track
roller frames are removed.
1. Put Tooling (A), bar stock, in position between the equalizer bar and the main frame on the
same side that the track roller frame is to be removed from. This will keep the equalizer bar in its
original position when the track roller frame is removed.
2. Remove the four bolts and panel (1) from the front of the tractor.
3. Raise the rear of the tractor until track guides (2) are above the track links. Put Tooling (B) in
position under the tractor as shown. Lower the tractor onto Tooling (B).
4. Put two 50 ton screw jacks (3) in position, and raise the front of the tractor until track guides (4)
are above the track links.
3/10
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5. Put Tooling (C) in position under the roller frame as shown. Use Tooling (C) to put pressure on
the track roller frame.
6. Remove bolt (6) from the equalizer bar pin and the track roller frame. Install Tooling (D) on
each side of the pin, between the equalizer bar and the track roller frame as shown.
7. Use Tooling (E) and remove equalizer bar pin (5) from the front side of the equalizer bar as
shown. Make sure Tooling (D) stays tightly in position while the equalizer bar pin is being
removed.
8. Remove the bolts and push arm trunnion (7) from the track roller frame.
4/10
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9. Use Tooling (F) and remove retainer (8) from the track roller frame.
10. Fasten chain (11) between the rear track roller frame and the front track roller frame to keep
the front track roller frame in position.
11. The weight of the track roller frame with six rollers and two idlers is 1500 kg (3,300 lb).
Attach a hoist and use Tooling (G) with chain (10) positioned as shown. Raise the track roller
frame and remove Tooling (C).
12. Remove the bolts and plate (9) from the end of the pivot shaft. Remove the washer that is
behind plate (9).
13. Remove the track roller frame by pulling it off the pivot shaft.
14. Remove seal (13) and sleeve (12) from the pivot shaft.
15. If necessary, remove bearings (14) and (15) from the track roller frame.
5/10
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