Caterpillar cat d6 r track type tractor (prefix 4hn) service repair manual (4hn00001 and up)

Service Repair Manual
Models
D6R TRACK-TYPE TRACTOR

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Product: TRACK-TYPE TRACTOR
Model: D6R TRACK-TYPE TRACTOR 4HN
Configuration: D6R Track-Type Tractor LGP 4HN00001-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
SENR83570004
Track
SMCS - 4170-015; 4170-016; 4170-076; 4170-077; 4170-010
Separate Track
The machine must be on a level hard surface before a separation of the
track is made. Any time a separation of both tracks is made the
machine must have blocks correctly in position so the machine will not
move.
Typical
1. Remove track adjuster cover (1) and the O-ring seal from the roller frame.
The adjuster cylinder for the track is under high hydraulic pressure. Do
not visually inspect the relief valve to see if grease is released when it is
1/15D6R Track-Type Tractor LGP 4HN00001-UP (MACHINE) POWERED BY 3306 Eng...
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open. Look to see that the track has loosened. Use this warning any time
the tracks are loosened or tightened.
2. Loosen the track as follows:
a. Turn the relief valve (2) one turn counterclockwise to permit grease to be released from the
track adjuster. If the track does not loosen go to Step b.
b. Turn fill valve (3) one turn counterclockwise to permit grease to be released from the track
adjuster. If the track still does not loosen, start the machine and move it forward and backward. If
grease is still not released go to Step c.
c. Install a piece of round bar stock between the bushing and sprocket inside the links. Move the
machine to the rear so the track will be pushed up by the round bar stock. This will put tension on
the track and move the track adjuster in.
3. Move the track until the master link is just above the centerline of rear idler (4). Put wood
blocks under the grouser bar just below the master link. Move the track to the rear until it has rigid
contact with the wooden blocks.
4. The weight of the master shoe is from 19.5 kg to 37.5 kg (43 lbs to 82.5 lbs), depending on
which track the vehicle is equipped. Remove four bolts (5) and master shoe (6).
5. Separate master link (7).

Keep away from the front of the machine when the track is pushed off
of the final drive. A minimum distance of 6.1 m (20 ft) is needed in front
of the track to permit the track to move out on to the floor.
6. Fasten a chain to the end of the track and to a wheel loader or similar machine. Turn the final
drive in a forward direction and let track (8) fall forward, as the wheel loader or similar machine is
moved forward.
7. The weight of the track is from 1676 to 2602 kg (3687 to 5724 lbs) depending on which track
the machine has on it. Lift the side of the machine and remove the track if necessary.
Connect Track
1. Put the track under the machine. Lower the side of the machine on to track (8).
2. Fasten one end of the chain to track (8) and the other end to a wheel loader or a similar
machine.
NOTICE
To avoid damage to the track or to the machine, the track must be
pulled in a straight line.

3. Pull the track until the track bushings engage with the sprocket segments on the final drive.
4. Start the machine and turn the final drive in a reverse direction to pull the track together.
5. Lift the end of the track and put wooden blocks (9) under the grouser as shown.
NOTE: Make sure the serrations on the master link are free of loose or thick rust, paint, and
lubricants.
6. Align the lower end of master link (7) with the upper end of the master link. Make sure the teeth
of both ends of the master link are engaged.
7. Put track shoe (6) in position on the master link. Put 2P2506 Thread Lubricant on the threads,
body and washer face of the master link bolts. Install bolts (5) that hold the master link together.
Tighten the bolts to a torque of 400 ± 70 N·m (300 ± 50 lb ft). Tighten the bolts an additional 1/3
of a turn. For inspection purposes, after assembly, the final torque must be a minimum of 680 N·m
(500 lb ft).

8. Tighten relief valve (2) and fill valve (3) in the track adjuster to a torque of 35 ± 7 N·m (25 ± 5
lb ft).
NOTICE
Measure the track (sag), distance from a straight line when the
machine is in its working condition. If dirt and debris are present in its
working condition, then measure the (sag) when normal dirt and
debris are present in the track and its components.
9. Adjust the track as follows:
a. Move the machine forward for a distance that is two times the length of the machine. Let it
come to a stop without the use of the brakes.
b. Put a tight line between the grouser tips at the sprocket and front idler.
c. Measure distance (X) from the line to the lowest point of (sag) of the grouser tips. Put 5P960
Multipurpose Type Grease in the track adjuster and make an adjustment to the track until
distance (X) is 115 ± 10 mm (4.53 ± .40 in). This is the sag (curve) in the track between the
sprocket and the front idler.
d. Do not tighten the track more if distance (Y) is 150 mm (5.9 in) or more. The track will have to
be removed and reconditioned.

10. Install the track adjuster cover (1) and O-ring seal onto the roller frame.
Track Adjustment-Adjust
Grease is under high pressure. Grease coming out of the relief valve
under pressure can penetrate the body causing injury or death. Do not
watch the relief valve to see if grease is escaping. Watch the track or
track adjustment cylinder to see if the track is being loosened. Loosen
the relief valve only one turn.
1. Move the machine forward. Allow the machine to stop without the use of service brakes. Adjust
the tracks while you are in the machine's typical operating conditions. If packing conditions
prevail on the workplace, the tracks should be adjusted with packing material.
NOTICE
Do not attempt to tighten track when dimension (1) is 105 mm (4.13 in)
or more. Contact your Caterpillar dealer for track service instructions.

2. The sag in the track is measured between the sprocket and the front idler (2). The correct
adjustment of dimension (2) is 100 ± 10 mm (3.9 ± .40 in).
3. If the machine is equipped with a carrier roller, the correct adjustment of dimension (3) and
dimension (4) is 130 ± 10 mm (5.12 ± .38 in).
Disassemble Track

1. Put the track pin, to be removed, in position behind the front idler as shown.
2. Put blocks (2) in position under the front of the track.
3. Put blocks (3) in position under the track to keep the track away from the track roller frame
when the pressure is released in the track adjuster.
4. Release the pressure in the track adjuster. See topic, Separate Track.
5. Put Tool (A) in position as shown. Use Tool (A) to keep the track in position when the track
pins are removed.
6. Remove the bolts, and use two persons to remove three track shoes (1) over the track pins to be
removed.

7. Fasten a hoist to Tooling (B). Put Tooling (B) in position against the track pin.
8. Push the track pin out of the track with Tool (B), and install Tool (C) to hold the track together
until the other track pin is removed.
9. Put Tooling (B) in position against track pin (4). Push track pin (4) out of the track, and install
Tool (C). Remove Tooling (B) from the track.
10. Put Tooling (D) in position between links (6) and (7). Use Tooling (D) to spread the links
apart far enough to move link (5) away from links (6) and (7).
11. Remove Tooling (C) from links (5), (6) and (7)
NOTICE
Use care when moving the links apart so the face of the seals are not
damaged.
12. Fasten a hoist to link (5). Move the link away from links (6) and (7).
13. Put a block under link (5) to keep it away from links (6) and (7)
14. Put Tooling (D) in position between links (9) and (10). Use Tooling (D) to spread the links
apart far enough to remove link assembly (8).
15. Fasten a hoist to link assembly (8).
16. Remove Tool (C) from links (9) and (10) and link assembly (8), and remove the link assembly.

17. Remove seal assemblies (11) from the track links.
18. Put the track links and track bushing in position in Tooling (E) as shown. Push the track
bushing from track link (6).
19. Put track link (7) and the track bushing in position in Tooling (E). Remove the track bushing
from track link (7).
20. Use a punch and hammer, and remove plug (12) from stopper (13) in the track pins.
21. Remove stoppers (13) from the track pins.
Assemble Track
10/15D6R Track-Type Tractor LGP 4HN00001-UP (MACHINE) POWERED BY 3306 E...

NOTE: Check all parts of the track assembly for wear or damage. Make replacements if
necessary. Make sure the parts are clean and dry before assembly.
1. Put 1P3482 Adapter (2) [part of Tooling (A)] in frame (1) of the press arrangement [part of
Tooling (A)] with the counterbore toward the ram as shown.
NOTICE
Use a maximum force of 760 kN (170 000 lb) when the track is
assembled. Excessive press force can cause damage to the thrust rings.

2. Put SAE 90 gear oil on each end of track bushing (4) for a minimum length of 5 mm (.197 in).
3. Use Tooling (A), and install track bushing (4) into track link (3). Push the track bushing in until
it makes contact with Tooling (A). The track bushing must extend 1.76 ± 0.13 mm (.069 ± .005
in) above the surface of the track link.
4. Put track link (5), track bushing (4) and track link (3) in position in Tooling (B). Install pin (6)
[part of Tooling (B)] for alignment purposes. Use Tooling (B), and install the track link on the
track bushing until the track makes contact with Tooling (B). The track bushing must extend 1.76
± 0.13 mm (.069 ± .005 in) above the surface of the track link.
NOTICE
The seal assemblies must be completely sealed in the track link
counterbores. The load rings of the seal assemblies must make a
minimum amount of contact with oil. Oil causes the load ring to
expand. This is not desired until after assembly.

NOTE: Make sure there is contact at area (X) between the seal and load ring.
5. Use Tool (C) and install the seal assemblies (the seals and load rings) in the track links as
shown in illustration A82927P1.
6. Put oil on stoppers (7), and install them in track pins (8). The stopper must be installed to a
depth of 8 ± 4 mm (.315 ± .157 in) below the surface of the track pins.
7. Put Tooling (D) in position between the track links. Use Tooling (D) to spread the links apart
far enough to install link assembly (9)
8. Fasten a hoist to link assembly (9). Put the link assembly in position, and install Tooling (E) to
hold it in place.

9. Put Tooling (D) in position between links in link assembly (9). Use Tooling (D) to spread the
links apart far enough to install link assembly (10).
10. Fasten a hoist to link assembly (10). Put the link assembly in position on the link assembly (9).
11. Align the pin hole in link assembly (10) with the hole in link assembly (9), and install tool (E).
12. Fasten a hoist to Tooling (F). Put Tooling (F) and track pin (12) in position on the track links.
NOTE: The pin must be installed with the hole end on the same side of the track assembly for the
entire length of the track assembly. The oil cross hole in the pin must be within 20° of the vertical
centerline of the pin bore and closest to the rail of the link. The pins have a mark on the end for
crosshole location. Also, the pin must be installed with a minimum amount of force to get a
maximum amount of end play 0.13 mm (.005 in) between the bushing and the thrust ring.
13. Install track pin (12) with Tooling (F) until the pin extends 3.22 mm (.127 in) beyond the link
assembly on both sides.
14. Put track pin (11) and Tooling (F) in position on the track links. Install track pin (11) until it
extends a maximum of 3.22 mm (.127 in) beyond the link assembly on both sides.
15. Use two persons, and put three track shoes (13) in position. Put 2P2506 Thread Lubricant on
the threads, body and washer's face of the master link bolts. Install the track shoe bolts and nuts.
Make sure the radius corner of the nuts are away from the links. Tighten the bolts to a torque of
400 ± 70 N·m (300 ± 50 lb ft). Tighten the bolts 1/3 turn more. For inspection purposes, after
assembly, the final torque must be a minimum of 680 N·m (500 lb ft).

16. Remove Tooling (G).
17. Fill the track pins with a minimum of 50.0 ml (1.7 oz) of SAE 90 gear oil.
18. Put oil on the plug, and install the plug in the stopper in the end of the track pin with Tool (H).
Install the plug until it is even with the end of the stopper.
19. Adjust the track. See topic, separate And Connect Track in this module for the adjustment
procedure.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Mon Apr 27 12:08:59 UTC+0800 2020

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SENR83570005
Field Repair for Dry Joints in Rotating Bushing Track (RBT)
SMCS - 4170
D7R Tractors Equipped with Rotating Bushing Track (RBT)
Introduction
NOTE: Seals are not shown.

Components of rotating bushing track.
(1) Bushing.
(2) Inner seals and thrust rings.
(3) Outer seals and thrust rings.
(4) Pin groove.
(5) Inserts.
The bushings are located between the track links and are not pressed into the bushing bores. Inner
seal and thrust ring (2) and insert (5) are located in each bushing bore. Insert (5) is factory installed
and is not serviceable. A portion of the pin boss is extruded (pressed) down and into groove (4) in
the end of the pin. The process of pressing the link material helps to retain the pin in the joints.
The extrusion process (method) of retaining the pins is a factory assembled procedure. Tools are not
yet available to do this type of pin retention in a field repair situation. A welding procedure is
available, however, for use in retaining the pins in a field repair of rotating bushing track.
The procedure given in this Special Instruction can be used to replace a damaged joint in rotating
bushing track (RBT). When this procedure is followed precisely, the joints can be welded without
causing damage to the non-metallic parts, including the seals, that are inside the joint.
Do not perform any procedure, outlined in this publication, or order any parts until you read and
understand the information contained within.
Reference: For more detail refer to, Special Instruction SEHS8957, "Repair Procedure for Non-
Restrained Seals and Lubricated Track".

Repair Procedure
Disassembly
Make reference to Special Instruction, SEHS8957, for a complete list of tools, field repair
procedure, and any additional information that may be needed. Standard tools for the D6H Tractor
can be used in the procedure.
1. Inspect the track and locate the dry joint.
2. Follow the procedure given under the topic entitled "Link Section Removal of Damaged Joint" in
the reference Special Instruction.
3. Pressing out the pin, sometimes cuts off extruded material from the pin bores. Inspect for loose
extruded material in the seal cavities after the pins have been removed.
Assembly
1. Use the following Weld Procedure as a replacement for the procedure given under the topic
entitled "Link Section Buildup with 8T7780 Track repair Group" in the reference Special
Instruction.
2. Equalize the pin projection in each joint to be repaired. Set each joint to zero end play.
Weld Procedure
NOTE: Equalizing the projection at each end of the pin permits an approximate 6-10 mm (1/4-3/8
in) fillet at each end of the pin.
Pin projection (solid end of pin shown).
1. Use an E6011 Weld Electrode to make a weld bead for approximately 120 degree (13 the
distance) around the circumference of the pin end as shown.
2. Immediately after the 120 degree weld bead is completed, put a wet paper towel (1U9579 Paper
Towel) directly om the weld bead.

Cover the entire end of the pin with the wet paper towel. Leave the towel in place 3-5 minutes while
welding the ends of the other pins.
Wet paper towel on the end of pin.
3. The ends of the pins must be cool to the touch before continuing the weld process. Repeat Steps 1
and 2 until the bead covers the entire circumference of the pin ends.
Completed weld (end of pin shown).
Completed weld (hole end of pin shown).
Note the undamaged stopper and plug in the end of the pin.
4. After all welding has been completed, refer to the topic entitled "Link Section Installation" in the
reference Special Instruction for the track assembly and joint lubrication information, and for track
installation information.
5. For track adjustment, refer to the topic entitled "Recommended Track Adjustment procedure" in
the reference Special Instruction.
Mon Apr 27 12:09:48 UTC+0800 2020

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SENR83570006
Sprocket Segments
SMCS - 4155-010
Remove & Install Sprocket Segments
1. Move the machine forward or backward until segment (2) to be removed, is in position as
shown.
2. Remove five bolts and nuts (1) and remove segment (2).
NOTE: The following steps are for installation of the sprocket segments.
3. Make sure the mating surfaces of the sprocket segment and the final drive are clean and free of
rust and scale.
NOTE: Install the segment so the head of the bolts are against the segment, and so the washers
and nuts (1) are against the final drive.
4. Put SAE 30 oil on the threads of the segment bolts. Put the segment in position on the final
drive and install bolts, washers, and nuts (1). Tighten nuts (1) to a torque of 175 ± 40 N·m (130 ±
30 lb ft). Tighten the nuts 1/3 of a turn more.
Mon Apr 27 12:10:37 UTC+0800 2020

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SENR83570007
Front Track Roller Frames
SMCS - 4151-012; 4151-011
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.

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

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.

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:

a. connect track
Mon Apr 27 12:11:26 UTC+0800 2020

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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:

Caterpillar cat d6 r track type tractor (prefix 4hn) service repair manual (4hn00001 and up)

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