Caterpillar cat d6 r track type tractor (prefix 4jr) service repair manual (4jr00001 and up)

Service Repair Manual
Models
D6R TRACK-TYPE TRACTOR

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Product: TRACK-TYPE TRACTOR
Model: D6R TRACK-TYPE TRACTOR 4JR
Configuration: D6R Track-Type Tractor 4JR00001-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
SENR83570003
Track Rollers
SMCS - 4180-010; 4180-015; 4180-016
Remove & Install Track Rollers
1. Loosen the track.
NOTE: Refer to "Separation Of Track" in this module for proper procedure.
2. Use Tooling (A) and lift the side of the tractor from which the roller is to be removed.
3. Put Tooling (B) in position to support the tractor and lower Tooling (A).
1/8D6R Track-Type Tractor 4JR00001-UP (MACHINE) POWERED BY 3306 Engine(S...
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4. Fasten a hoist and suitable lifting device to Tool (C). Put Tool (C) in position under the roller as
shown.
5. Remove bolts (3) and caps (1) from each side of the roller.
6. Remove track roller (2) from the machine. The weight of the track roller is 30 kg (66 lb).
NOTE: The following steps are for installation of the track rollers.
7. Fasten a hoist and suitable lifting device to Tool (C). Align the flat side of the roller shaft with
the roller frame and put track roller (2) in position.
8. Put caps (1) in position on each side of the roller and install bolts.
9. Use Tooling (A) to raise the side of the tractor. Remove Tooling (B). Lower the tractor to the
ground with Tooling (A).
10. Adjust the track tension.
NOTE: For adjusting the tension on the tracks, refer to the topic "Adjust Tracks" in the Operation
& Maintenance Manual.
Disassemble Track Rollers
Start By:
a. remove track rollers
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with
suitable containers before opening any compartment or disassembling any component containing
fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to
collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations
and mandates.
1. Use a hammer and punch, to remove the plug out of stopper (2).

NOTE: Removal of the plug and stopper (2) requires damaging stopper (2).
2. Use a slow speed drill and 12.7 mm (.50 in) drill bit, and remove stopper (2) from the shaft.
3. Remove lock ring (3) and end collar (1) from both sides of the track roller.
NOTE: If the Duo-Cone Seals are to be used again, put identification marks on the seals to assure
that they are assembled and installed in their original positions.
4. Remove Duo-Cone seal assembly (4) from end collar (1).
5. Use Tool (A) and remove retaining ring (5) from rim assembly (6).
6. Repeat step 5 for opposite side.
7. Use a press and roller shaft (7) to remove the bushing assembly on the opposite side.

8. Rotate the roller assembly over 180 degrees. Use a press and roller shaft (7) to remove the
remaining bushing assembly.
9. Remove O-ring seals (8) from roller shaft (7).
10. Remove O-ring seal (9) from bushing assembly (10).
11. Remove Duo-Cone seal assembly (11) from bushing assembly (10).
Assemble Track Rollers
NOTE: Refer to the topic "Conventional Duo-Cone Seals" for further information prior to
assembling the track rollers.
1. Clean and inspect all parts for wear or damage and replace if needed.
2. Make sure all parts are free of oil, film, dirt or other foreign material before assembling.

3. Install O-ring (9) on bushing assembly (10).
NOTE: Refer to the topic "Conventional Duo-Cone Seals" for proper installation procedure.
4. Use Tooling (B) to install Duo-Cone seal assembly (11) in bushing assembly (10).
5. Lubricate O-ring seals (8) lightly with SAE 30W oil. Install O-ring seals (8) on track roller
shaft (7).
6. Lubricate the bore of rim assembly (6), outside surface and seal of bushing assembly (10)
lightly with SAE 30W oil. Use a press and Tool (C) to install bushing assembly (10) in rim
assembly (6). Bushing assembly (10) should just clear the retaining groove in rim assembly (6).
7. Use Tool (A) to install retaining ring (5) in rim assembly (6).

NOTICE
The bushing assembly in track roller (6) can be damaged when shaft
(7) is installed in rim assembly (6). Use care when positioning shaft (7).
8. Rotate the track roller assembly over 180 degrees and install track roller shaft (7) in rim
assembly (6).
9. Lubricate the bore of rim assembly (6), outside surface and seal of bushing assembly (10)
lightly with SAE 30W oil. Use a press and Tool (C) to install remaining bushing assembly (10).
Bushing assembly (10) should just clear the retaining ring groove in rim assembly (6).
10. Use Tool (A) and install retaining ring (5) in rim assembly (6).

11. Rotate the track roller assembly over 180 degrees. Use a press against track roller shaft (7) to
move the opposite bushing assembly (10) out against retaining ring (5).
NOTE: Refer to the topic "Conventional Duo-Cone Seals" for proper installation procedure.
12. Use Tooling (B) and install Duo-Cone seal assembly (4) in end collar (1).
13. Install end collar (1) and lock ring (3) on track roller shaft (7).
14. Repeat steps 12 and 13 to install the remaining end collar (1) on the opposite end of track
roller shaft (7).
15. Use Tool (D) to pressure test the track roller as follows:
a. Use air (free of water) to pressurize the track roller to 280 kPa (41 psi).
b. Observe the pressure reading of the track roller. The pressure should remain the same for ten
seconds. A reduction in pressure in ten seconds or less indicates a leak in the track roller. In the
event of a leak, the track roller must be disassembled and checked.

Typical Example
16. Use Tool (E) to check the end play of shaft (7). The end play should be 0.25 to 1.33 mm (.010
to .052 in).
17. Fill track roller with 410 ± 25 ml (13.9 ± .8 oz) of SAE 30W oil. The track roller should be
filled through the opening in shaft (7) for the plug and stopper (2).
Typical Example
18. Put clean oil on a new stopper (2). Install stopper (2) in the end of shaft (8). The outside face
of stopper (2) should be 7 ± 7 mm (.275 ± .275 in) below the chamfer of shaft (8).
19. Use Tool (F) to install the plug in stopper (2). The outside surfaces of the plug and stopper
must be flush.
End By:
a. install track rollers
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Apr 29 11:38:38 UTC+0800 2020

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SENR83570004
Track
SMCS - 4170-077; 4170-010; 4170-015; 4170-016; 4170-076
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

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 4JR00001-UP (MACHINE) POWERED BY 3306 Engine(...

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.
Wed Apr 29 11:39:27 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.

Caterpillar cat d6 r track type tractor (prefix 4jr) service repair manual (4jr00001 and up)

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Caterpillar cat d6 r track type tractor (prefix 4jr) service repair manual (4jr00001 and up)