SystemOne Track Guiding Arrangements {4170, 4177} Caterpillar

Track-Type Tractor

D6H (S/N: 8KB1-UP; 4RC1-UP; 6FC1-UP; 7PC1-UP; 8FC1-UP; 8YC1-UP; 7ED1-UP; 3ZF1-UP; 5HF1-UP; 6CF1-UP; 3YG1-UP; 4LG1-4067,4068-UP; 1FJ1-UP; 3YJ1-UP; 6JJ1-UP; 7ZK1-UP)

D6H Series II (S/N: 1KD1-UP; 2KD1-UP; 3ED1-UP; 4YF1-UP; 2TG1-UP; 4GG1-UP; 4LG1-4067,4068-UP; 8ZJ1-UP; 9KJ1-UP; 2DK1-UP; 5KK1-UP; 6CK1-UP; 8KK1-UP; 8SK1-UP; 9LK1-UP; 9RK1-UP; 1YL1-UP; 2BL1-UP; 2TL1-UP)

D6R (S/N: 2HM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; 2YN1-UP; 3ZN1-UP; 4HN1-UP; 4MN1-UP; 5LN1-UP; 6JN1-UP; 7KN1-UP; 8LN1-UP; 8XN1-UP; 9MN1-UP; 9PN1-UP; DMP1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6GR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP; 1RW1-UP)

D6R Series II (S/N: BNC1-UP; AFD1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-UP)

D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP)

D6T (S/N: 2D21-UP; CR31-UP; 2B31-UP; MB51-UP; AK71-UP; MH71-UP; CG81-UP; 7C91-UP; SGA1-UP; JHB1-UP; ZEB1-UP; SMC1-UP; JWD1-UP; LBD1-UP; RAD1-UP; LAE1-UP; STE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; LKJ1-UP; JML1-UP; KJL1-UP; MEL1-UP; SKL1-UP; JNM1-UP; WRN1-UP; K1R1-UP; KMR1-UP; WES1-UP; GCT1-UP; HYT1-UP; SGT1-UP; RLW1-UP; LAY1-UP; NDY1-UP; TMY1-UP; HTZ1-UP; PEZ1-UP; SGZ1-UP)

Introduction

This instruction describes three track guiding arrangements for tractors with SystemOne undercarriage. Any tractor that is equipped with SystemOne undercarriage from the factory must use one of the track guiding arrangements. Any field tractor that is retrofitted with SystemOne undercarriage must use one of the track guiding arrangements. Selecting the proper track guiding arrangement will prevent damage to the SystemOne moving undercarriage and fixed track frame guiding components. Correct selection of the proper track guiding arrangement will increase the reliability and life of SystemOne undercarriage and lower owning and operating costs. Carefully read all of this information before selecting a track guiding arrangement for your application and underfoot conditions.

Note: This instruction does not include D6H XR or D6R XR “Wincher” arrangement tractors. Do not attempt to install SystemOne undercarriage on D6H XR or D6R XR tractors.

Background

It is extremely important to keep the track properly guided. The function, reliability, and life of the undercarriage will be enhanced when the track is correctly guided. Proper track guiding keeps the track on the rollers, idlers, and sprockets. A properly guided track stays between the guiding guard wear surfaces. The roller flanges, idler flanges, and guide guard wear surfaces perform the job of aligning and guiding the track. Tractors that are running on fairly level, even terrain generally keep a properly guided track without difficulty. Increased guiding of the track is required when a tractor operates on one or more of the following ground conditions:

• A sloped surface

• Uneven terrain

• Over various objects

The following conditions further increase the demand on track guiding:

• Steeper side slopes

• Increasingly uneven terrain

• Larger sized ground objects

When one or more of these demanding conditions coexist, improved track guiding is even more critical. Damage to the undercarriage and components of the track frame will occur without the proper track guiding for the three conditions that are described above. The typical damage cycle from inadequate track guiding is described below:

• The track comes off the track rollers, idlers, or both components.

• Moving undercarriage components are damaged.

• Fixed track frame guiding components are damaged.

• The life of the moving undercarriage and fixed guiding components is shortened.

• Owning and operating costs of the tractor are increased.

This damage cycle can occur even if a tractor operates for a short time with inadequate guiding of the track.

SystemOne Primary Track Guiding and Secondary Track Guiding

Good track guiding is accomplished by the proper combination of primary guiding and secondary guiding. Primary guiding occurs between moving undercarriage components. Examples of primary guiding are shown below :

• Guiding between the track and flanges of the track rollers

• Guiding between track and the center flanges of the idlers

• Guiding between track and sprockets

Secondary guiding occurs between the track and the wear surfaces of the track guiding guards that are mounted to the track frame. Examples of secondary guiding are shown below :

• Guiding between the track and the track guiding guards at the ends of the track frame

• Guiding between the track and the bolted short center guiding guards on the track frame

• Guiding between track and the bolted full length guiding guards on the track frame

Both forms of guiding are important. They work together in order to keep the track aligned and correctly guided. Primary guiding is used mostly to keep the track properly located in light guiding conditions to moderate guiding conditions. Both primary guiding and secondary guiding work together in order to keep the track located in moderate guiding conditions to heavy guiding conditions.

Primary Track Guiding

SystemOne primary track guiding is greatly improved over conventional primary track guiding. New SystemOne tall single flange track rollers have an increased flange height. Flange height is 40 percent taller than conventional track rollers. The taller flange height increases the guiding surface of the roller, which greatly improves retention of the track in the rollers. Only the tall single flange rollers are offered with SystemOne undercarriage. SystemOne primary guiding has also improved with the use of Center Tread Idlers. The tall center treads of these idlers deeply engage the track. This improves track guiding at each end of the track frame. Both the improved track roller and the Center Tread Idler are shown in Illustration 1.

Illustration 1	g01131265
(A) Conventional Undercarriage (B) Improved SystemOne Undercarriage (1) Tall Single Flange Roller (2) Center Tread Idler with Tall Center Tread

SystemOne track with the improved conventional idlers also improves primary track guiding. The improved conventional idlers have a taller center flange versus the former design. SystemOne must not be used with the early version, conventional idlers. Both the improved track roller and the improved conventional idler are shown in Illustration 2.

Illustration 2	g01131867
(A) Conventional Undercarriage (B) Improved SystemOne Undercarriage (1) Tall Single Flange Roller (3) Tall Flange Conventional Idler

Further details and machine effectivity on these improved conventional idlers can be found in Service Magazine, SEPD0642, 12, August 2002, "Track Idlers Have More Wear Material for Increased Service Life" or Information Release Memo UC02-11, PELM1079.

Secondary Track Guiding

SystemOne secondary track guiding has also been improved. The new SystemOne track link design is straight, and eliminates the conventional link pin boss. The fixed track frame guides have guiding surfaces that guide directly on the hardened side rail of the link. This is like the track guiding system on the undercarriage of large elevated sprocket tractors (D8 through D11). Additionally, profiled wear surfaces are now used on the fixed track frame guides in order to match the geometry of the side rail of the SystemOne track link. Secondary track guiding improvements are shown in Illustration 3.

Illustration 3	g01131892
(A) Conventional Undercarriage (B) Improved SystemOne Undercarriage (4) Track Link Without Pin Boss (5) Profiled Fixed Track Guides

Improvements to Primary track guiding and secondary track guiding are an integral part of the design of SystemOne undercarriage. However, the type, the number, and the location of fixed secondary track guides and bolted wear strips must be selected when SystemOne undercarriage is installed on a tractor. The type and the severity of the operating conditions will determine the configuration of SystemOne fixed track guiding guards and wear strips.

Determining the Correct SystemOne Guiding Arrangement

Use Table 1 in order to determine the correct SystemOne guiding arrangement. First, the correct operational conditions are selected as shown in Column A. This determines the corresponding tractor guiding requirement as shown in Column B. The tractor guiding requirement then determines the required guiding arrangement as shown in Column C.

Examples of various operating conditions for tractors are shown below. Each example includes the corresponding tractor guiding requirement and required track guiding arrangement.

Illustration 4	g01131956
Light Guiding Requirement, Flat Dozing (Level 1 - Standard)

Illustration 5	g01131967
Light Guiding Requirement, Flat Fine Grading (Level 1 - Standard)

Illustration 6	g01131973
Moderate Guiding Requirement, Sidesloping a 3:1 grade (Level 2 - Moderate Service)

Illustration 7	g01131977
Moderate Guiding Requirement, Sidesloping with Occasional V-Ditch Transition (Level 2 - Moderate Service)

Illustration 8	g01131989
Heavy Guiding Requirement, Large Ground Objects Creating High Impact (Level 3 - Heavy Duty)

Illustration 9	g01131990
Heavy Guiding Requirement, Steep Sidesloping (Level 3 - Heavy Duty)

Table 2 below shows the proper configuration of the guiding guards that are fixed on the track frame and the required wear strips. Track guiding arrangements are shown for each corresponding model and each configuration. Level 1 (Standard) is the standard track guiding arrangement for tractors with SystemOne from the factory. Level 2 and Level 3 guiding arrangements are factory attachments.

Note: The number of guards listed is per track roller frame.

Examples of various tractor models that are equipped with the different guiding arrangements are shown below. Some tractors that are shown are equipped with a conventional undercarriage, but the track guiding arrangements are very similar for SystemOne.

Illustration 10	g01132007
D6H/R/T LGP: Level 1, Standard Track Guiding Arrangement

Illustration 11	g01132008
D6H/R/T LGP: Level 2, Moderate Service Track Guiding Arrangement

Illustration 12	g02177392
D6H/R/T XL: Level 1, Standard Track Guiding Arrangement

Illustration 13	g01132012
D6H/R/T XL: Level 3, Heavy Duty Track Guiding Arrangement

Compatibility of Track Frames with SystemOne Guiding Arrangements

Note: Before any SystemOne guiding arrangement can be retrofitted onto a field machine, a simple inspection of the track frame guiding guards must be completed. The inspection includes three steps. These steps are listed below :

• Determine if the end guide guards are compatible with the Heavy Duty or the Rotating Bushing Track.

• Determine if the distance between the structural plates of the end guide guards are correct.

• Determine if the end guiding guards have a load bearing support bar for the wear strip that is welded to the inside of the guard structural plates.

1. SystemOne track has different bolted wear strips for the end guiding guards than wear strips that are used for the Heavy Duty, RBT, or SALT track. However, the fixed track frame end guards are the same for SystemOne track as for Heavy Duty or RBT track. So, any tractor currently equipped with Heavy Duty or RBT track has end guiding guards that are ready for SystemOne track. Tractors with SALT track may have end guiding guards compatible with SystemOne, Heavy Duty, or RBT track. The following process for inspection of the track and the guide guards will help determine if the end guide guards on any Series H or Series R tractor are compatible with SystemOne track.

   1. Any series D6R or any D6T tractor has end guiding guards that are compatible with SystemOne track.

   2. Any Series H tractor with Heavy Duty or RBT track has end guiding guards that are compatible with SystemOne track.
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      Illustration 14	g01132138
      (6) Removable Spacer

   3. Any Series H tractor with SALT track and end guiding guards that has a removeable spacer plate (6) installed between the wear strip and guard is compatible with SystemOne track. This is shown in Illustration 14.

   4. Any Series H tractor with SALT track and end guiding guards that does not have a removeable spacer plate between the wear strip and the guard is not compatible with SystemOne track. The end guiding guards on this tractor must be reworked by either of the two following methods :

      • Cut off the existing end guide guards with a torch. Reweld the same guards in the new location that is compatible with SystemOne track. Further details on this procedure are provided in Special Instruction, SEHS9585.

      • Cut off the existing end guide guards with a torch. Weld new end guide guards in the new location that is compatible with SystemOne track. Further details on this procedure are provided in Special Instruction, SEHS9350.

      When the type of end guide guards have been determined and any required rework in Step 1 is completed, go to Step 2.

2. This step ensures that existing end guiding guards are straight and properly aligned before the new SystemOne wear strips for the end guiding guards are mounted.

   1. Remove the existing wear strips that are part of the end guiding guard.

   2. Use a wire wheel to remove any rust or dirt from the mounting area for the wear strip or bolts.

   3. Inspect the distance between the components according to Illustration 15 below :

      • Dimension (D) is the distance from the center of the track frame (7) to each mounting surface for the end guiding guard wear strips (8).

      • Dimension (C) is the distance between the mounting surfaces for the end guiding guard wear strips (8)
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      Illustration 15	g01132150
      ( 7) Track Frame Centerline (8) Wear Strip Mounting Surfaces (C) 311 ± 3 mm (12.24 ± 0.12 inch) (D) 155.5 ± 1.5 mm (6.12 ± 0.06 inch)

   4. If the end guiding guards are bent, heat the guards and straighten the guards according to dimensions (C) and (D).
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   Illustration 16	g01132162
   Former Mounting System with “L-section” Wear Strips

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   Illustration 17	g01132163
   Current Mounting System with Flat Wear Strips (9) Required Support Bar for the Wear Strip

3. This step involves a final inspection of the end guide guards. This inspection ensures that the appropriate support bar for the wear strip is in place on the end guiding guards. The support bar keeps the SystemOne wears strips for the end guide guards in place. This support bar prevents the mounting bolts from loosening or breaking. These support bars went into effect when the wear strips for the end guide guard changed from the former “L-section” to the current flat section. This change was effective on D6R tractors that were built approximately 2000 and after. Pictures of the former “L-section” and current flat section mounting systems for the wear strips are shown in Illustration 16 and 17.
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   Illustration 18	g01132186
   (9) Required Support Bars for the Wear Strips

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   Illustration 19	g01132196
   SystemOne Wear Strip Mounting Arrangement (9) Welded Support Bar (10) SystemOne Wear Strip

4. Inspect the mounting area for the inside wear strip of the guiding guard in order to ensure that the required support bars for the wear strips are in place. See Illustration 18 and 19 above. If the end guiding guards on a tractor that is receiving a SystemOne retrofit do not have support bars for the wear strips, the support bars must be welded on. One support bar is required on the inside of each end guiding guard. The list below provides the parts information for the support bars for the wear strips on one tractor:
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   Table 3

   Item	Quantity	Pt. No.	Description
   9	8	3G-1323	Bar

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   Illustration 20	g01154943
   (9) Welded Support Bar (10) SystemOne Wear Strip (11) Front Track Guiding Guard (12) Rear Track Guiding Guard (E) 15 ± 2 mm (0.59 ± 0.08 inch) (F) Front End of Track Frame (R) Rear End of Track Frame

5. In order to install bars (9) on the guards, first bolt on the new SystemOne profiled wear strips (10). Next, lay support bars (9) along the top of the profiled wear strips (10). Illustration 19 shows the new SystemOne wear strip with the welded support bar on top. Locate bar (9) on the track guiding guard according to dimension (E). Refer to Illustration 20. Dimension (E) is the distance from the end of the support bar to the front edge of the front track guiding guard. Dimension (E) is also the distance from the end of the support bar to the rear edge of the rear track guiding guard. Once the support bar is properly located, weld the support bar to the guiding guard along the entire top edge of the support bar.

Parts Lists for SystemOne Guiding Arrangements

End guiding guard wear strips, short center guards, or full length roller guards for conventional track (SALT, HD, or RBT) cannot be used with SystemOne track. Illustrations 21 through 28 show the number and location of SystemOne (bolt on) track guiding guards and wear strips. This information is shown for each guiding arrangement on each model and each configuration. A table of the required parts is below each illustration. For guiding arrangements that only require wear strips for the end guide guards, one parts table is shown for both D6H and D6R tractors. The wear strip mounting bolts are metric (12 mm) for both models. For other guiding arrangements, separate parts tables are shown for the D6H and D6R tractors. This is based on 3/4 inch ( D6H) versus 20 mm ( D6R/T) bolts that mount the center or full length guiding guards to the track frame. The table below includes torques for the bolts of the following components:

• short guiding guards

• full length guiding guards

• end wear strips

Note: Only the end guiding guards have wear strips that bolt on. All short guiding guards and full length guiding guards have wear surfaces that are an integral part of the guard assemblies. Quantities of parts that are shown are for the entire tractor (both track roller frames).

Illustration 21	g01132223
D6H/R/T STD Track Frame with six Rollers: Level 1 Guiding Arrangement (Standard)

Illustration 22	g02178014
D6H/R/T STD Track Frame with Six Rollers: Level 2 Guiding Arrangement (Moderate Service)

Illustration 23	g01132233
D6H/R/T STD Track Frame with Six Rollers: Level 3 Guiding Arrangement (Heavy Duty)

Illustration 24	g02177699
D6H/R/T XL, XW, IG Track Frame with Seven Rollers: Level 1 Guiding Arrangement (Standard) and Level 2 Guiding Arrangement (Moderate Service)

Illustration 25	g01132258
D6H/R/T XL, XW, IG Track Frame with Seven Rollers: Level 3 Guiding Arrangement (Heavy Duty)

Illustration 26	g01132307
D6H/R/T LGP Track Frame with Eight Rollers: Level 1 Guiding Arrangement (Standard)

Illustration 27	g01132312
D6H/R/T LGP Track Frame with Eight Rollers: Level 2 Guiding Arrangement (Moderate Service)

Illustration 28	g01132314
D6H/R/T LGP Track Frame with Eight Rollers: Level 3 Guiding Arrangement (Heavy Duty)