SystemOne Track Guiding Arrangements{4150, 4177} Caterpillar

Track-Type Tractor:

D4H XL (S/N: 8PJ1-UP)

D4H LGP (S/N: 4NK1-UP; 9GJ1-UP)

Introduction

This instruction describes three track guiding arrangements for tractors with SystemOne undercarriage. 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.

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 exist, improved track guiding is even more critical. Damage to the undercarriage and componenets 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 period of 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 roller

• 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 the 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 fourty percent taller than conventional track rollers. The taller flange height increases the guiding surface of the roller, which grealy 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

Secondary Track Guiding

SystemOne secondary track guiding has also been improved. The new SystemOne track link design is straight, and eliminated 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 similar to 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 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 imporved idlers can be found in Service Magazine, SEPD0619 March, "Track Idlers Have Benn Improved" 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 similar to 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 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 Coumn B. The tractor guiding requirements 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 arrangment.

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. Level 2 and Level 3 guiding arrangements are attachments.

Examples of various tractor models that are equipped with the different SystemOne guiding arrangements are shown below.

Illustration 10	g01287749
D4H XL: Level 1, Standard Track Guiding Arrangement (Standard).

Illustration 11	g01287757
D4H LGP: Level 1, Standard Track Guiding Arrangement (Standard).

Illustration 12	g01287764
D4H XL: Level 2, Track Guiding Arrangement (Moderate Service).

Illustration 13	g01287769
D4H LGP: Level 3, Heavy Duty Track Guiding Arrangement (HeavyDuty).

When the proper guiding arrangement has been determined, proceed to ""Compatibility of Track Frames with SystemOne Guiding Arrangements" " section.

Compatibility of Track Frames with SystemOne Guiding Arrangements

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

• Determine if the distance between the structural plates of the end guiding 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. 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 14 below:
      • Dimension (D) is the distance from the center of the track frame (7) to each mounting surface (8) for the end guiding guard wear strips.

      • Dimension (C) is the distance between the mounting surfaces (8) for the end guiding guard wear strips.

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   Illustration 14	g01132150
   (7) Track frame centerline (8) Wear strip mounting surfaces (C) 240 ± 1.5 mm (9.45 ± 0.06 inch) (D) 120 ± 1.5 mm (4.72 ± 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 15	g01196206
Former mounting system with "L-Section" wear strips

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Illustration 16	g01196208
Current mounting system with flat wear strips (9) Required support bar for the wear strip

2. This step includes a final inspection of the end guiding 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 guiding 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 guiding guard changed from the former "L-Section" to the current flat section. Pictures of the former "L-Section" and the current flat section mounting systems for the wear strips are shown in Illustrations 15 and 16.

   It is critical to assure that the support bars are installed on any field tractor which is retrofitting to SystemOne undercarriage.

   Inspect the track frame end guiding guards for the support bars, as shown in Illustration 17 below:

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Illustration 17	g01132186
(9) Required support bars for the wear strips

Note: If these support bars are present, skip Step 3 and proceed to Step 4. If the support bars are not present, proceed to Step 3.

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Illustration 18	g01287773
SystemOne wear strip mounting arrangement (9) Welded support bar (10) SystemOne wear strip with "bump" pointed up towards top of guard

3. This step gives instructions for adding wear strip support bars to the track frame end guiding guards. If the track frames already have these support bars (shown in Illustration 18), then proceed to Step 3. Otherwise, continue with Step 4.

   One support bar is required on the inside of each guiding guard. The table 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	9U-9244	Bar Stock (9.5 mm x 180 mm long)

   In addition to the support bars, the wear strips and mounting hardware are required to proceed. Part numbers and quantities for the the wear strips and mounting hardware are found in the last section entitled ""Parts Lists for SystemOne Guiding Arrangements" ".

   In order to install support bars (9) on the end guiding guards, first bolt on the new SystemOne profiled wear strips (10). It is critical for the new SystemOne wear strips to be mounted in the correct position. Make sure the "bump" of the wear strip is pointed up, towards the top of the end guiding guard. This is shown in Illustration 18.

   Note: Installing the wear strip in the wrong direction can:

   • Negatively affect track guiding

   • Damage the track

   • Damage the track guiding guards

   Torque the wear strip mounting bolts to 100 ± 20 N·m (74 ± 15 lb ft).

   Next, lay support bars (9) along the top of the profiled wear strips (10). Illustration 18 shows the new SystemOne wear strip with the welded support bar on top. Locate the bar so the ends are centered between the end wear strip mounting bolts. This is the same for both front and rear, as shown in Illustration 18. Once the support bar is properly located, weld the support bar to the guiding guard along the entire top edge with an 8 mm (0.3 inch) fillet weld. Also, weld each end of the support bar to the guiding guard.

   Note: Take care not to weld the bolt-on wear strip to the guiding guard.

   Do this procedure for (4) support bars on each track frame. When Step 4 is complete, skip Step 4 and proceed to the section entitled ""Parts Lists for SystemOne Guiding Arrangements" ".

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Illustration 19	g01215325
(9) Welded support bar centered between end mounting bolts (10) SystemOne wear strip (11) Front track guiding guard (12) Rear track guiding guard (F) Front end of track frame (R) Rear end of track frame

4. This step provides instruction for properly mounting the end guiding guard wear strips to the end guiding guards. Before proceeding, make sure the wear strip support bars are present on the track frame end guiding guards to proceed. These support bars are shown in Illustration 18. If the support bars are not present, go back to Step 3. Part numbers and quantities for the wear strips and mounting hardware are found in the ""Parts List for SystemOne Guiding Arrangements" " section.

   It is critical for the new SystemOne wear strips to be mounted in the correct position. Make sure the "bump" of the wear strip is pointed up, towards the top of the end guiding guard.

   This is shown in Illustration 18.

   Note: Installing the wear strip in the wrong direction can:

   • Negatively affect track guiding

   • Damage the track

   • Damage the track guiding guards

   Torque the wear strip mounting bolts to 100 ± 20 N·m (74 ± 15 lb ft).

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 20 through 25 show the number and location of SystemOne (bolt on) track guiding guards and wear strips. This information is shown for each guiding arrangement level (1, 2, 3) for each tractor configuration (XL or LGP). D4H XL and LGP tractors have a 7 roller track frame.Table 4 below, provides the torque value for the mounting 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 20	g01215330
D4H XL Track Frame: Level 1 Guiding Arrangement.

Illustration 21	g01296295
D4H XL Track Frame: Level 2 Guiding Arrangement (Moderate Service).

Illustration 22	g01215349
D4H XL Track Frame: Level 3 Guiding Arrangement (Heavy Duty).

Illustration 23	g01296304
Late D4H LGP Track Frames: Level 1 Guiding Arrangement (Standard).

Illustration 24	g01296306
D4H LGP Track Frame: Level 2 Guiding Arrangement (Moderate Service).

Illustration 25	g01296308
D4H LGP Track Frame: Level 3 Guiding Arrangement (Heavy Duty)