Apltcl040 SGD L 01

Undercarriage
Student Guide
Caterpillar Service Technician Module
APLTCL040
Undercarriage
Published by Asia Pacific Learning

1 Caterpillar Drive
Tullamarine Victoria Australia 3043
Version 3.2, 2003
Copyright © 2003 Caterpillar of Australia Pty Ltd Melbourne, Australia.
All rights reserved. Reproduction of any part of this work without the permission of the copy-
right owner is unlawful. Requests for permission or further information must be addressed to
the Manager, Asia Pacific Learning, Australia.
This subject materials is issued by Caterpillar of Australia Pty Ltd on the understanding that:
1. Caterpillar of Australia Pty Ltd, its officials, author(s), or any other persons involved
in the preparation of this publication expressly disclaim all or any contractual,
tortious, or other form of liability to any person (purchaser of this publication or not)
in respect of the publication and any consequence arising from its use, including
any omission made by any person in reliance upon the whole or any part of the
contents of this publication.
2. Caterpillar of Australia Pty Ltd expressly disclaims all and any liability to any person
in respect of anything and of the consequences of anything done or omitted to be
done by any such person in reliance, whether whole or partial, upon the whole or
any part of the contents of this subject material.
Acknowledgements
A special thanks to the Caterpillar Family for their contribution in reviewing the curricula for this
program, in particular:
Caterpillar engineers and instructors
Dealer engineers and instructors
Caterpillar Institutes.
MODULE INTRODUCTION
Module Title
Undercarriage.
Module Description
This module covers the knowledge and skills of Undercarriage. Upon satisfactory completion of this
module students will be able to competently service and repair Undercarriage.
Pre-Requisites
The following modules must be completed prior to delivery of this module:
Occupational Health and Safety
Workshop Tools
Mechanical Principles
Power Train Fundamentals
Final Drives.
Learning & Development

Delivery of this facilitated module requires access to the Undercarriage Activity Workbook.
The successful completion of the curriculum provides the knowledge for competency assessment,
on further learning outcomes, by an Accredited Workplace Assessor.
Suggested References
No references recommended.
Assessment Methods
Classroom and Workshop
To satisfactorily complete this module, students must demonstrate competence in all learning outcomes.
Consequently, activities and assessments will measure all the necessary module requirements.
For this module, students are required to participate in classroom and practical activities and
satisfactorily complete the following:
Activity Workbook
Knowledge Assessments
Practical Activities.
Workplace
To demonstrate competence in this module students are required to satisfactorily complete the
Workplace Assessment(s).
APLTCL040
© Caterpillar of Australia Pty Ltd 1

UNDERCARRIAGE MODULE INTRODUCTION
APLTCL040
2 © Caterpillar of Australia Pty Ltd

UNDERCARRIAGE
KNOWLEDGE AND SKILLS ASSESSMENT
Learning Outcome 1: Identify undercarriage systems used on earth moving equipment.
Assessment Criteria
1.1 What is undercarriage.
1.2 Oval track.
1.3 Elevated sprocket track.
1.4 Suspended undercarriage.
1.5 Track frame design
1.5.1 Oval track
1.5.1.1 Track adjusters
1.5.1.2 Recoil spring
1.5.2 Elevated sprocket
1.5.2.1 Sealed and lubricated cartridge pin
1.5.2.2 Rubber pads
1.5.2.3 Roller frames
1.5.2.4 Equalizer bar.
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UNDERCARRIAGE K NOWLEDGE AND SKILLS ASSESSMENT
Learning Outcome 2: Identify and describe the purpose of track and roller components.
Assessment Criteria
2.1 Track link
2.1.1 Wear measurement.
2.2 Pins and bushings
2.2.1 Track pin.
2.3 Track section.
2.4 Track joining
2.4.1 Split master link
2.4.2 Master pin and master bushing.
2.5 Track joint construction
2.5.1 Link pitch
2.5.2 Track pitch
2.5.3 Sprocket pitch
2.5.4 Track pitch extension
2.5.5 Sealed track
2.5.6 Sealed and lubricated track
2.5.6.1 Seals
2.5.7 Heavy duty track
2.5.8 Positive pin retention track
2.5.9 Rotating bushing track.
2.6 Track shoes
2.6.1 Area specific wear
2.6.1.1 Terrain
2.6.1.2 Application
2.6.2 Operational factors
2.6.2.1 Single grouser shoe
2.6.2.2 Extreme service shoe
2.6.2.3 Double grouser track shoe
2.6.2.4 Self cleaning Low Ground Pressure (LGP)
shoe
2.6.2.5 Trapezoidal centre hole shoes
2.6.2.6 Chopper shoe.
2.7 Sprockets
2.7.1 Sprocket assembly
2.7.2 Mud and snow sprocket.
2.8 Track rollers
2.8.1 Components
2.8.1.1 Early design
2.8.1.2 Current design
2.8.2 Wear measurements.
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2.9 Carrier rollers

2.9.1 Components
2.10 Idlers
2.10.1 Components
2.10.1.1 Early design
2.10.1.2 Later design
2.11 Track roller guards.
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Learning Outcome 3: Conduct tests, inspections and adjustments on oval or elevated

sprocket type undercarriage.
Assessment Criteria
3.1 Describe the procedures for track adjustments on an elevated
sprocket type Track-type Tractor (an oval type track system
may be used in lieu)
3.1.1 Safety procedures
3.1.2 Preparing machine
3.1.2.1 Stoppage without braking
3.1.2.2 TAG OUT procedure
3.1.3 Track adjustment
3.1.3.1 Loose track
3.1.3.2 Tight track.
3.2 Describe roller frame compartment lubrication level
inspections
3.2.1 Cover plate
3.2.2 Fill plug.
3.3 Describe the procedures for Track-type Tractor dry joint field
repair
3.3.1 Machine preparation
3.3.2 Positioning of pin
3.3.3 Positioning of blocks
3.3.4 Track adjuster pressure
3.3.5 Removing track shoes
3.3.6 Removing pin and links
3.3.7 Assembly of link
3.3.8 Lubrication
3.3.10 Function test.
3.4 Describe the procedure for removal, disassembly, assembly
and replacement of a track roller without removing tracks
3.4.1 Inspection procedure
3.4.2 Removal of roller
3.4.3 Disassemble roller
3.4.4 Roller inspection
3.4.5 Assemble roller
3.4.6 Installation of roller
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3.5 Describe the procedure for track separation and reconnection

using a master link design
3.5.1 Safety procedures
3.5.1.1 Track frame falling
3.5.1.2 Track coming off roller frame
3.5.2 Track adjuster cover
3.5.3 Loosen track
3.5.4 Moving master link to position
3.5.5 Attach lifting straps
3.5.6 Separate master link
3.5.7 Track security
3.5.8 Reconnection of track
3.5.8.1 Processes
3.5.8.2 Torques
3.5.10 Track adjuster covers
3.6 Describe the methods of measuring track components
3.6.1 Calipers
3.6.2 Ultrasonic wear indicator.
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Learning Outcome 4: Conduct servicing and repair tasks on an oval or elevated sprocket
type undercarriage fitted to earthmoving equipment.
Assessment Criteria
4.1 State and follow the safety precautions that must be observed
to prevent personal injury or damage to equipment.
4.2 Tasks to include inspection of the:
4.2.1 Visual inspection, including measurement of track com-
ponents
4.2.2 Remove a track
4.2.3 Remove a roller assembly
4.2.4 Disassemble and assemble a roller assembly
4.2.5 Refit roller assembly
4.2.6 Remove a track link assembly
4.2.7 Refit the track link assembly
4.2.8 Connect track
4.2.9 Adjust track
4.2.10 Check lubrication levels
4.2.11 Function test..
4.3 Tasks are completed:
4.3.1 Without causing damage to components or equipment
4.3.2 Using appropriate tooling, techniques and materials
4.3.3 According to industry/enterprise guidelines, procedures
and policies
4.3.4 Using and interpreting correct information from the
manufacturer's specifications.
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UNDERCARRIAGE
TABLE OF C ONTENTS
TOPIC 1: Undercarriage Systems

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Oval Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Elevated Sprocket Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Track Frame Design - Oval Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Elevated Sprocket Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TOPIC 2: Track and Roller Components

Track Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pins and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Track Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Track Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Track Joint Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Track Shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Track Roller Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Reconditioning Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
TOPIC 3: Service, Repair and Adjustment

Track Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Track Type Tractor - Dry Joint Field Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Track Type Tractor - Sprocket Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Track Type Tractor - Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Track Type Tractor Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Track Type Tractor Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Track Separation and Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Master Pin Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Excavator Track Carrier Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Excavator Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Front Idler, Recoil Spring and Hydraulic Track Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . 118
Front Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Final Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
APLTCL040

UNDERCARRIAGE TABLE OF CONTENTS
APLTCL040

UNDERCARRIAGE
TOPIC 1
Undercarriage Systems
INTRODUCTION
Figure 1
Undercarriage is the generic term given to all the components which are part of the
track drive system (Figure 1). This topic identifies the various types of track systems
used on different Caterpillar machine models, and describes the purpose and
construction of the various undercarriage components. Also covered are the methods
of measurement used on the critical undercarriage components that normally wear.
Some years ago, Caterpillar introduced the CTS System (Custom Track Service),
which is a programme where dealer field representatives periodically visit customers
who own track type machines and measure the undercarriage components. Using
CTS, predictions of remaining track life remaining could be made to allow the
customer to schedule and budget for repairs to these expensive components. After
measurement, the percentage of wear can be established from the CTS handbook,
which has all the dimensions for the components used on each model.
More recently, Caterpillar has also implemented ultrasonic measurement tooling and a
computer program for the management of undercarriage in the field.
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UNDERCARRIAGE
OVAL TRACK
Figure 2 - Oval (Conventional) Undercarriage
Oval undercarriage design used to be the standard configuration for all tracked
vehicles (Figure 2). The drive sprockets are located at the rear of the machine and
the idlers are located at the front of the machine. There are one or two carrier rollers
at the top and a series of track rollers at the bottom support the machine.
Figure 3
Caterpillar introduced elevated sprocket track (Figure 3) in the 1978 to improve

various aspects of machine performance. All of the other manufacturers of track type
machines use oval track. In the Caterpillar system, elevated sprocket is now the
standard for all sizes of track type tractors although D4 and D5 size machines are
available with oval track as an option. Track type loaders and excavators have oval
track as standard.
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Track Loader
Figure 4 - Track Loader
Caterpillar Track loaders are produced with oval track with one carrier roller
(Figure 4).
Small Track-Type Tractors
Figure 5 - D4C Track-Type Tractor
The D3C, D4C and D5C Track-type tractors are available with oval track and one
carrier roller (Figure 5).
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Excavator
Figure 6 - Excavator
Excavators use oval track and have a relatively long frame to provide stability for the
machine whilst digging. Most hydraulic excavators have three undercarriage configurations.
These are standard, extended and narrow and each is designed for a specific type of
application. Narrow is used normally when size limitations for transport exist.
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UNDERCARRIAGE
ELEVATED SPROCKET TRACK
Track Type Tractor
Figure 7 - Track Type Tractor
The elevated sprocket design (Figure 7) is used in most Caterpillar track-type tractors
and in pipelayers. The elevated sprocket design isolates the final drive components
from shocks while improving machine balance and traction and provides maximum
flexibility for mounting track roller frames. This results in less chance of seal damage.
Elevated sprocket machines have a front and rear roller frame on each side of the machine.
The pivot shaft connects the right and left rear roller frames. The pivot shaft transmits
the ground shocks directly to the main frame rather than through the power train
components. The roller frames can oscillate around the pivot shaft.
The equalizer bar connects the right and left front roller frames.
The equalizer bar is pinned in the centre of the tractor and can rotate around the
centre pin joint. The equalizer bar controls the degree that the roller frames can
oscillate around the pivot shaft.
The front roller frame slides inside the rear roller frame. A recoil spring maintains
the track tension.
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Suspended Undercarriage
Figure 8 - Suspended undercarriage
Larger (Caterpillar D8 and up) elevated sprocket machines are equipped with a
suspended undercarriage (Figure 8). The suspended undercarriage provides up to
15% more ground contact.
The four major bogies and the four minor bogies can oscillate in the roller frame. This
causes the track to better follow the contour of the ground.
Pipelayer
Figure 9 - Pipelayer
Pipelayers also have an elevated sprocket design (Figure 9). The roller frames in
Pipelayers do not oscillate relative to one another. This undercarriage is designed to
absorb impact loads and reduce shock loads transferred to the machine.
The roller frames are rigidly connected to the main frame by a two-point mounting
system for maximum stability in pipelaying applications. The long, wide-track contact
area provides a large, stable work base. The pivot shaft connects the right rear and
left rear roller frame. The pivot shaft transmits the ground shocks directly to the main
frame rather than through the power train components.
A hard bar is used in place of the equalizer bar. The hard bar connects the two front
roller frames. The roller frames have constant position relative to the main frame.
Diagonal braces are not needed.
The front roller frame slides inside the rear roller frame. A recoil spring maintains
the track tension.
Mounting brackets for the boom frame and the counterweight frame are incorporated
into the respective roller frames. The counterweight is pinned to the right roller frame.
The boom is bolted to the left roller frame.
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Track Skidder
Figure 10 - Track Skidder
The track skidder (Figure 10) is equipped with an elevated sprocket that is in a more
forward location than the tractors. The position of the sprocket is determined by
balance requirements for the machine. Track Skidders are used in forestry
applications for retrieval of logs by towing or lifting with a grapple.
TRACK FRAME DESIGN - OVAL TRACK
Figure 11
Some machines use a rigid track frame design (Figure 11). In this design the track
frame (side frame) is mounted rigidly to the machine main frame at the front, as well
as at the rear. There is no relative movement between the track frame and mainframe.
This feature gives the machine greatly improved stability and is used on tracked
loaders and excavators.
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Dead Axle Arrangement
Figure 12 - Track Frame with Diagonal Brace
The track frame (Figure 12) pivots on a “dead” axle or pivot shaft that also supports
the sprocket. The axle is held stationary in the main frame.
A bearing on the outer end of the axle allows the track frame to pivot up and down, as
well as supporting the outer end of the sprocket hub.
The track frames are kept in the correct alignment with the machine main frame by
diagonal braces.
The inner end of the diagonal brace is mounted on a bearing block that is situated on
the dead axle under the main frame of the tractor.
In some cases the manufacturer may refer to a diagonal brace as an A-Frame.
Figure 13
The track frames are fastened to the final drive bearing case and to the steering
clutch and bevel gear case (Figure 13). The diagonal braces give stability and keep
the track frames parallel. The frames can move up and down separately.
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UNDERCARRIAGE
Figure 14
The mainframe contains a pinned equaliser bar that rotates inside a saddle (Figure 14).
The front of the roller frame is attached to the ends of the equaliser bar. This
arrangement allows the roller frames to oscillate through a small angle vertically but
are unable to move laterally.
Figure 15
The track roller frame pivots around the rear axle. The front of the frame is allowed to
move up or down by the equaliser bar at the front of the machine (Figure 15). This
arrangement increases the stability of the machine, and gives each track a maximum
ground contact area.
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UNDERCARRIAGE
Figure 16
The idler (Figure 16) mounted at the front of the roller frame guides the track and it is
also used to maintain the tension in the track.
Figure 17
The yoke that the idler sits in is connected by a shaft to a track adjuster (Figure 17).
The adjuster, which is used to control the tension in the track, can be either a
mechanical or hydraulic arrangement. The spring, directly behind the adjuster, serves
as a shock absorber.
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UNDERCARRIAGE
Figure 18
The idler slides forwards and backwards on the frame. Two adjustments are provided.
The alignment of the front idler is done by using shims between the collars and the
idler support blocks.
Shims are used to make the idler shaft parallel to the roller shafts and to keep the
clearance between the plate assembly and the yoke.
Figure 19
Shims are used to get a clearance (Figure 19 A) between the frame and guide (on
each side of the idler).
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Track Adjusters
Figure 20
The track adjuster is a hydraulic device (Figure 20). It is operated when lubricant is
added with a hand grease gun through a fitting (2) to move the idler forward and tighten
the track. To loosen the track, loosen the relief valve (1). When the tracks are loosened
lubricant will come out one or more holes (3) on the sides of the adjusting assembly.
Recoil Springs
Figure 21
The recoil springs are normally in compression (Figure 21). They are held between
brackets and stops on the track roller frames. Normally, the recoil springs do not push
against the track.
Track adjustment is made by the hydraulic mechanism for track adjustment. Pressure
lubricant is sent to a space (3) through a fill valve. This moves the recoil rod (4) and
the front idler forward. The movement of the recoil rod and the front idler tightens the
track. The tension on the track is released by opening a relief valve.
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UNDERCARRIAGE
WARNING
Never visually inspect the holes in the relief valve to see if lubricant is coming out of them.
Make sure the holes are clean before the tension is released on the track. Watch the
cylinder to see that it moves.
If rocks or other materials get between the track and rollers or idler or sprocket, the
recoil rod (4) moves to the rear. Since the lubricant in the space (3) cannot be
compressed, the piston (10) and sleeve (7) move to the rear. The sleeve (7) pushes
on the pilot (8), which puts the springs (1 and 2) in compression. This action absorbs
the shock loading created in the track.
Compression of the recoil springs is limited by the sleeve (7) on the recoil spring bolt
(6). The cover (9) is fastened to the recoil spring housing and holds the springs in
compression when the lubricant pressure is released. A nut (5) is used to keep the
recoil spring in compression if the spring assembly is removed.
ELEVATED SPROCKET DESIGN
Figure 22
One of the most easily seen design characteristics of the elevated sprocket design is
the triangular shape of the track (Figure 22). The reason for this shape is that the
sprockets and final drives are elevated (raised) above the track roller frames. In this
elevated location, the final drives are installed along a common centreline with the
bevel gear and the steering and brake clutches. Also, the final drives are raised above
the area where most of the abrasive wear and packing takes place during operation.
Since they are not directly connected to the roller frames, the final drives do not
support any of the weight of the machine. This permits the undercarriage and
suspension to be made resilient (flexible).
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UNDERCARRIAGE
Figure 23
This design is fitted to D4 through D11 track type tractors. The D8 and above are
fitted with suspended undercarriage whilst the models below D8 are fitted with a rigid
bottom roller design.
Figure 23 shows the relative locations of the movable components in the suspended
undercarriage arrangement. This resilient undercarriage arrangement will keep more
track on the ground at all times, help decrease undercarriage damage, and increase
operator comfort.
The four major bogies pivot on sealed and lubricated cartridge pins. The front and
rear major bogies each support an idler and a minor bogie. Each of the two major
bogies in the middle of the roller frame supports a minor bogie. Each minor bogie
supports two track rollers. The minor bogies also pivot on sealed and lubricated
cartridge pins. The idlers turn on sealed and lubricated shafts. Since the major and
minor bogies are free to pivot around the cartridge pins, the rollers, idlers, and track
have the ability to envelop (or surround) rocks and ground surfaces that are not level.
Eight rubber pads are used in pairs on each roller frame. A rubber pad is installed on
top of each major bogie. The other four rubber pads are installed on the bottom of the
roller frame in alignment with the pads on the major bogies. The pads limit the upward
movement of the major bogies and operate similarly to shock absorbers to cushion
the ride of the machine.
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Sealed and Lubricated Cartridge Pin
Figure 24 - Sealed and Lubricated Cartridge Pin
A sealed and lubricated cartridge pin is shown at Figure 24. There are 16 cartridge
pins in each roller frame (32 per machine). Two are used for each Major and Minor
Bogie. All the cartridge pins are identical. Except for the rubber stoppers and plastic
plugs in the ends of the pin, no individual parts are serviced. If pin replacement is
necessary, a complete new pin must be installed.
The end of the pin is stamped with a letter “X” to assist the service technician to install
the pin the correct way. The end marked “X” must be installed to the outside of the
roller frame. The letter “X” also designates the radial location of the cross drilled
lubrication hole. During installation the “X” must be on top or bottom of the vertical
centreline of the pin bore for proper lubrication of the bushings and seals.
Figure 25 - Cross-section of Sealed and Lubricated Cartridge Pin
The components and structure of the sealed and lubricated cartridge pin is shown in
this cross-section in Figure 25.
The components are:

Pin
Inner collar
Outer Collar
Bushing
Rubber stoppers
Plugs
Thrust rings.
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UNDERCARRIAGE
The hollow pin serves as an oil reservoir. Oil flows through the cross drilled holes in
the pin to lubricate the bushing and keep the seal surfaces wet.
The seals keep oil in and dirt out. The thrust rings maintain the correct distance
between the collars and bushing.
The inner and outer collars are laser welded to the pin and pressed into the roller
frame supports. The bushing is pressed into the bogie but is free to rotate around the
pin. This allows the bogie to pivot on the pins. The outer collar is slightly larger than
the bushing and the bushing is slightly larger than the inner collar. The inner collar
also has a radius on the outside diameter whilst the outer collar has a square corner.
The cartridge pins should be checked for leakage during service.
Rubber Pads
Figure 26 - Rubber Pads
The rubber pads are shown in Figure 26. 16 pads are installed on each machine.
Four bolts hold each pad in position. The pads should be inspected for large cracks or
missing pieces of rubber every 500 service hours.
Roller Frames
Figure 27
The roller frames are made of two tubular (tube shaped) steel sections with steel
support castings welded to them (Figure 27). This tubular design gives maximum
strength for resistance to the many stresses caused by ground impact, tool
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engagement, and normal operation of the machine. The front section of the roller
frame telescopes (slides) into the rear section. Inside of the front section are the recoil
spring and track adjustment mechanism. The roller frames are connected at the rear
of the machine by a large pivot shaft and at the front by an equalizer bar.
Two large covers are installed on the side of this roller frame. The cover nearest the
rear of the machine is for the pivot shaft. (Dozer, a trunnion for the dozer push arm is
installed instead of the rear cover.) The cover near the centre of the roller frame is for
one of two large keys. The keys prevent rotation of the front section of the roller frame
inside of the rear section. A second key is installed on the side of the roller frame
nearest the chassis.
Figure 28
Figure 28 is a close view of the area where the tube on the front section of the roller
frame telescopes into the rear section. The tube on the front section (in the area
shown has a chrome plated sleeve with a smooth outer surface. A large bronze
bearing in the front of the rear section is used to support the tube in the area of the
sleeve. The front section of the roller frame can be removed from the machine without
removing of the rear section.
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Figure 29
To remove the front section of the roller frame, it is first necessary to break (remove)
the track and install the strap (FT1552) as shown in Figure 29. The strap prevents
movement of the major bogie during the removal and installation procedure.
Figure 30
Figure 30 shows the tube on the front section of the roller frame after removal from
the rear section. The slot in the outer diameter of the tube is for one of the two keys.
At the right end of the tube is the chrome plated sleeve that is used as the bearing
and seal surface. At the left end of the tube is the track adjustment cylinder.
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Figure 31
Figure 31 shows the components in the recoil and track adjustment mechanism. The
area inside the cylinder at the left end of the piston is filled with oil. During recoil, the
front roller frame along with the piston and the spring support move to the left (toward
the rear of the machine). The cylinder cannot move because it is stopped against the
end of the bore in the rear section of the roller frame. This causes a large hydraulic
force in the oil chamber at the left end of the cylinder. The hydraulic force pushes the
sleeve and the guide to the right. This action compresses the recoil spring.
The area at the left of the piston is twice as large as the area as the left end of the
sleeve. During recoil, this difference in area causes a hydraulic force multiplication
ratio of 2:1 (two to one). This forces the recoil spring to compress (travel) farther than
the actual recoil distance. A force at the front idler of 90,000 pounds (400 kN) toward
the rear of the machine will start recoil action. At that time, the spring feels 45,000
pounds (200 kN) because of the ratio of areas inside the recoil mechanism.
During normal operation of the machine, the movable components of the

undercarriage start to wear. This wear causes the tension of the track chain to
decrease. To make up for wear and tighten the chain, adjustment of the track is
necessary. To tighten the track, grease (MPG) is pumped through the fill valve into the
chamber at the left end of the cylinder. This causes the front roller frame to move to
the right and increases the distance between the idlers.
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Figure 32
Near the end of the track adjustment cylinder are the fill valve (grease fitting) and the
bleed valve (relief valve) (Figure 32). When opened, the bleed valve permits oil (or
grease) to flow out of the oil chamber to loosen the track. A notch is machined in the
end of the track adjustment cylinder. When installed in the rear section of the roller
frame, the end of the cylinder makes contact with the end of the bore. The notch fits
over a small steel block, which is welded on the contact surface to prevent rotation of
the cylinder during operation.
Two bolts hold each of the two retainer locks in position on the end of the tube. The
retainer locks prevent rotation of the large threaded retainer, which is used to hold
and compress the recoil spring inside of the tube
Figure 33
A safety cable (Figure 33) (partially visible) is connected between the end of the track
adjustment cylinder and the end of the tube. After the front section of the roller frame
is removed from the machine, the track adjustment cylinder and the piston are free to
slide out of the tube. The cable keeps the cylinder and piston in position during
removal and installation of the roller frame.
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Pivot Shaft
Figure 34 - Pivot Shaft
The roller frames are connected together at the rear by a pivot shaft (Figure 34). Each
roller frame can oscillate (turn) 3o up and 3o down around the pivot shaft. The frames
oscillate on large bronze bushings in a sealed oil compartment in each roller frame.
Figure 35
Figure 35 shows the roller frame as it is removed from the chassis. The pivot shaft can
be seen at the rear. This consists of a long straight shaft, which passes straight through
the machine frame. Each track roller frame is anchored to the pivot shaft and bearings
are fitted in the roller frames to allow the frame to rotate around the pivot shaft.
The end of the equalizer bar and anchor point can be seen at the front of the illustration.
Figure 36 - Pivot Shaft
The pivot shaft (Figure 36) fits inside a large reinforced tube, which is welded between
the sides of the main frame. The tube also provides a connecting passage between
the rear oil chambers for both roller frames.
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Equalizer Bar
Figure 37
The roller frames are connected near the front of the machine by an equalizer bar.
Installed on top of the equalizer bar are two pairs of wedge-shaped rubber oscillation
pads (Figure 37). The rubber pads contact the bottom of the frame to control the
movement of the equalizer bar and improve the stability of the machine during hillside
or rough operation. In the centre of the equalizer bar is a special non-metallic bearing
which does not need lubrication. A hardened steel pin connects the equalizer bar to
the support member (saddle) in the centre of the main frame. The pin is installed in
the saddle with a press fit. During operation, the equalizer bar oscillates (turns)
around the centre pin.
Figure 38
As was said earlier, the pins in the ends of the equalizer bar (Figure 38) have
spherical bearings which permit oscillation and prevent twisting (bends caused by
rotation) during operation. When the machine is shipped, a plug is installed in each
end of the equalizer bar. When lubrication of the spherical bearings is necessary,
remove the plugs and install grease fittings. After lubrication of the bearings, remove
the grease fittings and install the plugs.
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CAUTION
Be sure to check the maintenance section of the service manuals for the correct procedure
for lubrication of the spherical bearings. Too much grease can damage the end pin seals.
Figure 39
Figure 39 is a view from under the machine and shows the connection between the
end of the equalizer bar and the roller frame. Two bearing caps fasten each end pin to
the roller frame support. Before the equalizer bar can be removed from the machine, it
is first necessary to remove one of the roller frames.
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TOPIC 2
Track and Roller Components
Figure 40
TRACK LINK
Figure 41
Two track links Figure 41 are used in each track section. The track links provide a
means to attach the track shoes and provide a continuous rail for the rollers.
The various components of the link are as follows:
1. The rail is the portion of the link that rides over the roller tread. The hardness of
the rail matches the hardness of the track roller tread and flange.
2. The pin bore holds the pin.
3. The bushing bore holds the bushing.
4. The counterbore is inside the pin bore. The counterbore holds the sealing
arrangement for sealed and lubricated track.
5. The shoe strap is bolted to the track shoe.
6. The strut helps support the link rail.
7. The bushing strap is the portion of the bushing bore at the rear of the link. When
the bushing bore is too thin, cracking can occur and prevent link rebuild.
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Wear Measurement
Figure 42
Track links wear in a number of areas. The rail surface is measured with a depth
gauge from the top of the rail to the bottom of the track shoe (Figure 42). Other wear
is more by observation and assessment.
For example:
Side rail wear is caused by hillside operation, steep ground or excessive turning.
Pin boss side wear caused by contact with the outside flange of the rollers.
Excessive face wear caused by slackening of the joints because of abrasive
materials on the ground.
Pin boss wear by track guards because of excessive slackness of the chain due
to sprocket and roller mis-alignment or uneven roller wear.
PINS AND BUSHINGS
Figure 43
In Figure 43, the pin is in the centre. The bushing is to the right of the pin. Pins and
bushings hold the two links of each track section together. The pin also acts as a
hinge to connect two track links.
In sealed track, the pins are solid. In sealed and lubricated track, the pins are hollow so
the area between the pin and the bushing of the next track section can be lubricated.
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Track Pin
Figure 44
The top pin shown in Figure 44 is for a sealed and lubricated track. (The different
types of track joint construction will be discussed later.)
The pin is centre drilled from one end nearly the entire length.
The cross drilled hole provides a passage for the oil to flow between the pin and the bushing.
The cross-drilled hole must be oriented toward the rail of the link. This keeps the
stress source away from the relative weakness created by the cross drilled hole.
TRACK SECTION
Figure 45
The track section (Figure 45) consists of two track links, a pin and bushing. The track
sections are connected together to form the track chain. The track pin of the next
section, fits into the track bushing.
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Figure 46
The track section has links, pins, seal washers and bushings (Figure 46). Each track
link (1) fits over the track link in front of it, making a chain. Each link has a
counterbore in the part that fits over the other link. The seal washers (2) between the
counterbore and the bush rings give a tight sealed fit to keep foreign material out.
Track pins (3) and bushings (4) are all similar.
Figure 47
The pin is pressed into the pin bore of the link. Although not shown in Figure 47 (left),
there is a substantial interference fit between the pin and the pin bore of the link. During
operation, there is no relative motion between the pin and the link.
The bushing must also be pressed into the bushing bore of the link (Figure 47, right).
There is also a substantial interference fit between the bushing and the bore for the
bushing. There is no relative motion between the bushing and the link during operation.
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Figure 48
The other link is pressed onto the pin and the bushing (Figure 48). The opposing links
are mirror images of one another.
There is no relative motion between any of these components.
Figure 49 - Link and Pin of the Next Track Section
The track pin for the next section slides into the bushing and is a loose fit (Figure 49 left).
In sealed assemblies, seals fit over the pin and seat against the track link.
Opposing links are pressed onto the pin and the next bushing simultaneously.
The assembly process is continued until the desired quantity of sections are produced
to make a track chain of the required length (Figure 49, right).
Figure 50
When a whole link assembly is complete, track shoes will be bolted onto the track
sections using four special bolts for each shoe (Figure 50).
The sprocket drives the track group. The rollers and idlers keep the track in the correct
position and provide support.
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TRACK JOINING
To remove track from a machine, a joining method needs to be provided. This is
accomplished in two ways.
Split Master Link
Figure 51
Use of the two piece, split master link (Figure 51) is the most effective way to allow
for track removal. This method is used for most Caterpillar machines.
One half of the master link shown in the above figure goes on one end of the link
assembly; the other half goes on the other end.
The master link halves are diagonally serrated and bolted together when the track is
assembled to provide a strong joint.
Figure 52
Figure 52 shows the bolts (6), which fasten the split master links, are a different
length to the other track bolts, and also fasten the shoes (5).
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Master Pin and Master Bushing
Figure 53 - Master Pin and Master Bushing
A master pin and bushing (Figure 53) are used to separate and connect the track on
excavators and some early track type tractors.
The master pin is slightly longer than the other pins in the track and has a machined
step on each end. The master bushing is shorter than the other bushings in the track
and does not extend into the link bores. A spacer is located between the end of the
master bushing and the seal.
To separate the track, the master pin is either hammered through or pressed through
using a portable press, until the track separates.
TRACK JOINT CONSTRUCTION

Before discussing the different types of track joint construction, it is necessary to
review link pitch, track pitch, sprocket pitch and track pitch extension.
Link Pitch
Figure 54 - Link Pitch
Link pitch is the distance between the centre of the bushing bore and the centre of the
pin bore on one link (Figure 54).
Link pitch does not change during service.
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Track Pitch
Figure 55 - Track Pitch
Track pitch is the distance between two adjoining track sections.
Track pitch is the distance from the centre of the pin of one section to the centre of
the pin in the adjoining section (Figure 55).
Wear causes track pitch to change.
Sprocket Pitch
Figure 56 - Sprocket Pitch
Sprocket pitch (Figure 56) is the distance measured from the centreline of a
bushing in a sprocket tooth to the centreline of the next bushing which is two
teeth over in the sprocket.
The sprocket pitch changes only very slightly during service due to wear of the
sprocket teeth.
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Track Pitch Extension
Figure 57
Track pitch and sprocket pitch are the same when a machine is new, however, when
using a track chain assembly that is not sealed, track pitch changes during operation
due to abrasive material flowing between the pin and the bushing.
As wear occurs, track pitch increases. The link pitch and the sprocket pitch do not
change therefore mismatch occurs (Figure 57).
When the track and sprocket pitch do not match, the teeth of the sprocket do not
engage the bushings properly and causes rapid additional wear.
This mismatch usually is the end point of the first life of the track chain, and can
happen before any significant wear has taken place on the other components.
When pitch extension reaches the limit, the track assembly is removed, disassembled,
and the pins and bushings are turned 180º to achieve the second life.
The problem of internal pin to bushing wear has been addressed in several different ways.
There are six different types of track joint assembly in use by Caterpillar. These are:
Conventional unsealed track
Sealed Track
Sealed and Lubricated Track
Heavy Duty Track
Positive Pin retention Track
Rotating Bushing Track.
Conventional unsealed track is the original configuration and due to the poor service
life achieved, is rarely used to-day.
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Sealed Track
Figure 58 - Sealed Track
Sealed track is used on excavators and early track type tractors.
Belleville spring washers are used to form the seal in sealed track. Figure 58 shows
how the springs work. When compressed together, these conical shaped spring
washers flatten to form the seal. The spring effect of the washers maintains sealing
pressure as the washers wear and therefore take up the end float. This form of
sealing is used mainly on excavators because these machines do not do a lot of
walking when compared to track type tractors or track loaders.
Figure 59 - Belleville Spring Washers
Actual view of the Belleville spring washers (Figure 59).
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Sealed and Lubricated Track
Figure 60 - Sealed and Lubricated Track
Sealed and Lubricated track (Figure 60) was developed by Caterpillar with the
objective of completely eliminating internal pin to bushing wear. This type of track
became essential for the increased horsepower of the D9L and original D10 elevated
sprocket tractors, which would have required massive track chains if sealed and
lubricated track was not available.
Sealed and lubricated track allows use of a lubricant reservoir and lubrication between
the pin and bushing. The pin contains two stoppers to contain the oil.
Not only does this design eliminate internal pin to bushing wear but it also reduces
friction in the joints and therefore more horsepower is available to do work. This is the
standard configuration for Caterpillar Track Type Tractors.
When using sealed and lubricated track, the end point of the first service life is either
an excessive number of dry joints due to seal deterioration or an excessive amount of
external bushing wear.
Seals
Figure 61
The seal (Figure 61) used in sealed and lubricated track has undergone a very
extensive and prolonged development cycle. The seal consists of two parts, a flexible
load ring, and a ring seal. The load ring is designed to keep the ring seal in contact
with the bushing by continually applying a small force.
The ring seal incorporates a lip, which is always in contact with the end of the polished
bushing. The ring seal is rigid and is constructed from a wear resistant urethane
material to maximise seal life.
Rigid seals can withstand a maximum temperature of 160°F (70°C).
A thrust ring made of hardened steel is used in the joint. The thrust ring fits in the space
between the end of the bushing and the link counterbore and therefore sets the correct
dimension for the seal assembly. Notches in the thrust ring allow oil flow the sealing areas.
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Heavy Duty Track
Figure 62 - Heavy Duty Track
Heavy duty track (Figure 62) are used in moderate to high impact conditions. It is
similar in design to sealed and lubricated track with some modification.
When using sealed and lubricated track in high impact conditions, the links tend to
“walk” off the pins and bushings, resulting in loss of compression on the seals, which
ultimately leads to joint failure.
In heavy duty track, the links, pins and bushings are designed for enhanced strength,
durability and retention with additional wear material on the link rails. The links are
thicker in the bore areas for the pins and bushings to improve retention and therefore
sealability. The bushings are stepped to provide more external wear material.
Positive Pin Retention Track
Figure 63 - Positive Pin Retention Track
Positive pin retention track (Figure 63) uses the same sealing system as sealed and
lubricated track.
Positive pin retention track is designed for very high impact, high load applications. In
positive pin retention track, the pin and link are designed to allow the use of a metal
retaining ring, which physically locks the joint to prevent bushing and pin “walking”.
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Rotating Bushing Track
Figure 64 - Rotating Bushing Track
Rotating bushing track (Figure 64) is available for Track Type Tractors from D4 to D7
size for use in moderate to high abrasion, low impact conditions.
Rotating bushing track allows the bushing to rotate and therefore wear evenly all the
way round. This feature eliminates the need to remove and disassemble the track to
turn the bushings.
The bushings are not pressed into the link bores and are allowed to float. A double
sealing arrangement is used and the bushing rotates on the pin. This eliminates relative
motion between the bushing and sprocket tooth and allows the whole of the bushing to
wear evenly. This reduces bushing wear and provides a much quieter track operation.
Rotating bushing track bushings are shorter than sealed and lubricated track bushings.
The link/roller system life is about 20% higher than sealed and lubricated track.
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TRACK SHOE
Figure 65
The track shoes (Figure 65) are bolted onto the link assembly. The track shoes
support the weight of the machine and provide traction and flotation.
The overlapped edge between two shoes keeps debris from lodging between the
shoes as the track bends around the sprocket and idler.
Track Shoe:
1. The grouser penetrates the ground to provide traction.
2. The plate provides flotation.
3. The leading edge is curved downward. The trailing is curved upward. The curves
eliminate interference between the leading edge of one shoe and the trailing
edge of the shoe in front of it. The curves also provide stiffness to reduce shoe
bending and loosening of the bolts.
4. The link reliefs prevent the leading edge from interfering with adjacent links as
the track bends over the sprocket and the idlers.
Various widths of track shoes exist for various applications. Wide track shoes are
used in wet, mucky conditions to provide flotation.
When choosing a track shoe, choose the narrowest shoe that provides adequate flotation.
Narrow shoes are more resistant to bending which reduces turning wear. When track
shoes are too wide the shoes bend, loosen, crack more easily, more power to turn
and affect manoeuvrability.
When wide track shoes are used in high impact conditions, the results are high track
wear and structural problems. A track shoe that is too wide puts strain on the track
shoes, pins and bushings.
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Area Specific Wear - Terrain

The terrain cannot be controlled, but when the machine is constantly working certain
kinds of terrain, area specific wear may occur. When area specific wear occurs on a
machine, component swaps can be used to extend undercarriage component life. A side
hill application shifts the weight and load balance to the downhill side of the machine.
This increases the wear rate on the components and parts on the downhill side.
Working on a crown shifts the load to the inboard components, increasing wear on the
inner side of the track roller, inner idler tread, inner grouser ends and inner links.
Working in a depression puts the load on the outboard components, increasing wear on
the outer side of the track roller, outer idler tread, outer grouser ends and outer links.
An uphill application moves the weight and load balance to the rear, causing higher
wear on the rear track rollers, bushings and forward drive side of the sprockets.
Working downhill shifts the weight and load balance forward causing a relatively higher
wear rate on front track rollers and on carrier rollers. Downhill is preferred to uphill.
Area Specific Wear - Application

When a machine is constantly working in a certain application, area specific wear may occur.
The application describes the type of work that the machine is performing. The
following application wear descriptions are on level ground.
When the machine is in a dozing or push loading application, the weight is shifted
toward the front, causing faster wear rates on the front track rollers and idlers.
A ripping or drawbar application, shifts the weight toward the rear, causing faster wear
rates on the rear track rollers and sprockets. In a loading application, the weight is shifted
from the rear to the front as the application changes from digging to carrying. Wear occurs
on the front track rollers and the rear track rollers more than the centre track rollers.
In an excavating application, the weight shifts to the side where the digging is being done.
Operational Factors
Operator habits also influence track life. Unnecessary reverse operations should be avoided.
Constantly turning the machine in only one direction can cause wear to the link side
rail, the track roller flange and the idler flange. Wear increases on the side of the
machine that is favoured for turning or working because of the greater horsepower
and distance travelled. If the work path to even out the turns cannot be changed,
regularly check for wear on the turn side. Undercarriage life can be increased by
rotating tracks when wear on one side is noticeable.
Operating the track at unnecessarily high speed may cause link wear, track roller wear
and idler tread wear. Wear is related to the distance the machine covers, not
necessarily hours of use. Wear increases proportionally to speed. The speed of the
machine should never be higher than the speed needed to maintain production levels.
Slipping the track causes the grousers to wear faster. When the track begins to slip,
decrease the load.
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Figure 66
Track shoes can be customized to a variety of underfoot conditions. Impact, abrasion

and packing conditions effect the selection of the track shoe (Figure 66).
The width of the track shoe is also customized. Flotation, traction, penetration,
contact area, bending resistance, self-cleaning action and wear are other factors that
cause a particular track shoe to be selected.
Single Grouser Shoe
Figure 67
Single grouser shoes (Figure 67) are designed for low to medium impact and low to
moderate abrasion conditions.
They are all-purpose shoes recommended for general application.
Single grouser shoes have good penetration and traction and resist wear and
bending. Single grouser shoes are available in various widths and modifications.
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Extreme Service Shoe
Figure 68
Extreme service shoes (Figure 68) are single grouser shoes with more hardened wear
material. Extreme service shoes are designed for moderate to high impact conditions
and are recommended for applications where the links outlast the shoes.
Double Grouser Track Shoe
Figure 69
Double grouser track shoes (Figure 69) are designed for applications that require less
penetration and traction, but better turning ability. They spread the weight of the
machine over the larger contact area of two short grousers instead of one tall grouser,
this results in a resistance to bending and less ground disturbance.
Double grouser track shoes are standard on track-type loaders and hydraulic excavators.
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Self-Cleaning Low Ground Pressure (LGP) Shoe
Figure 70
Self-cleaning low ground pressure shoes (Figure 70) are designed for loose, muddy
conditions and should not be used in impact conditions or abrasive conditions. As the
shoes move around the sprocket and idler, the shoes separate letting the debris fall out.
Self-cleaning low ground pressure shoes are recommended for applications where
flotation is a problem.
Trapezoidal Centre Hole Shoes
Figure 71
Trapezoidal centre hole shoes (Figure 71) are designed for applications in which
extrudable packing causes the track to tighten.
The trapezoidal centre holes allow the sprocket to punch out dirt and debris reducing
extrudable packing between the shoe and bushing.
Trapezoidal centre hole shoes are recommended for applications with large amounts
of debris that tend to pack in the track and are available for double grouser shoes and
chopper shoes.
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Chopper Shoe
Figure 72
The chopper shoe (Figure 72) has a full length front grouser to resist bending and
diagonal side grousers for increased chopping ability. The trapezoidal centre hole
provides material extrusion.
Chopper shoes work best where debris tends to stick in the shoes and are
recommended for landfills, demolition applications and transfer stations.
Wear Measurement
Track shoes are measured using a depth gauge to check grouser height and calipers
to measure plate thickness.
Other visual checks include bent plates and/or bent grousers from excessive grouser
wear or shoes being too wide for the grouser conditions.
Bolt hole wallowing (elongated holes) caused by bolts remaining loose during machine
operation is another potential problem. If the shoes are kept tight, and the shoe is in
relatively good condition, the grousers can be rebuilt using specially designed steel
bars welded into position.
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SPROCKETS
Figure 73 - Sprocket Segment
The function of the sprocket (Figure 73) is to transfer driving loads from the final drive
through the bushings. The sprocket teeth act like gear teeth, picking up the track
bushings and moving the track group on which the machine travels.
In current Track-type Tractors, the sprocket is in segments. These segments are

bolted onto the rim.
Sprocket Assembly
Figure 74 - Sprocket Assembly
On earlier tractors, the sprocket (Figure 74) assembly is one piece and is pressed
onto the hub of the final drive.
These sprocket assemblies can be rerimmed to reduce the cost of replacement. The
worn rim of the assembly is burned off and new rim is welded on. These assemblies
can also be converted to bolt-on sprocket segments. To accomplish this conversion,
the worn rim is burned off and replaced with a weld-on adapter ring to which sprocket
segments are bolted.
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Mud and Snow Sprocket Segment
Figure 75 - Mud and Snow Sprocket
Mud and snow sprocket segment and rims (Figure 75) have a slotted tooth root design
that prevents material buildup in extreme packing conditions. Packing is the term
given to build up of material between the sprocket teeth and under the track shoes.
This causes the track to become too tight. Running with tight track results in rapid
wear of the undercarriage.
Mud and snow sprocket segment and rims should only be used on terrain where the
material can be squeezed through a small opening and at locations where continual
packing conditions exist.
TRACK ROLLER
Figure 76
The track rollers are fastened to the track roller frames (Figure 76). The track rollers
are in contact with the inside surfaces of the track links. Flanges on the rollers prevent
the movement of the track from side to side. The inside surfaces of the track links
make distribution of the weight of the machine along the track even.
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Figure 77
The purpose of the track roller is to guide the machine along the track and support the
weight of the machine and distribute the weight along the tracks.
There are two types:

Single flange (Figure 77, left)
Double flange (Figure 77, right).
Single flange track rollers are used adjacent to the sprockets. The single flange allows
the first track roller to be placed close to the sprocket to achieve the best guiding effect.
Double flange track rollers are interspaced with single flange rollers. The track roller
arrangement is usually alternate single and double or two single and two double
flange rollers. These rollers help to prevent the track from separating from the rollers
in severe conditions.
Components - Earlier Design Roller
Figure 78
An early design roller is shown in Figure 78. The flange at the centre of the shaft (1)
gets the side load on the roller. Bearings (2) are the centre-thrust type and they also
get the side load on the roller. The amount of side movement or end clearance of the
shaft cannot be adjusted.
The track rollers have Duo-Cone floating seals (3) at both ends of the shaft. The track
rollers are lubricated for the life of the roller. The floating Duo-Cone seals (3) retain
the lubricant in the roller. The passage (4) drilled in the shaft (1) lets lubricant go
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through the roller. Spaces (5) are reservoirs for the lubricant. The roller is filled to the
level of the drilled passage (4) only. This is done with a 5M2080 Nozzle. A standard
grease fitting will not fit in these rollers.
It is necessary to inspect the rollers for leaks at regular periods. A red dye is added to
the roller lubricant so leaks can be seen.
All track rollers are lubricated and cooled by oil to reduce internal wear and minimize
friction and sealed with Duo-Cone seals.
Track rollers have surface hardness that matches the surface hardness of the track
links. Due to the Duo-Cone seals and lubrication, track rollers only need to be
reshelled during maintenance. Reshelling means the internal components are reused
and the shell is replaced.
Figure 79
An exploded view of an early design roller is shown in Figure 79
1. The plug holds the lubrication in the track roller.
2. The shaft supports the roller shell. The roller shell turns freely on this shaft.
3. The shell is the surface upon which the track links ride.
4. The bronze bearing is the wear surface between the roller shaft and the roller shell.
5. The cast bushing supports the bearing to the end collar.
6. The Duo-Cone seals are designed to last through several roller shell rebuilds.
7. The end collar retains the Duo-Cone seal and provides the means to attach the
roller to the machine.
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Components - Current Design Roller
Figure 80
Shown in Figure 80is the configuration used on H series, L series and N series Track-
type Tractors. This configuration is also used on Track-type Loaders.
The track roller contains:

a roller assembly
a shaft
a rubber stopper
a plastic plug
duo cone seal groups
retainers.
The components are similar to those used in earlier track-type machines.
Figure 81 - Single Flange Roller
The rollers are mounted close together to provide even pressure along the track,
good support and help provide the track with traction and flotation in varying ground
conditions (Figure 81). This does however make it more difficult for the technician to
measure and accurately assess track roller wear. Track rollers are sometimes
swapped between front, rear and centre to balance the wear provided excessive wear
has not already taken place.
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Figure 82
The rollers are removed without removing the track, using a lifting fork to support the roller
(Figure 82). The rollers are fastened to the frame with two bearing caps and four bolts.
Wear Measurement
Figure 83
Roller tread wear is measured using a large calliper to measure the diameter. Flange
height (Figure 83) is measured with a depth gauge, measurement can also be done
with an ultrasonic wear tester.
The rear roller of the undercarriage assembly usually wears quickest. The front roller
wears second quickest. Roller wear can be evened out by swapping the rollers at
required intervals.
Roller treads are rebuilt by welding.
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UNDERCARRIAGE
CARRIER ROLLER
Figure 84
Carrier rollers (Figure 84) are used in the undercarriage system on some machines to
support the weight of the track between the idler and the sprocket. Carrier rollers also
smooth the upper side track travel and increase the clearance between the track and roller
frame.
Carrier rollers are normally of single flange construction.
Figure 85
The carrier rollers (Figure 85) must be in alignment with the sprocket and front idler.
The alignment is done by moving the roller shaft inside the support bracket. The
carrier rollers turn on two separate tapered roller bearings (1). The floating Duo-Cone
seals (2) prevent oil leakage at the inner end of the roller. An O-ring seal (3) on the
cover (4) is an oil seal for the roller end.
The adjustment of the bearings is done by the nut on the end of the shaft. Refer to the
Service Manual for the correct procedure and the specifications for this adjustment.
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UNDERCARRIAGE
Figure 86
Lubricant is put into the roller through a (5M2080) nozzle installed in place of the plug (5) in
the cover plate (4) (Figure 86). The lubricant fills the space between the shaft and roller to
the level of the plug. During filling, air is pushed out through the nozzle relief threads.
Wear Measurement
Figure 87 - Carrier Roller
The carrier roller is measured for wear in a similar way as the track roller (Figure 87).
IDLER
Figure 88 - Idler
The Idlers (Figure 88) ensures that the track chain is accurately guided into the track
roller and also support some of the weight of the machine.
An elevated sprocket undercarriage has front and rear idlers on each side of the
machine. An oval undercarriage has a front idler on each side of the machine.
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Idlers provide a way to control slack and tension and maintain the vertical and lateral
alignment. Track tension is adjusted by moving the idler. An adjustment mechanism is
used to move the idler or to hold the idler in place.
Idler - Earlier Design
Figure 89
The components are in Figure 89.
If lubricant is added while the idler is removed from the machine, the shaft must be in
a horizontal position.
The idlers have Duo-Cone seals at each end of the shaft.
Lubricant is sent through a 5M2080 Nozzle into the centre passage. The lubricant fills
the reservoirs around the shaft. When the reservoirs are full, the pressure of the oil
causes the air and extra lubricant to go out the relief threads in the nozzle.
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Idler - Later Design
Figure 90
The internal construction of the late design idler (Figure 90) is similar to that for
the track roller.
1. The retaining ring holds the end collar to the idler shell. The retaining ring clips on
the shaft.
2. The shell is the surface that the track links ride on.
3. The shaft supports the shell.
4. The Duo-Cone seals are used to keep lubricant in the assembly.
5. The end collar retains the components inside the shell.
6. The bi-metallic bearing is the wear surface between the idler shell and the idler shaft.
Wear Measurement
Measuring idler wear is similar to track and carrier rollers except calipers are not
normally used. A tape is used instead. Wear also occurs on the slide rails and guides
in tractors which use this method of support.
Idlers can suffer excessive flange side wear in adverse operating conditions such as
hillside operation or when excessive turning is needed.
Idles can also suffer from cracking in high impact applications.
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TRACK ROLLER GUARDS
Figure 91 - Track Roller Guards
Track roller guards (Figure 91) are optional on the undercarriage system and guide the
track to reduce roller flange wear, and protect the rollers and track chain by preventing
some of the material from entering the area between the rollers and the chain.
Elevated sprocket tractors use guiding pads not guards.
RECONDITIONING BULLETIN
Introduction
This guideline enables dealers and their customers to benefit from cost reductions
made possible through an established parts reusability and salvage program. Every
effort has been made to provide the most current and relevant information known to
Caterpillar Inc. Since the Company makes ongoing changes and improvements to its
products, this guideline must be used with the latest technical information available
from Caterpillar to ensure such changes and improvement are incorporated where
applicable.
For questions or additional information concerning this guideline, contact

Caterpillar Dealer.
Written Documentation
The written documentation is available to provide written and illustrated instructions
on common undercarriage reconditioning practices. Along with the many bulletins
provided in the Undercarriage Reconditioning Guide, all of the current wall charts are
also included.
Form Number Title
SEBF8599 Undercarriage Reconditioning Guide
STEHP9138 Undercarriage Self-Help Study Course
Table 1
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Wall Charts
Wall charts are designed to provide guided instructions, useful tooling and proper
dimensions while the worker is performing a reconditioning procedure. These should
hang in shop where they can be utilized during all service procedures.
Form Number Title
SENR1788* Non-PPR Sealed and Lubricated Track Reconditioning
SENR1838* PPR Sealed and Lubricated Track Reconditioning
Disassembly and Assembly Procedures for Idlers with Inverted

RENR2052*
Duo-Cone Seals
Disassembly and Assembly Procedures for Rollers with Inverted

RENR2059*
Duo-Cone Seals
Disassembly and Assembly Procedures for Idlers with

RENR3960*
Conventional Duo-Cone Seals
Disassembly and Assembly Procedures for Rollers with

RENR3961*
Conventional Duo-Cone Seals
Disassembly and Assembly Procedures for Snap Ring Rollers and

RENR3962*
Oval Track Rollers
Disassembly and Assembly Procedures for Hydraulic Excavator

RENR3963*
Rollers
Disassembly and Assembly Procedures for Hydraulic Excavator

RENR3964*
Idlers
RENR061 Set-up and Use of the Caterpillar Test and Fill Machine
Table 2
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APLTCL040

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TOPIC 3
Service, Repair and Adjustment
TRACK ADJUSTMENT PROCEDURES
Elevated Sprocket
Example: D6R
WARNING
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.
Move the machine forward. Allow the machine to stop without the use of the 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.
Figure 92
NOTE:
Do not attempt to tighten track when dimension (1) is 150mm (5.9 inch) or more.
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Figure 93
If a machine does not have carrier rollers, the sag in the track is measured between
the sprocket and front idler (2). The correct adjustment of dimension (2) is 115 ±
10mm (2.2 ± 0.4 inch).
Loose Track Adjustment

1. Remove the access cover.
Figure 94 - Access Cover
2. Add multi-purpose grease (MPGM) through track adjustment valve (5). Add the
MPGM until dimension (2) is correct.
3. Operate the machine back and forth in order to equalize the pressure. Allow the
machine to coast to a complete stop. Do not use the brakes.
4. Remeasure dimension (2).
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Tight Track Adjustment
Figure 95 - Relief Valve and Track Adjustment
1. Loosen relief valve (6) by one turn or 360 degrees. Allow the grease to escape.
2. Close the relief valve.
3. Add MPGM through track adjustment valve (5). Add grease until dimension
(2) is correct.
4. Install the access cover.
Roller Frame Oil Compartments
Figure 96 - Cover Plate and Fill Plug
On top of each roller frame is a cover plate and fill plug. Inside the rear section of the
roller frame are two oil compartments. The rear compartment (below the plug)
supplies oil for the lubrication of the pivot shaft and it's bearings.
The front compartment, below the cover plate, supplies oil for the lubrication of the
tube of the front section of the roller frame, the front bearing, the keys, and the track
adjustment mechanism. Both compartments are filled with SAE 30 oil.After roller
frame installation, oil can be added at the plug opening to assist in the initial fill of the
pivot shaft oil compartment.
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Figure 97 - Oil Level for the Pivot Shaft Compartments
On D7 and larger elevated sprocket track type tractors the oil level for the pivot shaft
compartments is checked at the plastic bottle which is located below the hinged cover
at the left rear of the engine compartment. The oil level should be checked daily
during the prestart walkaround inspection. It is important that oil is not added above
the full mark. This will prevent overflow when the oil warms. If the oil level is
frequently found low, then leakage should be suspended.
On smaller elevated sprocket track type tractors, the oil level is checked under the
plate on top of the roller frame. The level should be just below the fill plug hole.
Figure 98 - Track Roller Frame cover removed (left)

Oil Level Indicator (right)
The oil in the front compartment should be checked every 50 hours or weekly
(Figure 98, left).
The oil level check is performed by observing the oil levels relative to two horizontal
surfaces of the track adjustment cylinder (Figure 98, right). The two surfaces indicate
the maximum and minimum oil levels.
APLTCL040

UNDERCARRIAGE
TRACK TYPE TRACTOR - DRY JOINT FIELD REPAIR
Disassemble
Required Tools
Tool Part Number Part Description Qty
A 8S-9906 Ratchet Puller 1

9U-6600 Hand Hydraulic Pump 1
8T-7780 1
B
6V-4103 1
6V-4109 1
C FT-1577 2
D
6V-3170 Double Acting Cylinder 1
8T-7780 1
E 6V-4103 1
6V-4105 1
6V-4107 1
Table 3
1. Put the track pin in position behind the front idler.
Figure 99
2. Put blocks (3) in position under the front of the track.
3. Put blocks (2) in position under the track in order 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 Disassembly and Assembly,
"Track - Separate".
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. Use two persons to remove four track shoes (1) over the track pins.
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Figure 100
7. Fasten an appropriate lifting device to tooling (B). Put tooling (B) in position
against the track pin.
8. Push the track pin out of the track with tooling (B). Install tool (C) in order to hold
the track together until the other end of the 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 (5) and (6). Use tooling (D) to spread the
links enough to move link (7) away from links (5) and (6).
11. Remove tool (C) from links (5), (6), and (7).
Note:
Make sure that you do not damage the face of the seals when the links are moved.
12. Fasten an appropriate lifting device to link (7). Move the link away from links (5) and
(6). Put a block under link (7) in order to keep the link away from links (5) and (6).
Figure 101
13. Put tooling (D) in position between links (8) and (9). Use tooling (D) to spread the
links enough to remove link assembly (10).
14. Fasten an appropriate lifting device to link assembly (10).
15. Remove tool (C) from links (8) and (9) and link assembly (10). Remove the link
assembly. The weight of the link assembly is 31 kg (68 lb).
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UNDERCARRIAGE
Figure 102
16. Remove seal assemblies (11) from links (5) and (6).
17. Put the link assembly in position in tooling (E), as shown.
18. Remove link (6) from the bushing with tooling (E).
19. Remove the other link from the bushing with tooling (E).
APLTCL040

UNDERCARRIAGE
Assemble
Required Tools
4C-8621 Seal Installer 1

8T-7780 Track Repair 1
A
6V-4103 Forcing Pin 1
6V-4105 Forcing Pin 1
B FT-1577 Guide Pin 1
C
6V-3170 Double Acting Cylinder 1
D FT-1577 Guide Pin 2
E 8S-9906 Ratchet Puller 1
8T-7780 Track Repair 1
F
6V-4109 Spacer 1
6V-4102 Guide Bushing 1
G
K 5P-7419 Plug Installer 1
Table 4
Note:
Check all parts of the track assembly for wear or damage. Make replacements, if
necessary. Ensure that the parts are clean and dry.
Make sure that there is clearance between the link and tool (B). See location (Y).
Figure 103
1. Put SAE 90 gear oil on each end of bushing (12) for a minimum length of 5.0 mm
(0.20 inch).
NOTE:
Use a maximum force of 910 kN (205000 lb) when the track is assembled.
2. Use tool (B) to install bushing (12) into link (5).
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UNDERCARRIAGE
3. Push the bushing into the link until the bushing makes contact with the 1P-3482
Adapter in tool (B). The track bushing must extend 1.76 ± 0.13 mm (0.069 ± 0.005
inch) above the surface of the link.
4. Put link (5), bushing (12), and link (6) in position in tool (B).
5. Install tooling (C) in order to align links (6) and (5).
6. Install bushing (12) into link (6) until the bushing makes contact with the 1P-3482
Adapter in tool (B). The track bushing must extend 1.76 ± 0.13 mm (0.069 ± 0.005
inch) above the surface of the link.
Figure 104
NOTE:
The seal assembly must be completely sealed in the link counterbore. The load ring of the
seal assembly must make a minimum amount of contact with oil. Oil causes the load ring
to expand. Expansion is not desired until the assembly is complete.
7. Use tool (G) to install the seal assemblies in links (6) and (5).
NOTE:
Ensure that there is contact at area (X) between the seal and the load ring.
8. Install the thrust ring in the links.
Figure 105
9. Put clean oil on stoppers (13) and install the stoppers in the track pins. The
stopper must be installed to a depth of 8 ± 4 mm (0.315 ± 0.158 inch) below
the surface of the pin.
10. Put tool (D) in position between the track links. Use tool (D) to spread the links
enough to install link assembly (10).
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UNDERCARRIAGE
11. Fasten an appropriate lifting device to link assembly (10). Put the link assembly
in position. Install tooling (C) in order to hold the link assembly in place.
Figure 106
12. Put tool (D) in position between links (5) and (6). Use tool (D) to spread the links
enough to install link assembly (7).
13. Fasten an appropriate lifting device to the link assembly. Put the link assembly in
position on link assembly (7).
NOTE:
If necessary, use tooling (H) to pull the track links together until tooling (C) can be
installed.
14. Install tooling (C) in order to hold the link assemblies together.
15. Fasten an appropriate lifting device to tooling (J). Put tooling (J) and track pin
(14) in position on the track links.
NOTE:
The pin must be installed with the hole end on the same side of the track assembly. The
oil cross hole in the pin must be within 20 degrees of the vertical centreline of the pin bore.
Also, the pin must be installed with a minimum amount of force. Maximum end play should
be 0.13 mm (0.005 inch) between the bushing and the thrust ring.
16. Install track pin (14) with tool (B) until the pin extends 3.74 mm (0.147 inch)
beyond the link assembly.
17. Put track pin (4) and tool (B) in position on the track links.
18. Repeat Steps 15 and 16. Install track pin (4) .
19. Use two persons and put the four track shoes in position. Put clean SAE 30 oil on
the threads of the bolts and the washer face. Install the bolts. Tighten the bolts to
a torque of 870 ± 70 N·m (642 ± 52 lb ft). Tighten the bolts 120 degrees more.
20. Fill the track pins with a minimum of 0.05 L (0.053 qt) of SAE 90 oil.
21. Put oil on the plug. Install the plug in the stopper in the end of the track pin with
tool (K). Install the plug until the plug is even with the end of the stopper.
22. Adjust the track. See Disassembly and Assembly, "Track - Connect".
APLTCL040

UNDERCARRIAGE
TRACK TYPE TRACTOR - SPROCKET SEGMENT
Remove and Install
Removal procedure
1. Move the machine forward or move the machine backward until the segment is in
position for removal.
Figure 107
2. Remove nine nuts (1). Use two people to remove segment (2). The weight of the
sprocket segment is 24 kg (53 lb).
Installation Procedure
1. Make a thick mixture of SAE 30W oil and Flowers of Sulphur or a similar lubricant.
Put lubrication on the bolts.
Figure 108
2. Use two people, and put sprocket segment (2) in position on the final drive.
3. Install the bolts and nuts (1). Be sure that the head of the bolts are against the
final drive. Tighten the nuts to a torque of 650 ± 70 N·m (480 ± 52 lb ft). Tighten
the nuts (120 degrees) more.
APLTCL040

UNDERCARRIAGE
TRACK TYPE TRACTOR - TRACK ROLLER
Remove and Install
Removal Procedure
Required Tools
A FT2223 Strap Group 1
B FT1311 Track Roller Lifting Bracket 1
Table 5
WARNING
Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure
can remain in the hydraulic system after the engine has been stopped. Serious injury can
be caused if this pressure is not released before any service is done on the hydraulic
system. Make sure all of the attachments have been lowered to the ground, and the oil is
cool before removing any components or lines. Remove the oil filler cap only when the
engine is stopped, and the filler cap is cool enough to touch with your bare hand.
1. Loosen the track. See "Separation of Track".
2. Install tool (A) in order to hold the major bogies in position.
3. In order to remove the track roller, lift that side of the tractor.
Figure 109
4. Fasten a hoist to tool (B). Put tool (B) under the track roller.
5. Remove four bolts (3) and two caps (2) that hold the track roller to the minor bogie.
6. Remove track roller (4) from the minor bogie with tool (B). The weight of the track
roller is approximately 97 kg (214 lb).
APLTCL040

UNDERCARRIAGE
Required Tools
A FT2223 Strap Group 1
B FT1311 Track Roller Bracket 1
Table 6
WARNING
Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure
can remain in the hydraulic system after the engine has been stopped. Serious injury can
be caused if this pressure is not released before any service is done on the hydraulic
system. Make sure all of the attachments have been lowered to the ground, and the oil is
cool before removing any components or lines. Remove the oil filler cap only when the
engine is stopped, and the filler cap is cool enough to touch with your bare hand.
Figure 110
1. Use a hoist and tool (B) and put track roller (4) in position in the minor bogie.
2. Align the pin in caps (2) with the hole in the track roller shaft, and install caps (2)
and bolts (3). Tighten the bolts to a torque of 750 ± 75 N·m (553 ± 55 lb ft).
3. Put track guide in position on the major bogie. Install the bolts that hold the major
bogie in place. Tighten the bolts to a torque of 475 ± 50 N·m (350 ± 37 lb ft).
4. Lower the tractor to the ground and remove tool (A).
5. Adjust the track. See, "Connection of Track".
APLTCL040

UNDERCARRIAGE
TRACK TYPE TRACTOR TRACK ROLLER
Disassemble and Assemble
Disassembly procedure
Start By: Remove the track rollers. See, "Track Roller - Remove".
NOTE:
Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the
internal mechanism.
Figure 111
1. Use a hammer and a punch, and drive the plug out of stopper (2).
2. Use a variable speed drill and a 12.7 mm (0.5 inch) drill bit to slowly remove the
stopper. Remove stopper (2) from the ends of the shaft.
3. Remove bolts (3) and retainer (1) from both sides of the track roller.
4. Remove O-ring seal (5) from retainer (1).
NOTE:
Put identification marks on the seals in case the seals need to be used again. The seals
can be assembled and installed in the original position.
5. Put identification marks on seal ring (4). Remove the seal ring from retainer (1).
Remove the O-ring seal from the seal ring.
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UNDERCARRIAGE
Figure 112
NOTE:
Early track rollers do not have toric stabilizer (7).
6. Put identification marks on seal ring (6). Remove the seal ring and toric stabilizer
(7) from shaft (8).
7. Remove the toric ring from seal ring (6).
8. Pull shaft (8) out of the track roller far enough to fasten a hoist to the shaft.
9. Fasten a hoist to shaft (8). Remove the shaft from track roller (9). The weight of
the shaft is 18 kg (40 lb).
Assembly procedure
Required Tools
A 8T-7641 Seal Installer 1
B 8T-0822 Alignment Sleeve 1
C 5P-7419 Plug Installer 1
D Testing Tool 1
E 8S-2328 Dial Indicator 1
Table 7
NOTE:
Cleanliness is an important factor. Before the disassembly procedure, the exterior of
the component should be thoroughly cleaned. This will help to prevent dirt from
entering the internal mechanism.
WARNING
Personal injury can result from acid. Wear all necessary protective equipment, such as
rubber gloves and goggles when working with acid. The bottle containing the etchant
should be properly marked ACID and should be stored in a protective place.
1. Clean the parts and inspect the parts for wear or for damage. Replace all parts
that are damaged or worn.
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UNDERCARRIAGE
2. Make sure that all parts are free of oil film, dirt or other foreign material. Use
Trichlorethane and a clean cloth for cleaning.
Figure 113
NOTE:
- The bearing in track roller (9) can be damaged when shaft (8) is installed in the track roller
- Early track rollers have no toric stabilizers (7)
- See, “Duo-Cone Floating Seals” before installing any of the Duo-Cone seals.
3. Fasten a hoist to shaft (8). Carefully put the shaft in track roller (9).
4. Put toric stabilizers (7) in position on both ends of shaft (8).
Figure 114
5. Put toric ring (10) in position in seal ring (6). Make sure that the toric ring is
straight in seal ring (6).
6. Put toric ring (10) and seal ring (6) in Trichlorethane until the entire toric ring is wet.
7. Use tool (A) to install the toric ring and seal ring (6) on shaft (8). Install the ring
until tool (A) makes contact with the end of the shaft.
Figure 115
8. Use a depth micrometer (11) to measure the distance between seal ring (6) and
the shaft. The shaft is 90 degrees and four locations away from seal ring (6). The
difference in these measurements must not be more than 0.8 mm (0.0315 inch).
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UNDERCARRIAGE
9. If adjustments to seal ring (6) are necessary, use tool (A) to adjust the seal ring
on the shaft.
10. Repeat steps 5 to 9 for installation of the toric ring. Also install the seal ring on the
other side of the track roller.
11. Put O-ring seal (12) in position on seal ring (4). Make sure that the O-ring seal is
straight on the seal ring.
Figure 116
12. Lubricate the O-ring seal on the seal ring with Trichlorethane.
13. Put the O-ring seal and seal ring (4) in position in retainer (1). Use tool (A) to
install the seal ring in the retainer. Install the O-ring seal and seal ring (4) until the
O-ring seal makes contact with the bottom of the retainer.
14. Use depth micrometer (11) to measure the distance from the surface of the retainer to
the surface of seal ring (4). The seal rings can be found at four locations. The
difference in these measurements must not be more than 0.1 mm (0.0039 inch).
15. If adjustments to the seal ring are necessary, use tool (A) to adjust the seal
ring in the retainer.
16. Put O-ring seal (5) in position in the groove in retainer (1).
17. Put petroleum jelly or grease on the O-ring seal. The petroleum jelly and grease
will hold the seal in place on the retainers.
Figure 117
18. Make sure that the faces of the seal rings are clean and free of any foreign material.
19. Put a thin film of clean oil on the face of the seal rings.
20. Put tool (A) in position in the bore of retainer (1) and the seal ring. Use tool (B) to
put the retainer and put the seal ring in the original position on the track roller.
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UNDERCARRIAGE
21. Use tool (B) to hold the seal ring and retainer (1) in the correct position, and
install bolts (3). Tighten the bolts evenly in order to keep the retainer in alignment
with the track roller.
22. Tighten the bolts to a torque of 135 ± 15 N·m (100 ± 11 lb ft).
23. Repeat steps 11 through 22 in order to install the retainer on the other side of the
track roller.
Figure 118
24. Put clean oil on stopper (2). Install the stopper in one end of shaft (8). Install the
stopper 10 ± 4 N·m (7.3756 ± 2.9502 lb ft) below the surface of the shaft end.
25. Use tool (C) to install the plug in stopper (2). Install the plug even with the
end of the stopper.
26. Use tool (D) to pressure test the track roller.

a. Put air free of water under a pressure of 280 kPa (41 psi) into the roller
shaft.
b. If there is a pressure reduction in ten seconds or less, there is a leak in the
track roller. The track roller must be disassembled and checked.
27. Use tool (E) to check the end play of shaft (8). The end play must be 0.22 to 0.98
mm (0.0087 to 0.0039 inch).
28. Fill track roller shaft (8) with 720 ± 15 mL (24.4 ± .51 oz) of SAE 30 Oil.
29. Put clean oil on the stopper. Install the stopper in the end of shaft (8). Install the
stopper 10 ± 4 mm (0.394 ± 0.158 inch) below the surface of the end of the shaft.
30. Use tool (C) to install the plug in the stopper. Install the plug even with the
end of the stopper.
End By: Install the track rollers. See, "Track Roller - Remove".
APLTCL040

UNDERCARRIAGE
TRACK TYPE TRACTOR IDLER
Remove and Install
Removal procedure
Required Tools
A 532-075 Lifting Tongs 1
Table 8
Start By: Separate the track. See Disassembly and Assembly, “Track - Separate”.
Refer to the address below for additional information about the tool in Table 8:
Wolff Mft. Co.

1611 Adrian Rd.
Burlingame, CA 94010
Figure 119
1. Fasten an appropriate lifting device and tool (A) to idler assembly (1).
2. Remove the following components from each side of the idler: washers and bolts
(4), washers and bolts (5), cap (3) and wedge (6).
3. Remove the idler. The weight of the idler is 408 kg (900 lb).
4. Remove insert (7) from major bogie (2).
APLTCL040

UNDERCARRIAGE
Required Tools
A 532-075 Lifting Tongs 1
Table 9
Refer to the address below for additional information about the tool in Table 9:
Wolff Mft. Co.

1611 Adrian Rd.
Burlingame, CA 94010
Figure 120
1. Install insert (7) in major bogie (2) .
2. Fasten an appropriate lifting device and tool (A) to the idler. Put the idler in
position in the major bogie.
3. Align the hole in the idler shaft with the pin in caps (3). Install washers and bolts
(4) and (5) on each side of the idler.
4. Tighten bolt (4) to a torque of 1850 ± 150 N·m (1364 ± 1110 lb ft).
6. Tap wedge (6) into position.
End By: Connect the track. See Disassembly and Assembly, "Track - Connect".
APLTCL040

UNDERCARRIAGE
Disassembly procedure
Start By: Remove the idlers. See Disassembly and Assembly, "Idler - Remove".
Figure 121
1. Use a drill for slow speeds and a 12.27 mm (0.5 inch) drill bit to remove plug (4)
and stopper (3) from the end of the shaft.
NOTE:
The shaft will be free to fall when the retainers are removed.
2. Remove twelve bolts (2) and retainer (1) from both sides of the idler.
3. Remove O-ring seal (6) from retainer (1).
NOTE:
Put identification marks on the Duo-Cone seals that will be used again, so that the seals
can be assembled and installed in the original location.
Early idlers do not have toric stabilizers (8).
4. Put identification marks on the Duo-Cone seal. Remove Duo-Cone seal (5) from retainer (1).
Figure 122
5. Put identification marks on Duo-Cone seal (7). Remove Duo-Cone seal (7) and
toric stabilizer (8) from shaft (9).
6. Pull shaft (9) out of the idler bar. The shaft must be pulled out enough to fasten an
appropriate lifting device to the shaft.
7. Fasten an appropriate lifting device to shaft (9). Remove the shaft from idler
assembly (10). The weight of the shaft is 22 kg (49 lb).
APLTCL040

UNDERCARRIAGE
Assembly Procedure
Required Tools
A 8T-7640 Seal Installer 1
B 1P-0520 Driver Group 1
C 8T-0823 Alignment Sleeves 1
D FT-0575 Test Tool 1
E 8T-5096 Dial Indicator Group 1
F 5P-7419 Plug Installer 1
Table 10
1. Clean the parts and inspect all of the parts for wear or for damage. Replace all of
the parts that are worn or damaged.
2. Make sure that all of the parts are free of oil film, dust, or other foreign materials.
Use trichlorethane and use a clean cloth for cleaning.
Figure 123
NOTICE
The bearing in idler assembly (10) can be damaged when shaft (9) is installed in the idler.
3. Fasten an appropriate lifting device to shaft (9). Put shaft (9) in position in idler
assembly (10).
NOTE:
Early idlers do not have toric stabilizers (8).
4. Put toric stabilizers (8) in position on both ends of shaft (9).
APLTCL040

UNDERCARRIAGE
Figure 124
NOTE:
See Disassembly and Assembly, "Duo-Cone Floating Seals - Install" before installation of
any of the Duo-Cone Seals.
5. Put toric ring (11) in position in Duo-Cone seal (7). Make sure that the toric ring is
straight in the Duo-Cone seal.
6. Put toric ring (11) and Duo-Cone seal (7) in Trichlorethane until the entire
toric ring is wet.
7. Use tooling (A) to install the toric ring and Duo-Cone seal (7) on shaft (9). Install
the seal until tooling (A) makes contact with the end of shaft (9).
Figure 125
8. Use a depth micrometer (12). Measure the distance between Duo-Cone seal (7)
and the shaft at four locations. The difference in these measurements must not
be more than 0.80 mm (0.031 inch).
9. If adjustments to Duo-Cone seal (7) are necessary, use tooling (A) to adjust the
seal ring on the shaft.
10. Repeat Steps 5 through 9. Install the toric ring and the Duo-Cone seal on the
other side of the idler.
11. Put O-ring seal (13) in position on Duo-Cone seal (5). Make sure that the O-ring
seal is straight on the Duo-Cone seal.
12. Lubricate the O-ring seal on the seal ring with Trichlorethane.
APLTCL040

UNDERCARRIAGE
Figure 126
13. Put the O-ring seal and Duo-Cone seal (5) in position on retainer (1). Use tool (B)
and an arbor. Press the Duo-Cone seal in the retainer. Install the O-ring seal and
the Duo-Cone seal until the O-ring seal makes contact with the bottom of the
retainer.
14. Use depth micrometer (12) to measure the distance from the surface of retainer
(1) to the surface of Duo-Cone seal (5) at four locations. The difference in these
measurements must not be more than 0.10 mm (0.004 inch).
15. If adjustments to the seal ring are necessary, use tooling (A) to adjust the seal
ring in the retainer.
16. Put O-ring seal (6) in position in the groove in retainer (1).
17. Put grease on O-ring seal (6) in order to hold the seal in place on the retainer.
18. Make sure that the faces of the seal rings are clean and free of any foreign material.
19. Put a thin film of clean oil on the faces of the seal rings.
Figure 127
20. Put tool (C) in position in the bores of retainer (1) and the Duo-Cone seal. Use tool
(C) to put the Duo-Cone seal and retainer (1) in the original position on the idler
assembly.
21. Use tool (C) to hold the seal ring and retainer (1) in the correct position on
the idler assembly.
22. Install bolts (2). Tighten the bolts evenly in order to keep retainer (1) in alignment
with the idler assembly.
23. Tighten bolts (2) to a final torque of 90 ± 15 N·m (65 ± 11 lb ft).
APLTCL040

UNDERCARRIAGE
24. Repeat Steps 11 through 23 in order to install the retainer on the other side of the idler.
25. Use tool (D) to pressure test the idler assembly. Use the following procedure:
a. Put air that is free of water and under a pressure of 280 kPa (401 psi) into the
idler shaft.
b. There is a leak in the idler assembly if there is a pressure reduction in ten
seconds or less. The idler assembly must be disassembled and checked.
Figure 128
26. Use tool (E) to check the end play of shaft (9). The end play must be 0.25 mm to
0.85 mm (0.009 inch to 0.033 inch).
27. Fill idler shaft (9) with 1.3 L ± 0.030 L (1.374 qt ± 0.032 qt) of SAE 30 oil.
28. Put clean oil on stopper (3). Install the stopper in the end of shaft (9). Install the
stopper until the stopper is 10 ± 4 mm (0.393 ± 0.16 inch) below the surface of the
end of the shaft.
29. Use tool (F) to install the plug in stopper (3). Install plug (4) so that the plug is
even with the end of the stopper.
End By: Install the Idlers. See Disassembly and Assembly, "Idler - Install".
APLTCL040

UNDERCARRIAGE
TRACK SEPARATION AND CONNECTION
Split Master Link Design
Required Tools
A FT-2223 Strap Group 1
8S-4755 Bolt 4
6B-9194 Bolt 2
3K-5234 Hard Washer 18
Table 11
WARNING
Personal injury can result from the track roller frame falling. The track roller frame can fall
if the eyebolts are installed in the pins. The pins can come out of the track roller frame if
the pins are used to lift the roller frame. Install the eyebolts in the track roller frame as
shown to prevent injury.
Personal injury can result from performing service on the track roller frame. Refer to
Special Instruction, SMHS8273 for inspection and removal procedures before performing
any service.
Personal injury can result from the track coming off of the roller frame. The track can
move off the track roller frame very quickly when a separation of the track is made. Keep
away from the front of the machine when the track is removed from the track roller frame.
Figure 129
1. Remove track adjuster cover (1) and the O-ring seal from the roller frame.
2. Loosen the track by using the following procedure:

a. Turn the relief valve (2) counter clockwise. After one turn the grease will be
released from the track adjuster. If the track does not loosen go to Step (b).
b. Turn fill valve (3) counter clockwise. After one turn the grease will be
released from the track adjuster. Roll the machine forward and backward. If
there are no results, 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. The round bar will move
the track adjuster inward.
APLTCL040

UNDERCARRIAGE
Figure 130
3. Move the track until the master link is just above the centreline of rear idler (4).
Put wood blocks under the grouser bar just below the master link. Move the track
to the rear until the track is in contact with the wood blocks.
4. Attach a lifting strap. Remove four bolts (6) and track shoe (7).
Figure 131
5. Separate master link (5).
NOTE:
Allow 7.6 m (25 ft) in front of the tractor for the track to move out onto the floor.
6. Fasten the chain to the end of the track. Attach the chain to a wheel loader. Turn
the final drive in a forward direction and allow track (8) to fall forward while the
wheel loader is moved forward.
APLTCL040

UNDERCARRIAGE
Figure 132
NOTE:
Tool (A) is installed after the machine has been lifted approximately 25 mm (1 inch) off
the ground. The pressure in the bogie pads is then released.
7. If the track is removed then lift the side of the machine approximately 25 mm (1
inch). Install tool (A).
8. Lift the side of the machine and remove the track. The weight of the track is from
3075 to 3548 kg (6780 to 7805 lb). The weight of the track varies on the kind of
track that is on the tractor.
Connection Procedure
Required Tools
A FT-2223 Strap 1
8S-4755 Bolt 4
6B-9194 Bolt 2
3K-5234 Hard Washer 18
Table 12
Figure 133
1. Put the track under the machine, as shown. Lower the side of the machine onto
the track. Remove tooling (A).
NOTE:
Make sure that you pull the cable in a straight line.
APLTCL040

UNDERCARRIAGE
Figure 134
2. Use a wheel loader or a similar machine and pull track (8) over the front idler.
3. Lift the end of the track and put wood blocks (9) under the grouser, as shown.
4. Pull the track until the track bushings engage with the sprocket segments on
the final drive.
5. Start the machine and turn the final drive in a reverse direction in order to pull
the track together.
Figure 135
6. Put the lower end of master link (5) in alignment with the upper end of the master
link. Ensure that the teeth of both ends of the master link are engaged.
7. Put master shoe (7) in position on master link (5). Put 4C-5593 Anti-Seize
Compound on the threads, the body, and the washer face of the master link bolts.
Install bolts (6) that hold the master link together. Tighten the bolts to a torque of
870 ± 70 N·m (642 ± 52 lb ft). Tighten the bolts 120 degrees more.
Figure 136
8. Tighten relief valve (2) and fill valve (3) in the track adjuster to a torque of 35 ± 7
N·m (26 ± 5 lb ft).
APLTCL040

UNDERCARRIAGE
NOTE:
Measure the track sag when the machine is in working condition. If dirt and debris are
present in the working condition, then measure the track sag when normal dirt and debris
are present.
9. Use the following procedure to make an adjustment to the track:

a. Move the machine forward for a distance that is two times the length of the
machine. Permit the machine to come to a stop without the use of the
brakes.
b. Put a tight line between the grouser tips at the sprocket and the front idler.
c. Measure distance (X) from the line to the lowest point of sag of the grouser
tips. Put 5P-0960 Molybdenum Grease in the track adjuster and adjust the
track until distance (X) is 140 ± 10 mm (5.5 ± 0.4 inch). 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 inch) or more.
The track will need to be removed and reconditioned.
Figure 137
10. Install track adjuster cover (1) and O-ring seal (10) on the roller frame.
APLTCL040

UNDERCARRIAGE
MASTER PIN DESIGN
Separation Procedure
Required Tools
A 5P-6214 Block Assembly 1

B 1U-7630 Impact Socket 1
C(1) 3S-6224 Electric Hydraulic Pump (115 Volt)(2) 1

8T-0820 Hydraulic Pressure Gauge 1
3B-7722 Pipe Bushing 2
1P-2376 Quick Connect Coupler 2
1P-2377 Dust Plug 2
6D-7726 Hose Assembly 2
5P-2379 Press Frame and Tooling Group 1
8S-7172 Double Acting Cylinder 1
8S-9903 Rollover Group 1
(1)
Use Tooling (C) if the master pin can not be removed.
(2)
8S-8033 Electric Hydraulic Pump (230 Volt) is available.
Table 13
1. Start the engine. Park the machine on a hard, level surface. Stop the engine.
WARNING
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.
2. Release the tension on the track assembly. Refer to Operation and Maintenance
Manual, "Track Adjustment - Adjust" for more information.
Figure 138
3. Move the track assembly until master pin (2) is in the position that is shown. Put Tooling
(A) under the track grouser, as shown. Move the track assembly onto Tooling (A).
APLTCL040

UNDERCARRIAGE
NOTE:
To provide additional clearance for removal of the master pin, the track shoe on each side of the
master pin may be removed. Use Tooling (B) in order to remove the track shoe mounting bolts.
Figure 139
WARNING
Personal injury can result from the track coming off of the roller frame.
The track can move off the track roller frame very quickly when a separation of the track is made.
Keep away from the front of the machine when the track is removed from the track roller frame.
NOTE:
The spacer for the track will fall out of the track links when the track assembly is
separated.
4. Remove cotter pin (3) from the master pin.
5. Use a hammer and a punch to remove master pin (2) from the track links.
Separate the track links, and locate the two spacers for the track. Slowly move
the machine forward until the track assembly is off the sprocket, the track carrier
rollers and the front idler.
NOTE:
If the track does not separate use Tooling (C) in order to remove the master pin. Move
the track assembly until the master pin is in a position between the centre track carrier
roller and the rear track carrier roller. Remove the master pin. For further information,
refer to Special Instruction, SMHS6954, "Track Disassembly".
6. Fasten a suitable lifting device to the rear of the track assembly.
7. Raise the track assembly off Tooling (A).
8. Remove Tooling (A). Lower the rear of the track assembly to the floor.
APLTCL040

UNDERCARRIAGE
Track - Connect
Connection Procedure
Required Tools
A 1P-3545 Coupler for Track Chain 1
B 1P-3533 Bar 1
3S-6224 Electric Hydraulic Pump (115 Volt) (1) 1
3B-7722 Pipe Bushing 2

C 1P-2377 Dust Plug 2
6D-7726 Hose Assembly 2
5P-2379 Track Press Tool Gp 1
8S-7172 Double Acting Cylinder
8S-9903 Track Press Rollover Gp
D 5P-6214 Track Block Assembly 1
E 1U-7630 Impact Socket 1

(1)
Figure 140
1. Install Tooling (A) in the track link and on the sprocket, as shown.
2. Start the machine. Move the sprocket forward until the track assembly is pulled
up on the sprocket. Move the sprocket forward until the end of the track assembly
is past a vertical line through the centre of the sprocket. Remove Tooling (A).
3. Install Tooling (B) between the first bushing in the track link and the sprocket, as shown.
4. Move the sprocket forward. Use Tooling (B) to guide the track assembly over the
carrier rollers and the front idler.
APLTCL040

UNDERCARRIAGE
Figure 141 - Typical example
5. Use a suitable lifting device to raise the front of the track assembly. Install
Tooling (D) in position under the track shoe, as shown.
6. Apply 5P-0960 Molybdenum Grease on two track bushings. Install the bushings
in the track links. The grease will hold the bushings in place.
7. Apply 5P-0960 Molybdenum Grease in the master pin bores in the track
assembly and on the master pin.
8. Connect the ends of the track assembly. Make sure that the pin bore in each end
of the track assembly is aligned with each other.
9. Install the 5F-9447 Pilot Pin in the track assembly. Make sure that the pilot pin is
centred in the track links.
10. Use Tooling (C) to install the master pin in the track assembly.
11. Install the cotter pin in the master pin. Remove Tooling (D) from the rear of the
track assembly.
12. Note: Refer to Special Instruction, "Track - Assembly" for further information
regarding Tooling (C).
13. If the track shoe on each side of the master pin was removed, reinstall the track
shoes. Use Tooling (E) to reinstall the track shoe mounting bolts.
14. Tighten the tension of the track. Refer to Operation and Maintenance Manual,
SEBU7439, "Track Adjustment - Adjust" for the correct procedure.
APLTCL040

UNDERCARRIAGE
EXCAVATOR TRACK CARRIER ROLLER
Remove and Install
Required Tools
A 8T-5255 Hydraulic Jack 1
Table 14
1. Start the engine. Park the machine on a hard, level surface. Shut off the engine.
WARNING
Personal injury or death can result from grease and oil coming out of the relief valve.
Grease and oil are under high pressure coming out of the relief valve and can penetrate
the body.
Make sure the vent holes are clean before the tension is released on the track.
Figure 142
2. Release the tension on the track.
3. Loosen relief valve (1) by one turn only. If the track does not loosen after opening the
relief valve, move the machine forward and backward until the tension is released.
4. Loosen bolt (2) that holds track carrier roller (3) to the mounting bracket on
the undercarriage.
Figure 143
5. Put wood blocks and Tooling (A) under the track assembly, as shown.
6. Use Tooling (A) in order to lift the track assembly off the track carrier roller.
7. Remove track carrier roller (3). The weight of the track carrier roller is 17 kg (38 lb).
APLTCL040

UNDERCARRIAGE
Required Tools
A 8T-5255 Hydraulic Jack 1
Table 15
1. Make sure that the shaft of the track carrier roller and the bore in the mounting
bracket on the undercarriage are clean and free of dirt.
Figure 144 - (x) Mounting bracket
2. Place the track carrier roller in position in the mounting bracket. Adjust the carrier
roller until distance (a), the distance between the outside face of the mounting
bracket and the carrier roller is 7.0 ± 0.5 mm (0.28 ± 0.02 inch).
3. After you adjust the position of carrier roller (3) in the mounting bracket, tighten bolt (2).
Figure 145
4. Make sure that carrier roller (3) rotates smoothly by manually turning the carrier roller.
5. Slowly lower the track assembly onto the carrier roller with Tooling (A).
"Track Adjustment - Adjust" for the correct procedure.
APLTCL040

UNDERCARRIAGE

Disassembly Procedure
Start By: Remove the track carrier rollers. Refer to Disassembly and Assembly,
“Track Carrier Roller - Remove” in this manual.
1. Thoroughly clean the outside of the track carrier roller prior to disassembly.
NOTE:
Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid
with suitable containers before opening any compartment or disassembling any
component containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for
tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Figure 146
Remove plug (2).
NOTE:
There are two types of carrier rollers: The rollers are welded or the rollers are cast. The
rollers that are welded will have a weld bead. The rollers that are cast will have no welds.
2. Drain the oil from the carrier roller into a suitable container for disposal. The
capacity of the welded track carrier roller is 120 ± 5 mL (4.08 ± 0.17 oz). The
capacity of the cast track carrier roller is 85 ± 5 mL (2.89 ± 0.17 oz).
3. Remove three socket head bolts (1) and cover (3) from the track carrier roller.
4. Remove O-ring seal (4) from cover (3).
Figure 147
5. Remove washer (5).

6. Remove two socket head bolts (6) and retainer (7) from the end of the shaft assembly.
APLTCL040

UNDERCARRIAGE
Figure 148
7. Carefully remove shaft assembly (8) from the track carrier roller.
8. Remove Duo-cone seal (9) from the track carrier roller.
Figure 149
9. Remove Duo-cone seal (10) from shaft assembly (8).
10. Measure distance (X) on the shaft assembly.
11. Record this dimension for assembly purposes. Use a press to push shaft (8) out
of collar (11).
12. Remove the O-ring seal from the inside of the collar.
Figure 150
13. Remove bearings (12) and (13) from the track carrier roller.
APLTCL040

UNDERCARRIAGE
Assembly Procedure
Required Tools
(A) 1P-0510 Bearing and Seal Driver 1
(B) 9U-5985 Duo-Cone Seal Installer 1
(C) 8T-5096 Dial Indicator Group 1
Table 16
1. Thoroughly clean all of the parts of the track carrier roller prior to assembly.
NOTE:
Do not reuse bearings (12) and (13). Use new parts for replacement.
Figure 151
NOTE:
Bearing (13) is a straight bearing.
2. Lower the temperature of bearing (13).
3. Use Tooling (A) and a press in order to install bearing (13) in the inside bore of
the carrier roller.
4. Install the bearing until the bearing is even with the shaft counterbore in the carrier roller.
NOTE:
Bearing (12) has a flange.
Lower the temperature of bearing (12).
5. Use Tooling (A) and a press in order to install bearing (12) in the outside bore of
the carrier roller. The outside bore can be identified by three threaded holes (H) in
the track carrier roller.
6. Install the bearing until the flange on the bearing contacts the counterbore in the
track carrier roller.
APLTCL040

UNDERCARRIAGE
Figure 152
7. Install the new O-ring seal in the collar. Apply clean oil on the O-ring seal.
8. Use a press to install collar (11) on shaft (8). Install collar (11) until dimension (X)
is 129.2 ± .2 mm (5.09 ± 0.01 inch).
9. Use the following procedure to determine shaft end play.
NOTE:
Do not install the Duo-Cone seals in the track carrier roller or collar (11) at this time.
a. Install shaft assembly (8) in the track carrier roller without the Duo-Cone seals.
b. Install retainer (7) and socket head bolts (6) on the end of shaft assembly
(8).
c. Use Tool (C) to measure the end play of shaft assembly (8).
d. The end play of the shaft assembly must be 0.20 mm (0.01 inch) to 0.75 mm
(0.03 inch). Bearing (12) controls the amount of shaft end play.
e. Disassemble the track carrier roller, but do not remove collar (11) from shaft (8).
NOTE:
The rubber seals and all surfaces that make contact with the seals must be clean and dry.
After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal
seals. For more information concerning the assembly and installation of Duo-Cone Seals,
refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.
10. Install Duo-Cone seal (10) in collar (11) with Tooling (B).
Figure 153
APLTCL040

UNDERCARRIAGE
11. Install Duo-Cone seal (9) in the track carrier roller on the side without three
threaded holes with Tooling (B).
12. Carefully install shaft assembly (8) in the track carrier roller.
13. Install retainer (7) and two socket head bolts (6).
Figure 154
14. Install washer (5), as shown.
15. Apply clean oil on new O-ring seal (4). Install the new O-ring seal on cover (3).
Figure 155
16. Install cover (3) on the track carrier roller and three socket head bolts (1).
NOTE:
There are two types of carrier rollers: The rollers are welded or the rollers are cast. The
rollers that are welded will have a weld bead. The rollers that are cast will have no welds.
17. Put the track carrier roller in a vertical position.
18. The capacity of the welded track carrier roller is 120 ± 5 mL (4.08 ± 0.17 oz). The
capacity of the cast track carrier roller is 85 ± 5 mL (2.89 ± 0.17 oz).
19. Fill the track carrier roller with clean SAE 30 oil.
20. Apply a thin coat 5P-3413 Pipe Sealant on the threads of plug (2).
21. Install plug (2).
End By: Install the track carrier rollers. Refer to Disassembly and Assembly, "Track
Carrier Roller - Install" in this manual.
APLTCL040

UNDERCARRIAGE
EXCAVATOR TRACK ROLLER
Remove and Install
Removal Procedure
Required Tools
8S-7611 Tube Assembly 2
A 8S-7615 Pin 2
8S-7640 Stand 2
B 183-4797 Track Roller Lifting Fork 1
Table 17
NOTE:
There is a track guide on each side of the machine. The procedure that follows is for the
removal of the track roller with the track guide.
1. Start the engine. Park the machine on a hard, level surface. Stop the engine.
WARNING
Personal injury or death can result from grease and oil coming out of the relief valve.
Grease and oil are under high pressure coming out of the relief valve and can penetrate
the body.
Make sure the vent holes are clean before the tension is released on the track.
Figure 156
2. Release the tension on the track. Loosen relief valve (1) by one turn only. If the
track does not loosen after opening the relief valve, move the machine forward
and backward until the tension is released.
APLTCL040

UNDERCARRIAGE
NOTE:
Adjust the height of Tooling (A) in order to have sufficient clearance for the removal of the
track rollers when Tooling (A) is installed under the undercarriage of the machine.
3. Lift the side of the machine. Install Tooling (A) under the undercarriage, as
shown.
Figure 157
4. Loosen the bolts that hold track guide (2) to the undercarriage.
NOTE:
Do not remove the bolts at this time.
5. Fasten a suitable lifting device to Tooling (B). Put Tooling (B) in position under
track guide (2), as shown. Remove the bolts that secure the track guide. Remove
the track guide.
Figure 158 - (X) Rock guard
6. Remove the rock guards from the undercarriage, if equipped.
7. Loosen the bolts that secure track roller (3) to the undercarriage.
NOTE:
Do not remove the bolts at this time.
8. Attach a suitable lifting device and a lifting strap to Tooling (B).
9. Put Tooling (B) in position under track roller (3), as shown.
APLTCL040

UNDERCARRIAGE
10. Remove the bolts that secure the track roller. Remove the track roller. The
weight of the track roller is approximately 40 kg (88 lb).
Required Tools
8S-7611 Tube Assembly 2
A 8S-7615 Pin 2
8S-7640 Stand 2
B 183-4797 Track Roller Lifting Fork 1
Table 18
NOTE:
There is a track guide on each side of the machine. The procedure which follows is for
the installation of the track roller with the track guide.
1. Make sure that all the mounting surfaces on the following components are clean
and free of debris before the following components are installed:
a. Track Roller
b. Track Guide
c. Frame Rail
Figure 159
NOTE:
Make sure that the fill/drain plug in the track roller is facing toward the outside of the
undercarriage.
2. Use a suitable lifting device and Tooling (B) in order to put track roller (3) in
position on the undercarriage. The weight of the track roller is approximately
40 kg (88 lb).
3. Install the bolts that hold the track roller in position.
4. Use Tooling (B) in order to put track guide (2) in position on the undercarriage.
Install the bolts that secure the guide.
APLTCL040

UNDERCARRIAGE
Figure 160 - (X) Rock guard
5. Install the rock guards, if equipped.
6. Prior to lowering the machine to the ground and tightening the track, make sure
that all of the track rollers rotate smoothly by manually turning the track rollers.
7. Lift the machine off Tooling (A).
8. Remove Tooling (A) from the machine. Lower the machine to the floor.
"Track Adjustment - Adjust".
APLTCL040

UNDERCARRIAGE
Start By: Remove the track rollers. Refer to Disassembly and Assembly, "Track
Roller - Remove" in this manual.
NOTE:
Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8568, "Hydraulic
Excavator Roller Disassemble and Assembly Procedures Guide" for additional
information on reconditioning.
NOTE:
The procedure to disassemble the single flange track roller is identical for the double
flange track roller.
1. Thoroughly clean the outside of the track roller prior to disassembly.
Figure 161
NOTE:
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide"
for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Figure 162
2. Drive plug (14) into the stopper in the end of the track roller. Drain the oil from
the track roller into a suitable container for disposal. The capacity of the track
roller is 225 ± 10 mL (7.65 ± 0.34 oz).
APLTCL040

UNDERCARRIAGE
3. Put the track roller in a press, as shown. The weight of the track roller is 40 kg (88 lb).
4. Press downward on end collar (1). Remove snap ring (10).
5. Release the pressure on the end collar. Remove end collar (1).
6. Remove plug (14) from the inside of the track roller.
7. Remove Duo-Cone seal (7) from end collar (1).
Figure 163
8. Remove O-ring seal (11) from shaft (15). Remove shaft (15) from roller (9).
9. Remove Duo-Cone seal (3) from end collar (5).
10. Remove spring pin (4) from end collar (5) and shaft (15).
11. Use a press to remove shaft (15) from end collar (5).
12. Remove O-ring seal (16) from shaft (15). Remove stopper (13) from the end of the shaft.
Figure 164
13. Remove Duo-Cone seals (2) and (8) from each end of the track roller.
14. Use a press to remove bearings (6) and (12) from each end of the track roller.
APLTCL040

UNDERCARRIAGE
Assembly Procedure
Required Tools
(A) 1U-8841 Duo-Cone Seal Installer 1
(B) 8T-5096 Dial Indicator Group 1
(C) FT-0575 Pressure Test Tool 1
Table 19
NOTE:
Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8568, "Hydraulic
Excavator Roller Disassemble and Assembly Procedures Guide" for additional
information on reconditioning.
NOTE:
The procedure to assemble the single flange track roller is identical to the double flange
track roller.
Figure 165
1. Thoroughly clean all the parts of the track roller prior to assembly.
NOTE:
Do not reuse bearings (6) and (12). Use new parts for replacement.
2. Lower the temperature of bearings (6) and (12), and install one in each end of
the track roller with a press.
3. Install the bearings until the bearings contact the counterbore in the track roller.
4. Use the following procedure to determine the shaft end play.
NOTE:
Do not install the Duo-Cone seals in the track roller or end collars at this time.
APLTCL040

UNDERCARRIAGE
Figure 166
NOTE:
Replace the two O-ring seals that are used on shaft (15) with new O-ring seals.
5. Install a new O-ring seal (16) on shaft (15). Lubricate the O-ring seal with clean oil.
6. Lubricate the bore in end collar (5) with clean oil.
7. Use a press to install shaft (15) in end collar (5). Make sure that the spring pin
hole in the shaft is aligned with the spring pin hole in the end collar.
8. Install spring pin (4) in the end collar and the shaft.
9. Install the spring pin with the split facing toward the shaft. The split in the shaft
must not be more than 20 degrees on either side of a centreline that runs through
the centre of the shaft.
Figure 167
10. Install shaft (15) in track roller (9) without the Duo-Cone seals.
11. Install end collar (1) without the Duo-Cone seals. Install snap ring (10).
12. Use Tooling (B) to measure the end play of shaft (15).
13. The end play of the shaft must be 0.25 mm (.010 inch) to 1.25 mm (.049 inch).
Bearings (6) and (12) control the amount of shaft end play.
14. Disassemble the track roller, but do not remove shaft (15) from end collar (5).
APLTCL040

UNDERCARRIAGE
NOTE:
The rubber seals and all surfaces that contact the seals must be clean and dry. After
installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals.
For more information concerning the assembly and installation of Duo-Cone Seals, refer
to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.
15. Install Duo-Cone seals (2) and (8) in each end of the track roller with Tooling (A).
16. Install Duo-Cone seal (3) in end collar (5) with Tooling (A).
Figure 168
17. Install Duo-Cone seal (7) in end collar (1) with Tooling (A).
NOTE:
Do not damage the Duo-Cone seals during the installation of the shaft in the track roller.
Do not damage the Duo-Cone seals during the installation of end collar (1).
18. Install shaft (15) with end collar (5) in track roller (9).
19. Install O-ring seal (11) in the groove on the end of shaft (15). Lubricate the O-ring
seal with clean oil.
20. Lubricate the bore in end collar (1) with clean oil.
21. Put the track roller in a press. Install end collar (1) on the end of shaft (15).
22. Push down on end collar (1) with the press, and install snap ring (10).
23. Install a new stopper (13) in the end of shaft (15).
24. Install the stopper until the stopper is even with the end of the chamfer or until
the stopper is 7 ± 7 mm (0.28 ± 0.28 inch) below the end of the chamfer in the
end of the shaft.
25. Check the track roller for air leaks.
26. Use Tooling (C) to apply 138 kPa (20 psi) of air pressure to the roller for a
minimum of thirty seconds.
APLTCL040

UNDERCARRIAGE
27. Make sure that the cavity is sealed and that the air pressure is observed for ten
seconds. A pressure drop of 3.5 kPa (0.5 psi) or less is acceptable.
NOTE:
Do not apply the air in a large surge. Do not exceed 138 kPa (20 psi) as this may damage
the seals.
Figure 169
28. Put the track roller in a vertical position. Fill the track roller with 225 ± 10 mL
(7.65 ± 0.34 oz) of clean SAE 30 oil.
29. Install a new plug (14) in the stopper in the end of the track roller.
30. Install the plug until the plug is protruding 0 mm (0.0 inch) to 5 mm (0.20 inch)
above the end of the stopper or until the plug is flush with the end of the stopper.
31. Make sure that the plug is not recessed below the surface of the stopper after the
plug is installed.
End By: Install the track rollers. Refer to Disassembly and Assembly, "Track Roller -
Install" in this manual.
APLTCL040

UNDERCARRIAGE
FRONT IDLER, RECOIL SPRING AND HYDRAULIC TRACK

ADJUSTER
Remove and Install
Removal Procedure
Start By: Separate the track assemblies. Refer to Disassembly and Assembly, "Track
- Separate".
Figure 170
1. Use a pry bar and move the front idler (1), the recoil spring, and the hydraulic
track adjuster partially out of the track roller frame. Fasten lifting straps and a
suitable lifting device to front idler (1), as shown.
2. Once front idler (1), the recoil spring, and the hydraulic track adjuster (2) is
partially out of the track frame reposition lifting straps in order to support the
recoil spring, the hydraulic track adjuster, and the front idler.
3. Slide the front idler, the recoil spring, and the hydraulic track adjuster (2) out of the
track roller frame as one unit. The weight of the unit is approximately 204 kg (450 lb).
4. Leave the suitable lifting device attached and turn the front idler, the recoil
spring, and the hydraulic track adjuster around 180 degrees.
Figure 171
5. Install the front idler partially into the track frame. The front idler, the recoil
spring, and the hydraulic track adjuster will be supported by the track frame.
APLTCL040

UNDERCARRIAGE
6. Reposition the lifting straps in order to support the recoil spring and the hydraulic
track adjuster (2).
7. Remove bolts (3) that hold the front idler to the recoil spring and the hydraulic
track adjuster together.
8. Separate recoil spring and the hydraulic track adjuster (2) from the front idler. The
front idler will be supported by the track frame.
9. The weight of the recoil spring and the hydraulic track adjuster as a unit is
approximately 95 kg (210 lb).
10. Attach lifting straps and a suitable lifting device to the front idler (1), as shown.
11. Remove the front idler from the track roller frame. The weight of the front idler is
approximately 109 kg (240 lb).
APLTCL040

UNDERCARRIAGE
FRONT IDLER
Start By: Remove the front idler, the recoil spring, and the hydraulic track adjuster as
a unit. Refer to Disassembly and Assembly, "Front Idler, Recoil Spring and Hydraulic
Track Adjuster - Remove and Install" in this manual.
1. Thoroughly clean the outside of the front idler prior to disassembly.
NOTICE
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide"
for tools and supplies suitable to collect and contain fluids on Caterpillar products.
2. Remove the fill/drain plug from the front idler. Drain the oil from the idler into a
suitable container for disposal. The capacity of the idler is 180 mL (6.12 oz).
Figure 172
3. Place the front idler on the idler's side, as shown. The weight of the front idler is
110 kg (243 lb).
4. Remove two spring pins (1) from bearings (2).
5. Fasten a hoist to two bearings (2). Remove the bearings from the shaft of the
front idler. The weight of each bearing is 18 kg (40 lb).
6. Remove Duo-cone seals (3) from bearings (2).
APLTCL040

UNDERCARRIAGE
Figure 173
7. Remove shaft (5) from the front idler.
8. Remove two O-ring seals (4) from shaft (5).
Figure 174
9. Remove Duo-cone seal (6) from each side of the front idler.
10. Remove bushings (7) from each side of the idler.
APLTCL040

UNDERCARRIAGE
Assembly Procedure
Required Tools
(A) 1U-8842 Duo-Cone Seal Installer 1
(B) 8T-5096 Dial Indicator Group 1
Table 20
NOTE:
For information on welding front idlers, refer to Undercarriage Reconditioning Bulletin,
SEBF8552-02, "Procedure for Idler Weld Rebuild".
1. Thoroughly clean all of the parts of the front idler prior to assembly.
Figure 175
2. Check the condition of bushings (7). If the bushings are worn or damaged, use
new parts for replacement.
3. Lower the temperature of bushings (7), and install one in each side of the front
idler with a press.
Figure 176
4. Temporarily install a bearing (2) on shaft (5).
5. Install the shaft in the front idler.
6. Install the other bearing (2) on the shaft.
APLTCL040

UNDERCARRIAGE
7. Use Tooling (B) to check the end play of the shaft. The shaft end play must be
0.26 mm (.010 inch) to 1.26 mm (.050 inch).
8. Remove two bearings (2) and shaft (5) from the front idler.
Figure 177
NOTE:
The rubber seals and all of the surfaces that make contact with the seals must be clean
and dry. After the installation of the seals, put clean SAE 30 oil on the contact surfaces of
the metal seals. For more information concerning the assembly and installation of Duo-
Cone Seal kits, refer to Disassembly and Assembly, "Duo-Cone Conventional Seals -
Install" in this manual.
9. Install a Duo-Cone seal (6) in each side of the idler with Tooling (A).
10. Install a Duo-Cone seal (3) in each bearing (2) with Tooling (A).
11. Install new O-ring seals (4) on shaft (5).
Figure 178
12. Install shaft (5) in either bearing (2). Make sure that the spring pin hole in the
shaft is aligned with the spring pin hole in the bearing. Also, make sure that the
marking "R" and the milled surface of the shaft are facing toward the rear of the
bearing when the bearing is positioned on the machine.
NOTE:
Do not reuse spring pin (1). Use a new part for replacement.
APLTCL040

UNDERCARRIAGE
13. Install a new spring pin (1) in order to hold the unit together. Position the slit in
the spring pin, as shown. Refer to Illustration 813.
14. Install the shaft and the bearing in the front idler.
15. Repeat Steps 12 and 13 in order to install the other bearing (2) on shaft (5).
16. Check the front idler for air leaks. Apply 245 kPa (35.5 psi) to 265 kPa (38.5 psi)
of air pressure to the idler. Apply the air pressure for a minimum of 30 seconds. If
the pressure gauge reading remains constant for 30 seconds, assume that there
are no leaks in the front idler.
17. Place the front idler in a vertical position. Use clean SAE 30 oil and fill the front
idler. The capacity of the front idler is 180 ± 20 mL (6.12 ± .68 oz).
18. Apply a thin coat of 9S-3263 Thread Lock Compound on the threads of the fill/
drain plug. Install the fill/drain plug.
End By: Install the front idler, the recoil spring assembly, and the hydraulic track
adjuster as a unit. Refer to Disassembly and Assembly, "Front Idler, Recoil Spring
and Hydraulic Track Adjuster - Install" in this manual.
APLTCL040

UNDERCARRIAGE
RECOIL SPRING
Required Tools
A 4C-9540 Recoil Spring Bench 1

B 3B-7722 Pipe Bushing 2
1P-2377 Dust Plug 2
8F-0024 Hose Assembly 2
C 8S-9971 Adapter 1
D 4C-4467 65 mm Socket 1
(1)
Table 21
Start By: Remove the front idler and the recoil spring assembly. Refer to Disassembly
and Assembly, "Front Idler, Recoil Spring and Hydraulic Track Adjuster - Remove".
WARNING:
The spring of the recoil spring assembly is compressed under several tons of force.
Do not attempt to compress or release the tension of the spring with the nut on the end of
the retaining rod.
Damaged threads on the retaining rod or nut can cause the assembly to come apart with
force, resulting in injury or death.
1. Prior to disassembling the recoil spring assembly, make sure that Tooling (A) is
on a level surface.
2. Thoroughly clean the outside surface of the recoil spring assembly prior to disassembly.
APLTCL040

UNDERCARRIAGE
Figure 179
3. Install Tooling (C) on Tooling (B), as shown.
NOTE:
Two adjustable supports (1), reaction plate (2) and movable plate (3) are part of Tooling (A).
Figure 180
4. Adjust the spacing between reaction plate (2) and movable plate (3) so that the
spacing is approximately the same length as the recoil spring assembly. Also,
make sure that two adjustable supports (1) are positioned between the reaction
plate and the movable plate, as shown. Level the two supports.
NOTE:
The recoil spring assembly may be installed in Tooling (A) from the end. In this case,
reaction plate (2) must be removed. Then reinstall the reaction plate after the recoil spring
assembly is in place on two adjustable supports (1).
NOTE:
Do not remove the hoist from the recoil spring assembly until the unit is levelled, centred
and locked in the specified tooling.
5. The combined weight of the recoil spring assembly is approximately 116 kg

(255 lb).
6. Fasten a hoist to the recoil spring assembly. Put the recoil spring assembly in
position on two adjustable supports (1) in Tooling (A).
APLTCL040

UNDERCARRIAGE
7. Adjust the two adjustable supports in order to align the centreline of the recoil
spring assembly with the centreline of Tooling (A).
Figure 181
8. The hoist has been removed from the recoil spring assembly in order to provide a
better illustration of level gauge (4).
9. Put a level gauge (4) on the recoil spring assembly.
10. Reposition the recoil spring assembly until the recoil spring assembly is level and
the retaining rod and nut (6) are centred in the hole in reaction plate (2), as shown.
11. The recoil spring assembly is levelled by moving adjustable supports (1) higher or
lower. After the recoil spring assembly is levelled and centred, install two pins (5)
on the back side of reaction plate (2), as shown.
12. Operate Tooling (B) enough to hold the recoil spring assembly in position
between reaction plate (2) and movable plate (3). Make sure that the recoil spring
assembly is level and centred.
Figure 182
WARNING
Several tons of force are required to compress the recoil spring during assembly.
Do not compress the spring assembly until the covers on the tooling have been closed.
It is possible for the recoil spring to twist under load and come out of the tooling resulting
in injury or death.
APLTCL040

UNDERCARRIAGE
13. Close covers (7) on Tooling (A). Use Tooling (B) to compress the recoil spring
assembly slightly.
14. Through the opening in the end of Tooling (A), remove the socket head bolts and
lock strip (8) from the end of the retaining rod for the recoil spring.
15. Remove nut (6) with Tooling (D). Release the force on the recoil spring
assembly.
16. Open the covers on Tooling (A). Fasten a hoist to the recoil spring assembly, and
remove the recoil spring assembly from Tooling (A).
Figure 183
17. Separate the components of the recoil spring assembly. Remove support (12),
spring (10), support (9), and rod (4).
APLTCL040

UNDERCARRIAGE
Assembly Procedure
Required Tools
A 4C-9540 Recoil Spring Bench 1

B 3B-7722 Pipe Bushing 2
1P-2377 Dust Plug 2
8F-0024 Hose Assembly 2
C 8S-9971 Adapter 1
D 4C-4467 65 mm Socket 1
(1)
Table 22
WARNING:
The spring of the recoil spring assembly is compressed under several tons of force.
Do not attempt to compress or release the tension of the spring with the nut on the end of
the retaining rod.
Damaged threads on the retaining rod or nut can cause the assembly to come apart with
force, resulting in injury or death.
NOTE:
Prior to assembling the recoil spring assembly, make sure that Tooling (A) is on a level surface.
Figure 184
1. Check the condition of the threads on rod (11) and nut (6). If the threads are worn
or damaged, use new parts for replacement.
2. Assemble the recoil spring assembly loosely. Position spring (10) onto support
(9). Install rod (11) into support (9). Position support 12.
APLTCL040

UNDERCARRIAGE
3. Install Tooling (C) on Tooling (B).
Figure 185
NOTE:
Two adjustable supports (1), reaction plate (2), and movable plate (3) are part of Tooling (A) .
4. Adjust the spacing between reaction plate (2) and movable plate (3) so that the
spacing is approximately the same length as the recoil spring assembly. Also,
make sure that two adjustable supports (1) are positioned between the reaction
plate and the movable plate, as shown. Level the two supports.
NOTE:
The recoil spring assembly may be installed in Tooling (A) from the end. In this case,
reaction plate (2) must be removed. Then reinstall the reaction plate after the recoil spring
assembly is in place on two adjustable supports (1).
NOTE:
Do not remove the hoist from the recoil spring assembly until the unit is levelled, centred
and locked in the specified tooling.
5. The combined weight of the recoil spring assembly is approximately

115.6654 kg (255 lb).
6. Fasten a hoist to the recoil spring assembly. Put the recoil spring assembly in
position on two adjustable supports (1) in Tooling (A).
7. Adjust the two adjustable supports in order to align the centreline of the recoil
spring assembly with the centreline of Tooling (A).
APLTCL040

UNDERCARRIAGE
Figure 186 - The hoist has been removed from the recoil spring assembly
in order to provide a better illustration of level gauge (4).
8. Operate Tooling (B) and guide the end of the recoil spring assembly through the
hole in reaction plate (2). Put a level gauge (4) on the recoil spring assembly.
Make sure that the recoil spring assembly is level and centred in Tooling (A).
Remove the hoist from the recoil spring assembly.
Figure 187 - Right, (X) Compressed length of the spring
9. Close covers (7) on Tooling (A). Compress the recoil spring assembly with
Tooling (B).
10. Open the covers on Tooling (A). Measure the assembled length of the recoil
spring. The compressed length (X) must be 551 ± 1 mm (21.69 ± 0.04 inch).
11. If the assembled length is not correct, close covers (7) on Tooling (A), and adjust
the spring length with Tooling (B). If the assembled length is correct, the
assembly of the recoil spring assembly can be completed.
APLTCL040

UNDERCARRIAGE
Figure 188
12. Apply a rust inhibitor to the threads on the end of the retaining rod for the recoil
spring. Install nut (6). Tighten nut (6) with Tooling (D).
13. Put 9S-3263 Thread Lock Compound on the threads of the socket head bolts that
hold strip (8) in place. Install the strip and the socket head bolts that hold the strip.
14. Fasten a suitable lifting device to the recoil spring assembly, and remove the
recoil spring assembly from Tooling (A). The combined weight of the recoil spring
assembly is approximately 116 kg (255 lb).
End By: Install the front idler and the recoil spring. Refer to Disassembly and
Assembly, "Front Idler, Recoil Spring and Hydraulic Track Adjuster - Install".
APLTCL040

UNDERCARRIAGE
FINAL DRIVE SPROCKET
Remove and Install
Removal Procedure
Required Tools
8S-7640 Stand 2
A 8S-7611 Tube Assembly 2
8S-7615 Pin 2
B 138-7574 Link Bracket 1
Table 23
Start By: Separate the track. Refer to Disassembly and Assembly, "Track - Separate".
Figure 189
NOTE:
Adjust the height of Tooling (A) so that there is sufficient clearance between the sprocket
and the track for the removal of the sprocket from the final drive.
1. Lift the side of the machine in order to install Tooling (A) under the frame, as shown.
Figure 190
2. Remove bolts (1) that hold sprocket (2) to the final drive.
NOTE:
Use several washers between Tooling (B) and the sprocket. This will prevent damage
to the sprocket.
3. Fasten Tooling (B) and a suitable lifting device with a bolt, and a nut to sprocket (2).
4. Remove sprocket (2). The weight of the sprocket is approximately 40 kg (88 lb).
APLTCL040

UNDERCARRIAGE
Required Tools
8S-7640 Stand 2
A 8S-7611 Tube Assembly 2
8S-7615 Pin 2
B 138-7574 Link Bracket 1
Table 24
1. Thoroughly clean the mating surfaces of the sprocket and the final drive prior to
installing the sprocket.
Figure 191
NOTE:
Use several washers between Tooling (B) and the sprocket. This will prevent damage to
the sprocket.
2. Fasten Tooling (B) and a suitable lifting device to sprocket (2) with a nut,
washers, and a bolt.
3. Put the sprocket in position on the final drive.
4. Install bolts (1) that secure the sprocket to the final drive.
5. Tighten the bolts in a crisscross pattern. Tighten the bolts to a torque of 530 ± 70
Nm (395 ± 50 lb ft).
Figure 192
6. Raise the machine. Remove Tooling (A) from the frame.

End By: Connect the track assembly. Refer to Disassembly and Assembly, "Track - Connect".
APLTCL040

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Undercarriage

Published by Asia Pacific Learning

Version 3.2, 2003

Copyright © 2003 Caterpillar of Australia Pty Ltd Melbourne, Australia.

Learning & Development

© Caterpillar of Australia Pty Ltd 1

2 © Caterpillar of Australia Pty Ltd

KNOWLEDGE AND SKILLS ASSESSMENT

Learning Outcome 1: Identify undercarriage systems used on earth moving equipment.

© Caterpillar of Australia Pty Ltd 315

316 © Caterpillar of Australia Pty Ltd

2.9 Carrier rollers

© Caterpillar of Australia Pty Ltd 317

Learning Outcome 3: Conduct tests, inspections and adjustments on oval or elevated

318 © Caterpillar of Australia Pty Ltd

3.5 Describe the procedure for track separation and reconnection

© Caterpillar of Australia Pty Ltd 319

320 © Caterpillar of Australia Pty Ltd

TOPIC 1: Undercarriage Systems

TOPIC 2: Track and Roller Components

TOPIC 3: Service, Repair and Adjustment

© Caterpillar of Australia Pty Ltd 9

10 © Caterpillar of Australia Pty Ltd

© Caterpillar of Australia Pty Ltd 11

Figure 2 - Oval (Conventional) Undercarriage

Caterpillar introduced elevated sprocket track (Figure 3) in the 1978 to improve

12 © Caterpillar of Australia Pty Ltd

Figure 4 - Track Loader

Small Track-Type Tractors

Figure 5 - D4C Track-Type Tractor

© Caterpillar of Australia Pty Ltd 13

14 © Caterpillar of Australia Pty Ltd

ELEVATED SPROCKET TRACK

Track Type Tractor

Figure 7 - Track Type Tractor

© Caterpillar of Australia Pty Ltd 15

Figure 8 - Suspended undercarriage

16 © Caterpillar of Australia Pty Ltd

Figure 10 - Track Skidder

TRACK FRAME DESIGN - OVAL TRACK

© Caterpillar of Australia Pty Ltd 17

Dead Axle Arrangement

Figure 12 - Track Frame with Diagonal Brace

In some cases the manufacturer may refer to a diagonal brace as an A-Frame.

18 © Caterpillar of Australia Pty Ltd

© Caterpillar of Australia Pty Ltd 19

20 © Caterpillar of Australia Pty Ltd

© Caterpillar of Australia Pty Ltd 21

22 © Caterpillar of Australia Pty Ltd

ELEVATED SPROCKET DESIGN

© Caterpillar of Australia Pty Ltd 23

24 © Caterpillar of Australia Pty Ltd

Sealed and Lubricated Cartridge Pin

Figure 24 - Sealed and Lubricated Cartridge Pin

Figure 25 - Cross-section of Sealed and Lubricated Cartridge Pin

The components are:

© Caterpillar of Australia Pty Ltd 25

The cartridge pins should be checked for leakage during service.

Figure 26 - Rubber Pads

26 © Caterpillar of Australia Pty Ltd

© Caterpillar of Australia Pty Ltd 27

28 © Caterpillar of Australia Pty Ltd

During normal operation of the machine, the movable components of the