Field Servicing Procedure for Non-Positive Pin Retention Sealed and Lubricated Track {0729, 4169, 4170} Caterpillar

Caterpillar Products

Machines with non-PPR Sealed and Lubricated Track

Excavator

330-A (S/N: 9NG1-UP; 9PJ1-UP; 6ZK1-UP)

350-A (S/N: 7RK1-UP; 8HK1-UP; 9DK1-UP; 2ZL1-UP; 3ML1-UP; 9FL1-UP; 8KZ1-UP)

350L (S/N: 9FL1-UP)

375-A (S/N: 8XG1-UP; 8WJ1-UP; 6NK1-UP; 6RL1-UP)

375L (S/N: 9WL1-UP; 1JM1-UP)

E300 (S/N: 2CF1-UP)

E300B (S/N: 1WJ1-UP)

EL300 (S/N: 4NF1-UP)

EL300B (S/N: 3FJ1-UP)

Pipelayer

583H (S/N: 38A1-UP; 78V1-UP)

583K (S/N: 78V1-UP)

583R (S/N: 2XS1-UP)

583T (S/N: CMX1-UP)

594 (S/N: 62H1-UP; 96V1-UP)

594H (S/N: 96V1-UP)

Track-Type Loader

941 (S/N: 70H1-UP; 80H1-UP)

941B (S/N: 70H1-UP; 80H1-UP)

943 (S/N: 03Y1-UP; 31Y1-UP; 63Y1-UP; 73Y1-UP; 04Z1-UP; 19Z1-UP)

951 (S/N: 69H1-UP; 79H1-UP; 86J1-UP)

951B (S/N: 32F1-UP; 69H1-UP; 79H1-UP; 86J1-UP)

951C (S/N: 69H1-UP; 86J1-UP)

953 (S/N: 63Y1-UP; 73Y1-UP)

955 (S/N: 60A1-UP; 61H1-UP; 65H1-UP; 87H1-UP; 64J1-UP)

955A (S/N: 42D1-UP)

955H (S/N: 60A1-UP)

955K (S/N: 61H1-UP; 71J1-UP; 85J1-UP; 57M1-UP)

955L (S/N: 64J1-UP; 85J1-UP)

963K (S/N: LBL1-UP)

977 (S/N: 20A1-UP; 46H1-UP; 29K1-UP)

977A (S/N: 43D1-UP)

977H (S/N: 53A1-UP)

977K (S/N: 46H1-UP; 48J1-UP; 11K1-UP)

977L (S/N: 48J1-UP; 11K1-UP)

983 (S/N: 38K1-UP)

983B (S/N: 58X1-UP)

Track-Type Skidder

D5 TSKH Series II (S/N: 7EG1-UP)

Track-Type Tractor

D5R2 (S/N: R5A1-UP; WRE1-UP; WDZ1-UP)

D6H (S/N: 5HF1-UP)

D6H Series II (S/N: 4LG1-UP)

D6K (S/N: 6S61-UP; 7P61-UP; MP71-UP)

D6K2 (S/N: DFR1-UP; JTR1-UP)

D6R (S/N: EMM1-UP; JEN1-UP)

D8 (S/N: 76V1-UP; 77V1-UP)

D8K (S/N: 76V1-UP; 77V1-UP)

D9 (S/N: 66A1-UP; 91J1-UP; 90V1-UP)

D9G (S/N: 66A1-UP; 90J1-UP; 91J1-UP)

D9H (S/N: 90V1-UP)

Introduction

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Undercarriage Reconditioning Bulletin contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Undercarriage Reconditioning Bulletin must be used with the latest technical information that is available from Caterpillar.

For questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding this document, submit a form for feedback in the Service Information System(SIS Web) interface.

Summary

This guideline provides the procedure for removal and installation of two adjacent pairs of links. Usually of dry joint field repair, it is necessary to replace the two adjacent pairs of links due to damage on the internal surfaces of the link and bushing.

The procedure for the field assembly of a link section is also included. When repairing a cracked link or master joint failure, the two pins of the affected area should be removed and the single joint repaired.

Illustration 1	g03024977

This field service bulletin illustrates one particular portable Track Repair Group. Refer to the "Tools and Equipment" section for other available repair groups.

References

Reference: Guide, SEBF8599, "Undercarriage Reconditioning Guide"

Reference: Catalog, PECP3003, "Undercarriage Parts Sales Kit"

Reference: Handbook, PEPK9400, "Custom Track Service"

Reference: Catalog, NENG2500, "Dealer Service Tools Catalog"

Reference: Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for reusable Track Parts"

Reference: Undercarriage Reconditioning Bulletin, SEBF8553, "Reusability Guidelines and Installation Procedures for Split Master Links"

Reference: Undercarriage Reconditioning Bulletin, SEBF8562, "Procedures and Guidelines for Cleaning Phosphate Coated Track Pins"

Reference: Special Instruction, SEHD8881, "Repair Procedure for Quad Track"

Reference: Undercarriage Reconditioning Bulletin, SEBF8566, "Track Data Charts"

Reference: Refer to the Operation and Maintenance Manual for your equipment.

Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

This bulletin may contain hazardous steps. A safety alert symbol like the one below is used to identify a hazard.

Warning messages identify a specific, imminent, latent, hazard that has a reasonable probability of resulting in personal injury or death if the warning is ignored.

Illustration 2	g02139237

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Inspect all threaded components before use. Damaged threads may fail under hydraulic pressure. Broken threads may release flying objects that are propelled with great force. Personal injury or death can occur if struck by flying objects.

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Do not stand near the hydraulic press while the press is in operation. A component that slips or breaks under pressure may fly into the air with great force. Personal injury or death can occur if struck by flying objects.

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The machine must be on a level, hard surface before a separation of the track is made. Any time a separation of both tracks is made, the machine must have blocks correctly positioned so the machine will not move.

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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

Canceled Part Numbers and Replaced Part Numbers

This document does not include all canceled part number and replaced part number information. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Tools and Equipment

Refer to the"Tools Required" section for a complete list of required items.

Link Section Removal Preparation

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Illustration 3	g02397127
(1) Dry Joint

1. Position dry joint (1) above the front track roller frame as shown in Illustration 3.
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   Illustration 4	g01159329

2. Remove the five track shoes near the dry joint. Use the 194-7586 Hydraulic Wrench , or 194-7582 Hydraulic Wrench for removing the track bolts (depending on torque capabilities).
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   Illustration 5	g01179354
   (2) Cover

3. Remove cover (2).
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   Personal injury can result from grease under high pressure. The adjuster cylinder for the track is under high hydraulic pressure. Grease under high pressure can cause injury. Do not visually inspect the adjuster cylinder to see if grease is released when the valve is opened. Look to see that the track has loosened.

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   Illustration 6	g01179371
   (3) Track adjusting mechanism

4. Release the pressure from track adjusting mechanism (3).

5. Move the track until the master link is in alignment with the center line of the rear idler.
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   Illustration 7	g02397139

6. Block the track under the grouser bar, just below the master link. Move the track to the rear until the tracks are in solid contact with the wooden blocks.
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   Illustration 8	g01159329

7. Remove the master shoe bolts with the hydraulic wrench and separate the master link.
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   Keep away from the front of the machine when the track is pushed off the final drive. A minimum distance of 7.6 m (25 ft) is needed in front of the track to permit the track to move out onto the floor.

8. Turn the final drive in a forward direction and let the track fall forward.

9. Move the tractor to a position where the dry joint is unobstructed to perform the repair.
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   Illustration 9	g01159675

10. Use wooden blocks to provide clearance for the Track Repair Group.
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    Illustration 10	g02397280
    (4) 8T-0820 Hydraulic Pressure Gauge (5) 1P-2375 Quick Connect Coupler (6) 3B-7722 Pipe Bushing (7) 003-9514 Pipe Coupling (8) 1U-7046 Indicator Gauge Gp (9) 3S-6224 Electric Hydraulic Pump Gp

11. Use calibrated 8T-0820 Hydraulic Pressure Gauge (4) and 1P-2375 Quick Connect Coupler (5) connected with 3B-7722 Pipe Bushing (6) and 003-9514 Pipe Coupling (7) to check the accuracy of 1U-7046 Indicator Gauge Gp (8) on 3S-6224 Electric Hydraulic Pump Gp (9).

The 8T-0820 Hydraulic Pressure Gauge should be calibrated on the 5P-8558 Gauge Calibration Gp and be used as a master checking gauge in the field.

Recommended calibration range of the master gauge is 34500 kPa to 60300 kPa (5004 psi to 8746 psi). Connect the master gauge to the high-pressure hose on the 3S-6224 Electric Hydraulic Pump Gp. Mark the pressure observed on the permanently mounted gauge when the calibrated gauge reaches the correct assembly pressure. The marked pressure is the pressure that should be used to assemble the track.

Link Section Removal of Damaged Joint

Refer to "Tools Required"for complete tooling for the following steps.

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Illustration 11	g02397156
(10) Bolster (11) Track repair group (12) Forcing pin

1. Remove bolster (10) from the track repair group (11). Install correct forcing pin (12) and connect the hydraulic lines. Use 9S-9101 Load Positioner Gp to suspend the track repair group. The sling assembly will make positioning the track repair group easier.
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   Illustration 12	g02397157
   (10) Bolster (13) Pin receiver

2. Position the track repair group over the chain. Install bolster (10) and proper pin receiver (13). The pin receiver has an increased inside diameter to permit the pin to pass through. Carefully align the tooling and remove the track pins.
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   Illustration 13	g02397158

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   Illustration 14	g02397159
   (14) Guide pin

3. Remove the pins near the dry joint. Install proper guide pin (14) as each pin is removed.
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   Illustration 15	g02397160
   (15) 6V-3160 Double Acting Cylinder

4. Remove the track repair group and one guide pin. Install 6V-3160 Double Acting Cylinder (15). Use the hydraulic cylinder to spread the links apart carefully. Use only minimal force. Excessive force will cause the links to move on the bushings, resulting in incorrect bushing projection and possible check-to-check interference on the links. When the links have been spread apart, separate the joint.
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   Illustration 16	g02397161
   (15) 6V-3160 Double Acting Cylinder

5. Move 6V-3160 Double Acting Cylinder (15) to the adjacent pair of links. Attach a hoist to the pair of links to be removed. Remove the other guide pin. Use the cylinder group to spread the adjacent pair of links apart, and remove the links. Do not use excessive force when spreading the links.

6. Remove the old seals. Clean the link pin bores, counterbores, and surrounding surfaces thoroughly. Remove all loose material before installing seals.
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   Illustration 17	g02397176

7. Install the new seals with the proper seal installer. Make sure that the seal is seated properly in the link counterbore. Do not lubricate the pin, pin bore, or bushing bore.

   Note: The thrust rings may be reused if free of defects. Thrust rings to be reused should be cleaned and inspected prior to installation. Refer to Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts" for track component reuse information.

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   Illustration 18	g02397177

8. Apply a small amount of molykote paste to one side of the thrust ring. Take this thrust ring and rub the coated side against the other thrust ring using a twisting motion. The result is a thin, even layer of molykote.

Apply a small amount of grease to the uncoated side of each thrust ring and stick to the link counter bore with the molykote side toward the bushing.

Illustration 19	g02397178

The replacement link assemblies should consist of one complete joint (four links, two bushings, two thrust rings, one pin, and two seals). Link assemblies should be assembled on the shop track press prior to the field repair. However, if the complete joint cannot be assembled prior to the field repair, assemble using the track repair group.

Link Section Buildup

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Illustration 20	g02397179
(1) Forcing pin

1. Place the proper offset adapter in the bolster of the 8T-7780 Track Repair Group. Place the bushing forcing pin (1) on the end of the forcing pin. To prevent damage to the tooling or the link, hold the link in position as the bushing is pressed into the bushing bore.
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   Illustration 21	g02397180

2. Place the other link against the offset adapter, use the press to snug the link and bushing against the bushing bore of the link. Insert the guide pin into the two pin bores to obtain correct alignment and finish pressing the bushing into the bushing bore.
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   Illustration 22	g02397181

3. Measure the bushing projection with FT1953 Gauge (dial indicator) or a depth micrometer. Refer to Undercarriage Reconditioning Bulletin, SEBF8566, "CaterpillarTrack Data Charts" for bushing projection specifications.

   The second link section should be assembled as previously described. To complete the assembly, use the instructions in the following section "Link Section Installation".

Link Section Installation

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Illustration 23	g02397182

1. Attach a hoist to the new set of links.

2. Use the 6V-3160 Double Acting Cylinder to spread the adjacent links open enough for the bushing to clear the seals. Carefully slide the two links together.

3. Install the guide pin, release the hydraulic pressure, and remove the 6V-3160 Double Acting Cylinder.

4. After the guide pin has been installed, use a hoist to raise the links out of the way. Install new seals using the correct seal installer.
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   Illustration 24	g02397184

5. Install the thrust rings in the adjoining section.
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   NOTICE
   Extreme care should be taken to prevent the bushing from contacting the seal lips as the joint is brought into alignment. Sharp corners on the edge of the bushing can cut the seal lips resulting in a leak and a dry joint.

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   Illustration 25	g02397196

6. Use the 6V-3160 Double Acting Cylinder between the raised links to spread the links apart. Rotate the mating links to the full extent of the upward arc. Carefully align the bushing with the seals and lower the hoist to position the link pairs together, at the same time. Allow the joint to fold together.

7. After the two link pairs are in alignment, install the other guide pin.

8. Release the hydraulic pressure and remove the 6V-3160 Double Acting Cylinder.
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   Illustration 26	g02085476

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   Illustration 27	g01237738

9. Lubricate the new stopper with lightweight oil and install the stopper in the pin end.
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   Illustration 28	g02397198
   (1) Piston rod cap (2) Pin receiver

10. Install the track repair group with the proper piston rod cap (1) and pin receiver (2).
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    Illustration 29	g02397199

11. Install the new track pin with the cross hole towards the wear surface of the links, and position the pin (end for end) with the oil hole facing the same side of the track as the other pins.

12. Carefully align the tooling with the links as close as possible. Press the pin into the link pin bores.
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    Illustration 30	g02397236

13. Do not remove the guide pin from the link bore until the pin is pushed out completely. Once the pin is installed completely, increase the hydraulic pressure to the proper assembly force. This pressure will make sure that the joint is assembled to “ZERO” end play.

    Note: The correct pin projection should occur automatically, provided the tooling is maintained in good condition and all foreign material (burrs and cold-flowed material) is removed from the counter-bore surfaces on the links.

14. Move the tooling to the second joint and install the track pin, following the same procedure.

15. Remove the track repair group.
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    Illustration 31	g02085483
    Nitrogen tank and cart, Regulator, Pressure Test Tool FT2724

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    NOTICE
    Before the track joint can be filled with oil. The following leak check must be performed.

16. Obtain a copy of Bulletin, SEBF88594, "Nitrogen Pressure Test Unit FT2724" to test the rebuilt track joint. Refer to illustration 31.

    1. Obtain a joint cavity pressure of 138 kPa (20.0 psi) with the FT2724 tip in the stopper.

    2. After closing the Pressure Differential Valve Knob, the joint should have a pressure drop less than 3.5 kPa (0.50 psi) in the 10 second timeframe.
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    NOTICE
    Repair Process Engineering no longer supports shop air vacuum testing of undercarriage components. Refer to Bulletin, SEBF88594, "Nitrogen Pressure Test Unit FT2724" for proper practice.

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    NOTICE
    If the joint fails the pressure test, the joint will have to be disassembled, repaired, and retested.

17. Fill track joints with oil. Refer to Bulletin, SEBF8577, "Oil Volumes for Track Link Assemblies"

18. Fill the second joint using the same procedure.
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    Illustration 32	g02086973

19. Use the 5P-7419 Installer Tool to install the plastic plug in the rubber stopper. Put the tapered end of the plug into the stopper first. The plastic plug must protrude slightly out of the rubber stopper.

20. All paint, loose rust, metal debris, and dirt must be removed from the mating surfaces of the shoes, bolts, nuts, nut seats, and links so the correct clamping force between the track shoe and links will be achieved.

21. Lubricate bolt thread, body, and washer face with 4C-5593 Anti-Seize compound. The bolt and nut threads must be in good condition.

22. Clean the teeth (serrations) of the split master links. Remove dirt, loose rust, and debris from the master link bolt holes. If necessary, use a pick or compressed air. Clean the bolt threads with a thread tap or use new bolts. Close one master link so the teeth (serrations) are in full contact. The other master link should have no more than a 3.20 mm (0.126 inch) gap between the teeth (serrations).
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    Illustration 33	g02397239

23. Fasten a cable and chain to the track. Fasten the other end of the cable to another tractor or similar machine to pull the track over the front idler.
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    Illustration 34	g02397240

24. Block the other end of the track as described in step 6 of the section "Link Section Removal Preparation". Pull the track until the track bushings engage with the sprocket segments on the final drive. Start the machine and turn the final drive in a reverse direction to pull the track together.
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    NOTICE
    Make sure to pull the cable in a straight line.

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    Illustration 35	g02397256

25. Put the lower end of the master link in alignment with the upper end of the master link. Make sure the teeth of both ends of the master link are clean and engaged properly.
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    Illustration 36	g02397257

26. Place the master shoe in position and start all fours bolts by hand. Use the 194-7586 Hydraulic Wrench, or 194-7582 Hydraulic Wrench to tighten the bolts to the proper pretorque.

    For torquing values, refer to Bulletin, SEBF8557, "Track Shop Servicing Procedure for Non-PPR Sealed and Lubricated Track".

27. Remove all blocks, chains, and tooling.
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    NOTICE
    It is not necessary to set the track sag to the tight end of the tolerance during break in. Track sag for properly assembled track will not change noticeably. Setting track sag tighter than specified can result in excessive heat build-up and pin-to-bushing galling.

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    Illustration 37	g02397258

28. Adjust the sag to the proper dimension following the track sag adjustment procedure. Refer to the Operation and Maintenance Manual for your equipment.
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    Illustration 38	g02397259

29. Install the five track shoes and tighten using the torque turn method. Follow the proper track shoe bolt tightening sequence shown in the Illustration 38.

    Note: Lubricate bolt thread, body, and washer face with SAE 80W-90 oil. The bolt and nut threads must be in good condition.

    For torquing values, refer to Bulletin, SEBF8557, "Track Shop Servicing Procedure for Non-PPR Sealed and Lubricated Track".

Tools Required

The following information covers tools available in the Tooling catalog, NENG2500, "Dealer Service Tools Catalog".

Track Repair Groups

Various Repair Groups exist. Refer to the information below.

Illustration 39	g03024976
Typical Track Repair Group

Illustration 40	g02397117
8T-7780 Track Repair Group tooling identification. (1) Forcing pin (2) Spacer/receiver (3) Guide pin (4) Piston rod cap (5) Bushing forcing pin (6) Offset adapter

Illustration 41	g02397118
Track pin removal with 8T-7780 Track Repair Group. (7) Forcing pin (8) Track pin (9) Track links (10) Spacer/receiver

Illustration 42	g02397119
Track bushing removal with 8T-7780 Track Repair Group. (11) Forcing pin (12) Bushing forcing pin (13) Track link

Illustration 43	g02397120
Track pin installation with 8T-7780 Track Repair Group. (14) Piston rod cap (15) Track pin (16) Guide plate (17) Guide pin (18) Track links (19) Spacer/receiver

Illustration 44	g02397121
Track bushing installation with 8T-7780 Track Repair Group. (20) Forcing pin (21) Bushing forcing pin (22) Track bushing (23) Track link (24) Offset adapter

Press Frame, Cylinder, and Rollover Group

Illustration 45	g03025622

Illustration 46	g02397122
Tools from 5P-2379 Tool Group. (22 tools total). (25) Removal ram adapter (26) Remove and install adapter (27) Install ram adapter (28) Install plug (29) Install pilot pin (30) Removal bushing adapter (31) Remove and install pusher (32) Install adapter

Illustration 47	g02397123
Track pin removal with 5P-2379 Press Frame, 8S-7172 Cylinder Group, and 8S-9903 Rollover Group. (33) Removal ram adapter (34) Track links (35) Track pin (36) Remove and install adapter

Illustration 48	g02397124
Track bushing removal with Press Frame, Cylinder, and Rollover Group. (37) Removal ram adapter (38) Remove and install pusher (39) Removal bushing adapter (40) Track link

Illustration 49	g02397125
Track pin installation with Press Frame, Cylinder, and Rollover Group. (41) Install ram adapter (42) Install plug (43) Track pin (44) Guide pin (45) Track links (46) Remove and install adapter

Illustration 50	g02397126
Track bushing installation with Press Frame, Cylinder, and Rollover Group. (47) Removal ram adapter (48) Remove and install pusher (49) Track bushing (50) Install adapter

Installers, Gauges, and Track Shoe Data