Field Repair of Swaged Grease Lubricated Track{4169, 4170, 4171} Caterpillar

Caterpillar Products: Machines with Grease Lubricated Track with Swage

Introduction

© 2015 Caterpillar All Rights Reserved. This guideline is for the use of Cat 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 in order to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Cat dealers and customers to benefit from cost reductions. Every effort has been made in order 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 or additional information concerning this guideline, submit a form for feedback in the Service Information System. In order to address an urgent issue, use the following resources in order to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

Summary

The instructions in this guideline will provide the necessary information in order to repair the track link assembly. This bulletin will allow the evaluation of the track components. If the track components do not meet the required specifications, the components must be replaced or rebuilt to the specified dimensions.

References

ReferenceUndercarriage Reconditioning Guide, SEBF8599

ReferenceUndercarriage Reconditioning Bulletin, SEHS8957, "Field Servicing Procedure for Non-PPR Sealed Lubricated Track"

ReferenceUndercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts"

ReferenceUndercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts"

ReferenceServicing Handbook, PEKP9400, "Caterpillar Track Service Handbook"

ReferenceParts Sales Kit, PECP3003

ReferenceDealer Service Tool Catalog, NENG2500

Illustration 1	g02139237

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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.

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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.

Canceled Part Numbers and Replaced Part Numbers

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

Track Press Tooling

Note: 100 ton track press 5P-2380 is replaced by three part numbers in Illustration 2.

Illustration 2	g02999477
(1) 5P-2379 Track Press Tool Gp (2) 8S-9903 Track Press Rollover Gp (3) 8S-7172 Double Acting Cylinder

Illustration 3	g03003597
For additional tooling of 5P-2379, refer to Dealer Service Tool Catalog, NENG2500. (1) 5P-2379 Track Press Tool Gp

Components of the Swaged Grease Lubricated Track

Illustration 4	g01217798
(1) Track Pin (2) Seal and Thrust Ring (3) Bushing (4) Pin Groove and Swage

The swage is used to retain the track links on the track pin. A portion of the pin boss is forced by extrusion into the pin groove. This process increases retention of the track link on the track pin.

The swage cannot be duplicated by most dealers. A welding operation on the ends of the track pins is used to replace the swage. The retention will still be maintained. This guideline explains the procedure for the proper welding operation.

Disassembly of the Track

Read the procedure for disassembly of the track in the Service Manual for your machine. The information here includes procedures and a complete list of tools.

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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.

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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.

1. Park the machine on a flat level surface so the damaged track joint is located above the front track roller frame.

2. Use the Hydraulic Torque Wrench to remove the track bolts and nuts from the track shoe of the damaged track joint and the two adjacent track shoes.

3. Remove the track shoe from the damaged track joint and the two adjacent track shoes.

4. Relieve the track tension from the track roller frame.

5. Use wood blocks to support the track under the grouser bar on the front and the rear of the track link assembly. Wood blocks will prevent the track from rolling off the track roller frame. Refer to Disassembly and Assembly Guideline, SENR3287, "Duo-Cone Seals (Conventional & Inverted)" for details.

6. Support the track link assembly in order to remove the tension on the damaged track joint. All tension should be removed from the track link assembly.

7. Mark and number the pins and bushings as shown with a permanent paint pen or marking device.

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Illustration 5	g03006497
(1) Press Frame (2) Pin Adapter (3) Ram Adapter

8. Install the pin adapter (2) and ram adapter (3) onto the press frame (1) to remove the track pin.

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Illustration 6	g03006517

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Illustration 7	g01229853

9. Use the press frame (1) to press the track pin out of the damaged track joint.

   Note: When the track pin is pressed out of the pin bore of the track link, the track pin will break off the portion of the track link that engaged the groove in the track pin.

   Note: Refer to Undercarriage Reconditioning Bulletin, SEHS8957, "Field Servicing Procedure for Non-Positive Pin Retention Sealed and Lubricated Track" for additional information.

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Illustration 8	g03006526
(4) Manual Press

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Illustration 9	g03006530
(4) Manual Press

10. Use the Manual Press (4) in order to spread the track links.

Note: Use only minimal force. Excessive force will cause the track links to move on the bushing, resulting in incorrect bushing projection and possible interference of the track links.

11. After the track links have been spread apart, carefully separate the track joint.

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Illustration 10	g03006533

12. Remove the track seals and thrust rings (5) from the track link counterbores.

13. Clean the track components for easier inspection of the track components.

14. Inspect the following track components for damage:
    • Track Pins

    • Bushings

    • Thrust Rings

    • Track Seals

    • Bores of the Track Links

    Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts".

Assembly of the Track

Replacement of the bushing and track link should be performed at the shop. If necessary, remove two track pins and repair a section of the track at the shop.

1. Replace any track components that have been damaged. Refer to Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts".

2. Determine if the bushing should be rotated in order to contact a different wear surface.

   Note: If the bushing does not need rotating, install the track pin and the bushing with the marks in the original position. If the bushing needs to be rotated, flip the track pin and the bushing 180 degrees and rotate the bushing 180 degrees around the track pin.

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Illustration 11	g02996317

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Illustration 12	g03015477
Mark and number the pin and bushing as shown with a permanent paint pen or other marking device.

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Illustration 13	g02996319

3. Consult Custom Track Service Handbook, PEKP9400, for reusability standards.

   1. Bushing Good: Install the track pin and bushing with the marks in the original position.

   2. Bushing Worn: If bushing meets allowable wear according to Custom Track Service Handbook, PEKP9400, then rotate the track pin and bushing 180 degrees and rotate the bushing while holding the track pin stationary.

   3. Bushing Bad: If bushing is bad, discard and replace with a new bushing.

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NOTICE
Install the track pin so the pin cross-hole and paint mark are towards the wear surface of the track lines. Any other position may cause the pin to break.

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Illustration 14	g03011277

4. Apply an even coat of grease to the bore of the bushing. Refer to Table 5 for the part numbers of the grease.

   Note: The excess grease will be pushed out of the bore of the bushing when the track pin is installed.

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   Table 5

   Specifications for the Grease
   Part Number	Grease	Quantity
   183-3432	ALG Auto-Lube Grease 5% MoS2	19.0 L (5.0 US gal)
   206-7405	ALG Auto-Lube Grease 5% MoS2	60.0 L (16.0 US gal)
   206-7406	ALG Auto-Lube Grease 5% MoS2	209.0 L (55.0 US gal)
   161-9203	ALG Auto-Lube Grease 5% MoS2	Cartridge

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Illustration 15	g03006537
(1) Track seals and Thrust ring

5. Install the track seals and thrust ring (1) in the last two track links of the track link assembly.

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Illustration 16	g03006558
(2) Manual Press

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Illustration 17	g03006559
(2) Manual Press

6. Use the Manual Press (2) to spread the adjacent track links in order to assemble the track link assembly.

7. Install the rebuilt track joint between the last two track links on the track link assembly.

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Illustration 18	g03006577
(3) Pilot Pin

8. Install the pilot pin (3) to align the track link assembly temporarily.

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Illustration 19	g03006580
(4) Ram Adapter (5) Hydraulic Cylinder

9. Install the correct size ram adapter (4) onto the hydraulic cylinder (5) .

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Illustration 20	g03008758
(6) Track Pin (7) Press Frame

10. Use the assembled press frame (7) to press the track pin (6) into the track link assembly. Refer to Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts" for the correct assembly force.

11. Release the hydraulic pressure and remove the Manual Press (2). Refer to Illustration 20.

    Note: Do not remove the Pilot Pin (3) until the track pin is installed completely. Refer to Illustrations 18 and 20.

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Illustration 21	g01229861

12. Equalize the pin projection on both sides of the track joint. This process will position the track pin for the fillet weld of 6 mm (0.24 inch) to 10 mm (0.40 inch) that will be welded on each end of the track pin.

13. Repeat the assembly process for any remaining track sections that need installed.

Welding Procedure

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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Illustration 22	g01229861

1. Verify that the pin projection is equal on both ends of the track pin.

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Illustration 23	g01229862

2. Use AWS Class E6011 welding electrodes to weld a bead 120 degrees around the ends of the track pin.

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Illustration 24	g01229866

3. Apply a wet paper towel directly to the weld bead after welding to prevent damage to the track seal.

   Note: Make sure that the entire end of the track pin is covered with the wet paper towel. Leave the paper towel in place for 3 to 5 minutes.

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Illustration 25	g01229868

4. Once the end of the track pin is cool enough to touch, repeat Steps 1 through 3 until the weld bead covers the entire circumference of the ends of the track pin.

Installation of the Track Shoes and Track Adjustment

1. All paint, loose rust, metal debris, and dirt must be removed from the mating surfaces of the track components. The correct clamping force cannot be achieved if all the paint is not removed. The following methods may be used in order to remove the paint:
   • Use a 24-grit sandpaper to remove the paint from the mating surfaces of the track links and the track shoes. A light mist of water should be sprayed on the mating surface during the sanding. The water will help keep the sandpaper clean during sanding.

   • A paint remover may be used to remove the paint from the mating surfaces of the track link and the track shoes. Make sure that the paint remover does not contact the track seal. The paint remover may damage the track seal.

   • Do not use a torch to remove the paint from the mating surfaces of the track links and the master track links. The high temperatures may damage the track seal.

   • Do not drag the track link assembly across the ground to remove the paint from the mating surfaces of the track links. Dragging of the track link assembly may damage the master track joint and other track components. High spots may be created on the track links. Dragging the track link assembly may cause the track joints to open.

   Note: The track bolt and threads on the track nuts must be in good condition.

2. Lubricate the bolt threads, the bolt shank, and the washer face with SAE30 oil.

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Illustration 26	g01225632

3. Install the track shoes and tighten each bolt to the correct preliminary torque of 400 ± 70 N·m (295 ± 52 lb ft). Follow the correct pattern to torque the track bolts. Refer to Illustration 26 for the correct torque sequence.

4. Perform an additional 120 degree turn on each track bolt to complete the torque procedure. Refer to Illustration 26 for the correct torque sequence.

5. Adjust the tension of the track roller frame. Refer to the Disassembly and Assembly of your machine for the correct procedure.

6. Remove all blocks that were used to support the track.

7. Remove the blocks under the grouser bar on the front and rear of the track. The blocks were used to prevent the track from rolling off the track roller frame.