Shop Repair Procedures for Positive Pin Retention 2 (PPR2) Track. {0374, 0599, 0700, 0729, 4169, 4171} Caterpillar

Caterpillar Products

Machines with Positive Pin Retention 2 (PPR2) Track

Introduction

© 2016 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 in order 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 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

Illustration 1	g03785897
Illustration of Positive Pin Retention 2 (PPR2)

Positive Pin Retention 2 (PPR2) is a Grease Lubricated Track Assembly. (PPR2) was developed by Caterpillar in order to increase the wear life of the track for Hydraulic Excavators by preventing pin walking and link cracking. Each end of the pin has a machined groove. Special tooling will be needed to extrude pin boss material into the grooves on the pin. The information in this bulletin includes a procedure for disassembly and assembly of the track link assembly, specifications, and the required tooling. Follow each step carefully to ensure that each track joint has minimum end play and maximum service life.

Illustration 2	g03785919

Illustration 3	g03786017

The rigid track seal used in Sealed and Lubricated Track is also used in (PPR2) Grease Lubricated Track. The rigid track seal design on the (PPR2) Grease Lubricated Track allows longer retention of the grease. Refer to Information Release Memo, PELJ0541. Refer to Illustration 3.

References

Reference: Undercarriage Reconditioning Guide, SEBF8599

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

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

Reference: Tool Operating Manual, NEHS0650, "Caterpillar Track Press Manual"

Reference: Tool Operating Manual, NEHS0826, "Caterpillar 300T Track Press Manual"

Reference: Tool Operating Manual, NEHS0803, "Caterpillar 375T Track Press Manual"

Reference: Tool Operating Manual, NEHS0830, "Caterpillar Track Torque Wrench"

Reference: Information Release Memo, PELJ0541

Reference: Servicing Handbook, PEKP9400, "Caterpillar Track Service Handbook"

Reference: Parts Sales Kit, PECP3003

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

Safety

Illustration 4	g02139237

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 in order to perform these functions properly.

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

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Operating the track press incorrectly may result in a flying object hazard. Always operate the track press with protective guards installed and eye wear protection to prevent injury. Always read and understand the operator's manual for the track press before using.

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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 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.

Required Tooling

Illustration 5	g02022171
Nominal side of the track press. The first assembly side whether (right hand or left hand) will be the Nominal side. (A) Pin protrusion. (B) Offset of the track link (C) Bushing protrusion.

Disassembly of the Track

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Illustration 6	g03745699

1. Use a high-pressure washer in order to remove mud and debris from the track assembly before the track is brought into the shop.

   Note: Cleaning the track helps reduce the possibility of scoring of the pin bore. If the pin bore is scored across the entire length of the pin bore, the track link cannot be reused.

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   Illustration 7	g03787175

2. Use the Caterpillar Track Torque Wrench to remove the bolts from the track shoes. Remove the track shoes.

3. Measure the track shoes, track links, and bushings and record the measurements.

   Note: Refer to Service Handbook, PEKP9400, "Caterpillar Track Service Handbook" for measurements of percent of wear.

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   Illustration 8	g03745722

4. Use a permanent pen to mark the track pins and bushings for proper reinstallation.

5. Reference Table 4 for disassembly / assembly contact tooling used for PPR2 Track Link Assemblies.

6. Examine the track press and the components of the track press before disassembling the track.

7. For both disassembly and assembly tooling, calculate Dimension (B) Track link offset. This calculation will determine whether shims / spacers are needed. Then physically measure Dimension (B) once the shims / spacers are in place and tooling is attached to tool bar.

8. Reference Tables 3 for track link offset dimensions (B).
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   Illustration 9	g03780110

9. Measure the height of the track pin disassembly tooling use tooling (D) calipers.
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   Illustration 10	g03780119

10. Measure the height of the bushing disassembly tooling use tooling (D) calipers.

11. Determine track link offset by using this calculation (height of bushing tooling - height of pin tooling = track link offset.)

    Note: If the dimensions for the track link offset of the tooling is incorrect, spacers / shims can be used to the correct tooling dimensions. Reference for Table 4 for contact tooling modifications.

12. Align the tooling with the track pin and the bushing.

13. Follow Steps 13.a through 13.e before the track pin or the bushing is pressed out of the track link.

    1. Make sure that the bushings are fully seated in the saddle of the track press.
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       Illustration 11	g03748436

    2. Lower the hold down shoe, allow a small amount of clearance between the hold down shoe and bushing.

       During disassembly, the bushing will slide to the left and right in the saddle.

       Reference Illustration 11.

       Due to the wear step, the bushing will need to float within the saddle and hold down shoe.

       A small amount of clearance between the hold down shoe and bushing must be maintained during disassembly.

       The amount of clearance depends on the amount of wear on the bushing.

    3. Ensure that the correct tooling is being used.

    4. Make sure that the face and the chamfer of the pin / bushing tooling are clean and smooth.

    5. Confirm that the tooling is centered on the end of the track pin and the bushing.

       Note: Gouging on the bores of the track link will occur if the tooling is not centered.

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    Illustration 12	g03745743

14. Press the track pins and bushings out of the track links.

15. Remove the thrust rings from the track joints as the track pin is pressed out of the bore of the track link.

16. Examine the thrust ring for reusability. Strike the thrust ring against a metal object in order to check for cracks. .

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

    Note: If the thrust ring is not cracked, the thrust ring will make a clear ringing sound. Thrust rings that are cracked will not have the clear ringing sound, but will make a dull thumping sound.

17. Examine the track links for cracks, scoring in the pin bore, and damaged seals.

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

Preparation for Assembly

Caterpillar recommends cleaning the track pins and bushings. Cleaning the track components removes any foreign material and contaminated grease. Inspection of the track components is easier when the components are clean.

Note: Whenever any track joint is disassembled, always replace the seal with a new seal.

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Illustration 13	g03745749

1. Inspect the track pin for cracks, spalling, or galling.

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

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   NOTICE
   Do not grind the end of the pin. Any change in the pin end will adversely affect assembly and result in damage to the tooling and the track. Small burrs may be removed with light grinding.

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   Illustration 14	g03745782

2. Inspect each bushing for external cracks. Inspect each bushing for internal cracks by holding the bushing up to a bright light.
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   Illustration 15	g03787538

3. Remove all seals and thoroughly clean the counterbores of the track link. Clean the counterbores with Tooling (A) and Tooling (B)

   Note: Tooling (B) should be rated at the maximum rpm of Tooling (A)

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   Illustration 16	g03745759

4. Wipe the counterbore of the track link with a lint free cloth.
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   Illustration 17	g03745061

5. Place the seal into Tooling (S) seal installer.

   Note: Never reuse track seals. For ease of seal installation, the outer load ring should be lubricated with a light weight oil.

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   Illustration 18	g03745062

6. Use Tooling (S) to install new seals into the track link counterbore. Use firm, even pressure to fully seat the seal in the link counterbore. Use the proper seal installer on the track seals.

   Note: Do not lubricate the track pin, the bore for the track pin.

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   Table 5

   Rigid Track Seal Installers
   Sales Model	Part Number
   324FM 511 1090 TK711	4C-8617
   345 349 568	4C-8619
   365 374 385 390 5090 MD6640	4C-8622

First and Second Assembly Side Concept

The Caterpillar assembly contact tooling requires that only one link be pressed onto the assembly at a time. For example, to service a track joint, the tooling on the left side is used to hold the track assembly while the right link is pressed completely onto the pin and bushing. The right side tooling then remains in the extended position while the left side link is pressed onto the pin.

Note: During the assembly process, it is important that the links never hit the saddle.

The pin assembly plunger on the first assembly side or nominal side is longer than the pin assembly plunger on the second assembly side or the non-nominal side. The nominal side longer plunger initially establishes the correct pin projection, and the non-nominal shorter plunger allows the joint to be pressed to zero endplay. The shorter second side pin assembly plunger never “bottoms-out” against the base; therefore, the joint cannot be released from the zero endplay condition. According to Caterpillar track assembly specifications, pin projection is established and controlled on one side only. Due to the “stack-up” of tolerances throughout the track joint, it is necessary to assemble the joint one side at a time.

In contrast, bushing projection is controlled on both sides of the track joint. Thus, the two bushing assembly plungers are both the same length resulting in the same projection. The establishment of proper bushing projection is critical to ensure that adjacent links do not scrub against one another.

Setup of the Track Press

The operator of the track press must use great care in the adjustment and operation of the track press and selecting the correct tooling. The cleanliness and condition of the tooling must be checked frequently. Buildup of dirt and metal shavings in the counterbores of the tooling for the track pins will cause the track pins to bottom out before the track links have been pressed-on far enough to remove all the end play. Bushing projection will also be affected by any foreign material. Reference Table 3 for the dimensions for the track link assemblies.

1. Clean any foreign material off the tooling for the track press with a lint free cloth.

2. Remove the springs from the pin and bushing tooling and reinstall the plunger and the base.
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   Illustration 19	g02022171
   (A) Pin protrusion. (B) Offset of the track link. (C) Bushing protrusion.

3. Verify the correct track link offset of the tooling dimensions by measuring the pin and bushing tooling on both sides of the track press. Refer to Table 3 for the correct dimensions.
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   Illustration 20	g03780149

4. Use Tooling (D) calipers to measure the height of the tooling for the track pin.
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   Illustration 21	g03780141

5. Use Tooling (D) calipers to measure the height of the tooling for the bushing.

6. Determine track link offset by using this calculation (height of bushing tooling - height of pin tooling = track link offset.)

   Note: If the dimensions for the track link offset of the tooling is incorrect, spacers / shims can be used to the correct tooling dimensions. Reference Table 3 for contact tooling modifications.

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   Illustration 22	g03787624

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   Illustration 23	g02077954

7. Use Tooling (F) dial indicator to measure the correct bushing projection for the bushing tooling on both sides of the track press.

   Refer to Table 3 or Table 4 for the correct dimensions.

   Note: If the dimensions for the bushing projection of the tooling is incorrect, spacers / shims can be used to the correct tooling dimensions. Reference Table 3 for contact tooling modifications.

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   Illustration 24	g03745923

8. Assemble the bushing tooling including the spring, plunger, and base.
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   Illustration 25	g03787981

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   Illustration 26	g02078053

9. Use Tooling (F) dial indicator to measure the tooling for the track pin on both sides of the track press.

10. Verify the correct pin projection on the nominal side of track press.

    Refer to Table 3 or Table 4 for the correct dimensions.

11. Verify the non-nominal side pin assembly plunger never “bottoms-out” against the base during assembly.

    Note: If the dimensions for the pin projection of the tooling is incorrect, spacers / shims can be used to the correct tooling dimensions. Reference Table 3 for contact tooling modifications.

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    Illustration 27	g03745943

12. Assemble the pin tooling including the spring, plunger, and base.

13. Perform a final check in order to verify that the tooling is set up properly. Refer to Step 14 through Step 20.
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    Illustration 28	g03745960

14. Place a track pin and a bushing in the front and rear pockets of the saddle.
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    Illustration 29	g03745974

15. Install the tooling on the left and right-hand side of track press.

    Install the Nominal side tooling on the first assembly side.

    This document will reference the right side as the Nominal side.

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    Illustration 30	g03777137

16. Lower the hold down shoe, ensure light contact with the bushings.

17. Move the cylinders toward the track pins and bushings
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    Illustration 31	g03787993

18. Alignment of the tooling / pin and bushing is critical adjust as needed.

19. Continue moving tooling toward the track pins and bushings until the tooling firmly presses onto each of the bushing ends.
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    Illustration 32	g03777159

20. Locate relief valves (1) and (2) on the operators station. Relief valves (1) will adjust the left ram and (2) will adjust the right ram assembly force.
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    Illustration 33	g01347392

21. Adjust the setting on the relief valve in order to achieve the recommended assembly force.

    Refer to Table 6 maximum allowed assembly forces.

    Other References:

    Undercarriage Reconditioning Bulletin, SEBF8566, "Track Data Charts"

    Decal, NEEG2430, "Track Assembly Specifications" reference Illustration 33

    Do not exceed the recommended assembly force. Higher assembly forces will result in damaged track components and damaged tooling.

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    Table 6

    Specifications for Assembly Force
    Sales Model	Maximum Assembly Force
    385B 385C 390D 390F 5090 MD6640	1040 kN (117.0 tons)
    365B 365C 374D 374F	840 kN (94.5 tons)
    345B 345C 345D 349D 349E 568	615 kN (69.13 tons)
    324FM 511 1090 TK711	565 kN (63.5 tons)

22. Periodically check the calibration of the gauge on the track press. Refer to the Operation and Maintenance Manual for the track press for the instructions on calibrating the gauge.

23. Make sure that the conveyor is perpendicular and level with the track press.

    Note: Improper alignment will cause the track to become twisted as more track links are assembled. The tooling may be damaged if the track links twist.

Assembly of the Track

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Illustration 34	g03747620

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NOTICE
During the assembly of the track links, prevent the links from any contact with the saddle. Reference Illustration 34.

1. Determine if the bushing should be rotated in order to contact a different wear surface.
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   Illustration 35	g01233892
   Bushing with the marks in the original position

2. If the bushing does not need to be rotated, install the track pin and the bushing with the marks in the original position.
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   Illustration 36	g03747701
   Proper pin and bushing rotation.

3. If the bushing needs to be rotated, horizontally rotate the track pin and the bushing by 180 degrees. Then, rotate the bushing around the track pin by 180 degrees.
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   Illustration 37	g03790377

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   Illustration 38	g03790396

4. Apply an even coat of grease to the track pin and bushing before assembly.

   Note: Do not allow contaminants to come into contact with the grease.

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   Table 7

   Specifications for the Grease
   Part Number	Grease	Quantity
   452-5996	Grease 5 Percent Molydenum NLGI No. 1	Cartridge
   452-5999	Grease 5 Percent Molydenum NLGI No. 1	16 kg (35.0 lb)
   452-5998	Grease 5 Percent Molydenum NLGI No. 1	54 kg (120.0 lb)
   452-5997	Grease 5 Percent Molydenum NLGI No. 1	180 kg (400.0 lb)

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   Illustration 39	g03790501

5. Place track pins and bushings in the saddle.
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   Illustration 40	g03790520

6. Wipe off excess grease from pin.
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   Illustration 41	g03790969

7. Wipe off remainder of grease using solvent and a lint free cloth.

   Note: All grease must be removed from pin end prior to link assembly. Grease not removed can promote pin walking.

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   NOTICE
   The hold down shoe must always be used for assembly of the track links. The hold down shoe was used during the development of this document. For better photo opportunity the hold down shoe may be retracted in the following illustrations.

   Note: Apply a thin coating of oil to the outer diameter of the bushing.

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   Illustration 42	g03791017
   The Illustration above displays the right-hand side being assembled first. The first assembly side whether (right hand or left hand) will be the Nominal side.

8. Place the right-hand track link on the right-hand side assembly tooling.

   Lower the hold down shoe, ensure light contact with the bushings.

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   NOTICE
   Alignment of the tooling / pin and bushing is critical and must be monitored during assembly.

9. Press the right-hand track link onto the bushing.

   Assembling the right-hand side first makes the right-hand side the Nominal side.

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   Illustration 43	g03791093

10. Place the left-hand link on the left-hand side assembly tooling.

    Lower the hold down shoe, ensure light contact with the bushings.

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    NOTICE
    Alignment of the tooling / pin and bushing is critical and must be monitored during assembly.

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    Illustration 44	g03791877

11. Press the left-hand track link onto the bushing.

    Assembling the left-hand side second makes the left-hand side the Non-Nominal side.

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    Illustration 45	g03791934

12. Press the track links onto the bushing.

    Press on the track link that is on the Nominal side of the track press first.

    Use only half of the recommended assembly force.

    Note: Make sure that the track links do not contact the saddle.

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    Illustration 46	g03792805

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    Illustration 47	g01233961

13. Bushing projection must be maintained on both (Nominal and Non-Nominal) sides of the assembled track joint.

    Use Tooling (F) to measure the bushing projection on the assembled track joint.

    Refer to Table 4 or Table 4 for the correct dimensions.

    Other Reference:

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

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    Illustration 48	g03747741

14. Index the assembled track-joint into the rear pocket of the saddle.

15. Install the thrust rings on the ends of the track pin.

    Use molybdenum grease to lubricate the thrust rings.

    Do not use oil to lubricate the thrust rings.

    Oil will not provide the desired lubrication necessary to help prevent galling of the thrust ring.

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    Illustration 49	g03790377

16. Apply an even coat of grease to another track pin and bushing.
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    Illustration 50	g03790969

17. Insert a track pin and a bushing in the front pocket of the saddle.

    Wipe off remainder of grease using solvent and a lint free cloth.

    Note: All grease must be removed from pin end prior to link assembly. Grease not removed can promote pin walking.

18. Apply a thin coat of oil to the outer diameter of the bushing in order to eliminate galling.
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    Illustration 51	g03747753

19. Use a lint free cloth to wipe both ends of the bushing and faces of the seals.
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    Illustration 52	g03747777

20. Place the right-hand track link on the right-hand side assembly tooling.

    Lower the hold down shoe, ensure light contact with the bushings.

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    Illustration 53	g03747780

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    NOTICE
    Alignment of the tooling / pin and bushing is critical and must be monitored during assembly.

21. Move the right-hand track link with the track press until the track link contacts the track pin and the bushing.

22. Move the tooling on the left side of the track press until the tooling contacts the track pin and the bushing.

23. Use force from each ram to press the track link onto the track pin and the bushing.

    The assembly forces may vary based on part conditions and dimensions.

    Refer to Table 6 for the maximum allowed assembly forces.

    Note: Make sure that the track link does not contact the saddle.

    Do not exceed the recommended assembly force in order to assemble the track.

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    Illustration 54	g03747783

24. Repeat Steps 19 through 23 in order to assemble the left-hand track link.

    Note: Make sure that the track link does not contact the saddle.

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    Illustration 55	g03792805

25. Use Tooling (F) dial indicator in order to measure the bushing projection on both sides of the assembled track joint.

    Refer to Table 3 or Table 4 for the correct dimensions.

    Other Reference:

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

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    Illustration 56	g03793779

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    Illustration 57	g03793703

26. Use Tooling (F) dial indicator to measure the pin projection on the nominal side of the assembled track joint.

    Refer to Table 3 or Table 4 for the correct dimensions.

    Other Reference:

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

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    Illustration 58	g03747850

27. Install the anvil assembly tooling onto both sides of the track press.
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    Illustration 59	g03747882

28. Index the assembled track joint to the middle pocket of the saddle.

    The procedures for extrusion and unlocking will be performed when the assembled joint is moved into the middle pocket of the saddle.

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    Illustration 60	g03793796

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    Illustration 61	g03793804

29. Position the extruder assembly tooling between the anvil and the track joint.

    Note: Verify that extruder assembly tooling is properly located on the track link. If the track link has been previously swaged, the extruder assembly tooling will need to be rotated 45 degrees from the previous swaged extruded areas. Reference Illustration 65 for the correct location.

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    Illustration 62	g03793808

30. Apply the recommended press force to swage the track joint. Reference Table 8 for swage press force.
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    Illustration 63	g03709353

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    Illustration 64	g03709357

31. Material from the link will be swage into the pin groove.
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    Table 8

    Specifications for Swaging Force
    Sales Model	Maximum PPR2 Swaging Force
    365B 365C 374D 374F 385B 385C 390D 390F 5090 MD6640	880.0 kN (197832.80 lb)
    324FM 511 1090 TK711 345B 345C 345D 349D 349E 568	670.0 kN (150622.70 lb)

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    Illustration 65	g03793821
    The darker shaded extruded area is from previous assembly swaging procedure. The lighter shaded extruded area is from current assembly swaging procedure.

32. Inspect the extruded area of the track joint.
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    Illustration 66	g03748003

33. Check joints for flexibility / articulation.

    Flexibility is the ability for movement, from its own weight.

    All links assembly joints must have flexibility, even with measurable end play of zero.

34. Check for end play generation for assembled joints that display flexibility.

    Reference steps 43through 51 for proper end play measuring procedures.

35. Unlock the assembled joints that display no flexibility.

    Reference Table 9 for unlocking force.

    Reference steps 36 through 40 for unlocking procedures.

    After unlocking the joint, reference steps 43 through 51 for proper end play measuring procedures.

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    Illustration 67	g03748006

36. Place the joint to be unlocked in the center position of the saddle position the pin unlocking tool between the anvil assembly and the track pin.

37. Slowly move the cylinder toward the pin unlocking tool until the anvil contacts the back of the pin unlocking tool.

38. Ensure that tooling is properly aligned. Care must be taken in order to avoid misalignment.

39. Repeat Steps 36 through 40 for the other side of the track joint.
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    Illustration 68	g03748008

40. Unlock the track joint by applying force to the track pin through the pin unlocking tooling.

    Maximum allowable forces for unlocking the track joints are listed in Table 9.

    This force is a reference value and may be adjusted to meet end play requirements.

    The need to continually adjust this force indicates problems with component characteristics and / or assembly procedures.

    Applying and releasing the unlocking force allows the links to move slightly outward. This gives the joint end play and the ability to articulate.

    Note: Make sure that the track links do not contact the saddle

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    Table 9

    Specifications for Unlocking Force
    Sales Model	Maximum PPR2 Unlocking Force
    385B 385C 390D 390F 5090 MD6640	980.0 kN (220313.80 lb)
    365B 365C 374D 374F	980.0 kN (220313.80 lb)
    324FM 511 1090 TK711 345B 345C 345D 349D 349E 568	444.0 kN (99815.64 lb)

41. Frequently check the tooling for damage. Replace tooling if damaged.

42. Remove the pin unlocking tooling from the track press.
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    Illustration 69	g03794326

43. Check the end play of the track links.

44. Use a pry bar to apply force between the track links of one side of the assembled track joint. Refer to arrow (1) in Illustration 69.

45. Maintain the applied force between the track links. Adjust the point of reference to 0.0 mm (0.00 inch) on Tooling (E) Dial Indicator Gp. Refer to arrow (2) (2) in Illustration 69.

46. A display of 0.0 mm (0.00 inch) for the Dial Indicator's point of reference must be maintained prior to the removal of the applied force of the pry bar.

47. Use the pry bar to apply force between the track links of the opposite side of the assembled track joint. Refer to arrow (3) in Illustration 69.

48. Maintain the applied force between the track links. The Dial Indicator's point of reference will display total end play generation. Refer to arrow (4) in Illustration 69.

49. Acceptable end play is 0.00 mm to 0.20 mm (0.000 inch to 0.008 inch).

50. Repeat Steps 43 through 51 for the remaining track joints until the track is assembled.
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    Illustration 70	g03748003

51. All links assembly joints must have flexibility, even with measurable end play of 0.0 mm (0.00 inch). Flexibility is the ability for movement, from its own weight.
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    Illustration 71	g03748015

52. All paint, loose rust, metal debris, and dirt must be removed from the mating surfaces of the track components.

    The paint on the mating surfaces of new track link assemblies needs to be removed before installation of the track shoes. 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 sandpaper of 24 grit to remove the paint from the mating surfaces of the track links and track shoes. A light mist of water should be sprayed on the mating surface during 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 links and the track shoes. Make sure that the paint remover does not contact the track seal. The paint remover can damage the track seal.

    • Do not use a torch to remove the paint from the mating surfaces of the track links and track links. The high temperatures can cause damage to the track seals.

    • Do not drag the track link assembly across the ground in order to remove the paint from the mating surfaces of the track links. Dragging of the track link assembly may cause damage to the 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 of the track nuts must be in good condition.

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    Illustration 72	g03748019
    Caterpillar Track Torque Wrench

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    Illustration 73	g03748022
    443-7801 Pneumatic Wrench Gp

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    Illustration 74	g03748113
    385-7874 Hydraulic Torque Wrench.

53. Place the track on the conveyor of the Caterpillar Track Torque Wrench in order to install the track shoes.

    Note: If the Caterpillar Track Torque Wrench is not available, 443-7801 Pneumatic Wrench or 385-7874 Hydraulic Torque Wrench may be used in order to install the track shoes.

54. Lubricate the threads of the track bolts and lubricate the mating surface of the bolt head with Tooling (J) antiseize compound .

55. Align the holes in the track shoes with the holes in the track links.

    Note: The threads of the bolts will be damaged if the holes are not aligned.

56. Place a track bolt in each hole and start the nut by hand.
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    Illustration 75	g03748114

57. Turn the switch on the side of the Caterpillar Track Torque Wrench to the 120° position.
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    Illustration 76	g03748116

58. Press the "Set Pre Torque" button. Enter the correct preliminary torque value into the display panel. Press "Enter". Refer to Table 4 for the correct preliminary torque values.

59. Press the "Check Set Values" button to display and check the values that have been set.
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    Illustration 77	g01234180

60. Follow the correct pattern in Illustration 77 in order to torque the bolts.

    Note: A yellow light will illuminate when the preliminary torque value is complete. A green light will illuminate when the torque is complete. The screen will display "Cycle Complete"