Shop Repair Procedure for Sleeve Bearing Track {4169, 4170, 4171, 4174, 4175} Caterpillar

Caterpillar Products

Machines with Sleeve Bearing Track

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 bulletin contains the information regarding Caterpillar Sleeve Bearing Track. Sleeve Bearing Track was made available in 2002for the D11T/R/N Track-Type Tractor. This track link assembly is designed to address galling from contact of the track pin and the bushing by incorporating an additional floating component of the sleeve bearing between the track pin and the bushing. Galling from the track pin that contacts the bushing is the major cause of failure of the track components of D11 track. Sleeve Bearing Track utilizes many of the existing track components. The track links, track pins, thrust rings, retaining rings, plugs, and stoppers remain unchanged. The same basic track bushing is used in Sleeve Bearing Track. However, the ends are counterbored to accept the sleeve bearing. There are specific guidelines that must be followed in ordertosuccessfully service Sleeve Bearing Track.

Illustration 1	g03776116
Sleeve Bearing Track

The information in this bulletin describes the tooling that will be used and the required service procedures. It is important to use the correct tooling. Follow each step to ensure that each track joint has minimum end play and maximum service life.

A list of important references and training materials is shown below. The operator of the track press should become familiar with this material for training prior to servicing Sleeve Bearing Track.

References

Reference: Undercarriage Reconditioning Guide, SEBF8599

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: Service Letter, REBE9847, "Product Support Program for Replacing Master Links on Certain D10T, D10R, and D10N Track Type Tractors."

Reference: Undercarriage Reconditioning Bulletin, SEBF8620, "Reusability Guidelines for Single Tooth Master Links"

Reference: Undercarriage Reconditioning Bulletin, SEBF8621, "Shop Disassembly and Assembly of Single Tooth Master Links"

Reference: Special Instruction, REHS3371, "Shop Procedure for the Correct Installation of Serrated Master Links on Large Track-Type Tractors"

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8554, "Track Press Assembly Specifications Decals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8594, "Nitrogen Pressure Test"

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8577, "Oil Volumes for Track Link Assemblies"

Reference: Shop Repair of Positive Pin Retention Track, PEVN4329

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

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

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

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

Reference: Tool Operating Manual, NEHS0785, "Test and Fill Manual"

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

Reference: Parts Sales Kit, PECP3003

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

Safety

Illustration 2	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 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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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.

Required Tooling

Illustration 3	g03427390
Nominal side of the track press. The first assembly side whether (right hand or left hand) will be the Nominal side. (A) Inner diameter of the tooling for the track pin. (B) Pin projection. (C) Track link offset. (D) Bushing projection. (E) Inner diameter of the tooling for the bushing.

Sleeve Bearing Track Servicing Guidelines

Always monitor the force of the track press during the service procedures of Sleeve Bearing Track. Follow instructions for the press and calculate the tonnage of the press.

Do not exceed the recommended track press force for the D11 track link assembly. If the maximum force for the D11 track is exceeded, the sleeve bearing may fracture.

Always reassemble Sleeve Bearing Track with thrust rings that are coated with 9W-9621 Ring Group. Refer to Illustration 29.

Do not exceed the recommended track press force to unlock the track joints.

Carefully follow instructions for examination of the cleaned bushing. Carefully follow instructions to inspect the sleeve bearings. Refer to Illustrations 3031, and 32.

Do not ignore the inspection procedures of Sleeve Bearing Track.

Always ensure that the track pin is free to rotate after pressing the bushing into the bore of the track link.

Do not consider rotation of the sleeve bearing to be necessary after pressing the bushing into the bore of the track link as long as the track pin rotates freely. Rotation of the sleeve bearing will occur under load.

Preparation for Disassembly

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Illustration 4	g03745699

1. Use a high-pressure washer 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.

2. Inspect each opening to the oil reservoir of the track pins for smearing and peening of the track pin.
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   Illustration 5	g03744826

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   Illustration 6	g01234843

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   NOTICE
   When using Tooling (B) deburring tool, do not plunge it directly into the center of the oil reservoir of the track pin. This can cause the tool to shatter, seize up, and break. Use a high-speed grinder and orbit the deburring bit around the side of the oil reservoir of the track pin.

3. Remove any burrs from the track pin with Tooling (A) die grinder and Tooling (B) deburring tool. Make a new chamfer at the opening of the oil reservoir.
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   Illustration 7	g03745709

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   Illustration 8	g03745715

4. Remove the stoppers from the track pins with a slow drill and a 12.5 mm (0.50 inch) drill bit. The stopper can also be removed by pushing the plug into the oil cavity and removing the stopper with a small punch. Do not push the stopper into the oil reservoir of the track pin.
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   Illustration 9	g03745018

5. Use Tooling (C) vacuum tank to remove the oil from the oil reservoirs of the track pins. It may be necessary to wash the oil from the track pins after the oil has been removed.

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

   Note: Refer to Servicing Handbook, PEKP9400, "Caterpillar Track Service Handbook" for the correct measurements needed to calculate the percentage of wear.

Disassembly of the Track

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Illustration 10	g03745717

1. Use the Caterpillar Track Torque Wrench to remove the bolts from the track shoes. Remove the track shoes.
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   Illustration 11	g03745722

2. Use a permanent pen to mark the track pins and bushings for proper installation.

3. Reference Table 4 for correct tooling.

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

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

6. Reference Table 3 or 4 for correct track link offset dimensions.
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   Illustration 12	g03784146

7. Measure the height of the track pin disassembly tooling use tooling (R) calipers.
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   Illustration 13	g03784148

8. Measure the height of the bushing disassembly tooling use tooling (R) calipers.

9. 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 are incorrect, spacers / shims can be used to the correct tooling dimensions. Reference Table 4 contact tooling modifications.

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

11. Follow Steps 11.a through 11.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 14	g03748436

    2. Lower the hold down shoe just above the bushings.

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

       Reference Illustration 14.

       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. Verify that the correct tooling is being used.

    4. Ensure 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 15	g03745743

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

13. The retaining ring will break off as the track pin is pressed from the track link. If the retaining ring does not fall out of the groove on the track pin, use a hammer and a chisel to remove the retaining ring.

    Note: Do not damage the angle on the groove of the track pin. The angle and depth of the groove are critical.

14. Remove the thrust rings as each track pin is pressed out of the bore of the track link.

15. Examine the thrust ring for reusability. Strike the thrust ring against a metal object to check for cracks. Refer to Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts".

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

16. Remove the sleeve bearings from each end of the bushing as the track joint is disassembled.

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, bushings, sleeve bearings, and thrust rings. Cleaning the track components removes any foreign material and contaminated oil. Inspection of the track components is easier when the components are clean. A cross section of the track joint is shown in Illustration 1 to help the serviceman identify the track components.

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

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Illustration 16	g03745749

1. Inspect each track pin for cracks, plugged crossholes, or other signs of damage such as spalling or galling.

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

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   Illustration 17	g03745754

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   Illustration 18	g03776888

2. Lubricate the stopper with a lightweight oil and install the stopper in the end of the track pin with Tooling (E) installation tool.

   Note: The stopper must be installed 7.0 - 15.0 mm (0.28 ± 0.59 inch) below the surface of the track pin.

   Note: Absorption of the oil by the stopper causes the rubber to swell. Swelling of the stopper locks the stopper in place. Installing all stoppers before inspecting the remaining track components will allow time for the stoppers to swell. The plastic plugs will be installed later.

3. Remove any burrs, material, and any paint from the spot face of the track link that will interfere with the tooling on the track press.
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   Illustration 19	g03776891

4. Thoroughly clean the counterbores of the track links for the seals with Tooling (A) die grinder and Tooling (D) brush.

   Note: Tooling (D) brush should be rated at the maximum rpm of Tooling (A) die grinder.

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   Illustration 20	g03745759

5. Wipe the counterbore of the track link with a lint free cloth.
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   Illustration 21	g03745782

6. Hold each bushing up to a bright light to examine the bushings for cracks.
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   Illustration 22	g03776297

7. Inspect the bushing for internal galling.

8. Weld an identification number on the master track link.
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   Illustration 23	g03745840

9. Use Tooling (T) end groove gage to check the end grooving of the bushing. Replace the seal with a Post Turn Seal if the bushing is reused. Replace the seal with a standard seal if a new bushing is used.

   Post Turn Seals are now available for all D11T/R/N and D11 track link assemblies. These new seals have a smaller diameter than the original seals. If a bushing has a maximum of 50 percent end grooving and the bushing is being reused, the post turn seal should be used. The post turn seal will contact a new, unworn surface of the bushing which will provide a better reliability of the seal after service. Reference Information Release Memo, PELJ0242, "New D11R/N Post Turn Track Seals" for more information.

   Use the new 241-1854 Seal Installer with the D11T/R/N and D11 post turn seal.

   The original seal is still available for use when the bushings are replaced. If the end grooving is visible outside Tooling (T), the bushing should be replaced. Ignore the shiny band of contact area. Reference Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts".

   Refer to Table 5 or Parts Sales Kit, PECP3003 for the seal part numbers.

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   Table 5

   	Original Seal	Post Turn Seal
   Seal Assembly	222-7007	261-4338
   Seal Set	248-5531	261-4408

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   Illustration 24	g03745843
   Standard Seal (1) Seal (2) Link (3) Bushing (4) Thrust ring (5) Pin

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   Illustration 25	g03745846
   Post Turn Seal (1) Seal (2) Link (3) Bushing (4) Thrust ring (5) Pin

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   Illustration 26	g03776298

10. Place the seal into Tooling (P) seal installer.
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    Illustration 27	g03776316

11. Use Tooling (P) to install the seals. Make sure that the seal is seated properly in the counterbore of the track link and use a firm even pressure to properly seat the seal.

    Note: For ease of seal installation, the outer load ring should be lubricated with a lightweight oil.

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

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    Illustration 28	g03776318
    (1) Facing group (P) Seal installer

12. Install the optional facing group (1) on Tooling (P) seal installer with the adhesive side facing upward.

    Note: The facing group is optional to help achieve proper articulation of the track joint after installation on the tractor. Some models of machines have oil impregnated thrust rings available. If oil impregnated thrust rings are used, the facing group will not be necessary. However, unlocking the track joint is the best practice to achieve the proper end play.

    Note: Thrust rings can be ordered with the applied ring. 257-8845 Thrust Ring is the thrust ring with the applied facing group. Refer to Parts Sales Kit, PECP3003.

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    Illustration 29	g03776325
    (1) Facing group (2) Thrust ring (P) Seal installer

13. Slide the thrust ring onto Tooling (P) seal installer. Press firmly on the thrust ring until the ring adheres to the thrust ring (2).

14. Remove the thrust ring from Tooling (P) seal installer.

15. Repeat Steps 12 through 14 for the reverse side of the thrust ring.
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    Illustration 30	g03776334
    Sleeve Bearing

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    Illustration 31	g01236005
    The rings of galling exceed 4.0 mm (0.16 inch).

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    Illustration 32	g01236007
    The individual rings add up to 4.0 mm (0.16 inch).

16. Inspect the sleeve bearings for galling.

    Note: Do not reuse the sleeve bearing if the galling exceeds 4.0 mm (0.16 inch). If the sleeve bearing contains several rings of galling, add up the individual rings of galling.

17. Install the sleeve bearing in the bushings.

    Note: The sleeve bearings may be installed in any orientation.

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. The use of Molykote paste or facing groups establishes slight endplay. 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. Refer to Table 3 or 4 for the dimensions for the track link assemblies.

Another reference is the Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts"

1. Reference Table 4 for correct contact tooling used for Sleeve Bearing Track.

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

3. Remove the springs from the pin and bushing assembly tooling and reinstall the plunger and the base.

4. 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 or 4 for the correct dimensions.
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   Illustration 33	g03427390
   Nominal side of the track press. The first assembly side whether (right hand or left hand) will be the Nominal side. (A) Inner diameter of the tooling for the track pin. (B) Pin projection. (C) Track link offset. (D) Bushing projection. (E) Inner diameter of the tooling for the bushing.

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

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   Illustration 34	g03783601

5. Measure the height of the tooling for the track pin with Tooling (R) calipers.
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   Illustration 35	g03783618

6. Measure the height of the tooling for the bushing with Tooling (R) calipers.

7. Determine Dimension (C) 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 are incorrect, reference Table 4 and shim as needed.

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   Illustration 36	g03776340

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   Illustration 37	g02085171
   Use Tooling (N) dial indicator to measure the tooling for the correct bushing projection Dimension (C).

   Note: Dimension (D) bushing projection must be maintained for both nominal and non nominal sides.

8. Use Tooling (N) dial indicator to measure the correct Dimension (D) bushing projection for the bushing tooling on both sides of the track press. Refer to Table 3 or 4 for the correct dimensions.

   Note: For incorrect Dimension (D) bushing projection, shims can be added to the tooling. Refer to Table 4 for tooling modifications. Make sure that the correct track link offset is maintained.

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   Illustration 38	g03745923

9. Consider inserting shims or machining the tooling if needed. Assemble the bushing tooling including the spring, plunger, and base.
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   Illustration 39	g03776365
   Use Tooling (N) dial indicator to measure the tooling for the correct track pin projection Dimension (B).

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   Illustration 40	g02085173

   Note: Maintain correct Dimension (B) pin projection on the nominal side of the pin assembly tooling only. The non-nominal side pin assembly plunger never “bottoms-out” against the base during pin assembly.

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

11. Verify the correct Dimension (B) pin projection on the nominal side of track press. Refer to Table 3 or 4 for the correct dimensions.

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

    Note: For incorrect Dimension (B) bushing projection, shims can be added to the tooling. Refer to Table 4 for tooling modifications. Make sure that the correct track link offset is maintained.

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    Illustration 41	g03745943

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

14. Perform the final check of the track press to verify that the tooling is set up properly. Refer to Step 14.a through Step 14.g.
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    Illustration 42	g03745960

    1. Place a track pin and a bushing in the front and rear pockets of the saddle.
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       Illustration 43	g03745974

    2. Install the tooling on the left and right-hand side of track press.
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       Illustration 44	g03777137

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

    4. Move the cylinders toward the track pins and bushings.

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

    6. Continue moving the cylinders toward the track pins and bushings until the bushing tooling firmly presses onto each of the bushing ends.
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       Illustration 45	g03777159

    7. 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 46	g03776379

15. Adjust the setting on the relief valves to achieve the recommended force for assembly. Reference Table 6 or for the recommended assembly force.

    Other References:

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

    Decal, NEEG2430, "Track Assembly Specifications"

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

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

17. 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 47	g03747620

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NOTICE
During the assembly of the track links prevent the links from any contact with the saddle. Reference Illustration 47.

1. Determine if the bushing should be rotated to contact a different wear surface.
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   Illustration 48	g01236157
   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 49	g03777236

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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   NOTICE
   The track pin must always be installed so the cross drilled hole is towards the wear surface of the track links. The track pin must be installed in this position to ensure minimum load on the track pin in the area of the cross drilled hole. The track pin may break if installed with the cross drilled hole in any other position.

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   Illustration 50	g01236159

4. Make sure that the bushing is aligned correctly so the wear groove is located in the correct position.

   Note: Correct alignment of the track pin and bushing is necessary to allow the seal lip to run correctly in the wear groove.

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   Illustration 51	g03747707

5. Use a lint free cloth to clean the bushing bores on the track link and the ends of the bushings.

6. Bolt the split master links together in ordertoproperly align the bushing ends.
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   NOTICE
   Use only half of the assembly force when assembling the master track links.

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

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   Illustration 52	g03747731
   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.

7. 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.

8. Press the right-hand master track link onto the bushing.

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

9. Press the left-hand master 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 53	g03776385
   Tooling (N) dial indicator.

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   Illustration 54	g01236166

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

    Reference Table 3 or 4 for the correct bushing projection dimension.

    Use Tooling (N) dial indicator to measure the bushing projection.

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    Illustration 55	g03747741

11. Index the assembled track joint into the rear pocket of the saddle.

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

    Note: The use of 9W-9621 Ring Group or 257-8845 Track Link Ring (with applied facing groups) will aid in articulation of the joint after the joint is unlocked.

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    NOTICE
    Use molybdenum grease or the facing group 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 56	g03747750

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

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

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    Illustration 57	g03747753

14. Use a lint free cloth to wipe both ends of the bushing and faces of the seals.
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    NOTICE
    Caterpillar does not recommend use of a liquid gasket as a seal in the pin bores. Liquid gasket provides only a temporary seal, which will cause premature failure of the track joint.

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    Illustration 58	g03747777

15. Place the right-hand track link onto the tooling.

16. Lower the hold down shoe, ensure light contact with the bushings.
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    Illustration 59	g03747780

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

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

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

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

    The maximum allowed assembly force for Sleeve Bearing Track is 1210 kN (272000 lb).

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

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

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    Illustration 60	g03747783

20. Repeat Steps 15 through 19 to assemble the left-hand track link.

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

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    Illustration 61	g03776385

21. Use Tooling (N) dial indicator to measure the bushing projection on both sides of the assembled track joint.

    Reference Table 3 or 4 for the correct bushing projection dimension.

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    Illustration 62	g03777278

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

    Reference Table 3 or 4 for the correct pin projection dimensions.

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    Illustration 63	g03747850

23. Install the anvil assembly tooling onto both sides of the track press.
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    Illustration 64	g03747882

24. Index the assembled track joint to the middle pocket of the saddle. The procedures for extrusion and unlocking can be performed when the assembled joint is moved into the middle pocket of the saddle.
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    Illustration 65	g03747889
    Retainer rings.

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    Illustration 66	g03747894

25. Insert a retaining ring into the track pin grooves on both sides of the link assembly. Lower the hold down shoe, ensure light contact with the bushings.
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    Illustration 67	g03747898

26. Position the extruder assembly between the anvil assembly and the track pin.

    Refer to Table 4 for the correct extruder assembly tooling.

27. Slowly move the cylinder toward the extruder until the anvil contacts the back of the extruder.

28. Pivot the extruder tooling in place to make sure that the extruder is properly aligned. Care must be taken to avoid misalignment.

29. Repeat Steps 25 through 28 for the other side of the track joint.
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    Illustration 68	g03747900

30. Press the retaining rings into the grooves on the track pin.

    The maximum allowable force for extruding the retaining rings is 1245 kN (280000 lb).

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

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    Illustration 69	g03747921

31. Remove the extruder assemblies from the track press.

    Tap the extruder with a hammer if the extruder sticks to the track joint.

    Replace the extruder if the extruder is damaged.

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    Illustration 70	g03747995

32. Check the retaining rings for proper assembly.
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    Illustration 71	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 43 through 49 for proper end play measuring procedures.

35. Unlock the assembled joints that display no flexibility.

    Reference steps 36 through 42 for unlocking procedures.

    After unlocking the joint, reference steps 43 through 49 for proper end play measuring procedures.

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    Illustration 72	g03748006

36. Position the pin unlocking tool between the anvil assembly and the track pin.

    Refer to Table 4 for the correct pin unlocking tool.

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

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

39. Repeat Steps 33 through 38 for the other side of the track joint.
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    Illustration 73	g03748008

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    NOTICE
    Unlocking forces higher than 1334 kN (300000 lb) can cause the hardened sleeve bearing to fracture.

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

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

    The maximum allowable force for unlocking the track joints is 1334 kN (300000 lb).

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

    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.

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

42. Remove the pin unlocking tools from the track press.
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    Illustration 74	g03777769

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 74

45. Maintain the applied force between the track links . Adjust the point of reference to 0.0 mm (0.00 inch) on Tooling (H) Dial Indicator Gp. Refer to arrow (2) in Illustration 74

46. A display of 0.0 mm (0.00 inch) for the Dial Indicators 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 74

48. Maintain the applied force between the track links. The Dial Indicators point of reference will display total end play generation Refer to arrow (4) in Illustration 74

49. Acceptable end play is 0.03 mm to 0.20 mm (0.001 inch to 0.008 inch).

50. Repeat steps 43 through 49 for the remaining track joints until the track is assembled.
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    Illustration 75	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.

Lubrication of the Track Joints

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NOTICE
Before track joints can be filled with oil, the joint must be checked for leaks. The following methods are recommended to ensure a proper seal before lubrication.

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Illustration 76	g03777723
Tooling (J) 170-5664 Test and Fill Cart

1. Use Tooling (J) 170-5664 Test and Fill Cart to test the track joint and fill the track joint.

   Note: Caterpillar uses only synthetic oil for filling the track pins. This oil was previously used for arctic applications. This oil is now the standard oil from the factory. This oil is recommended for use at the turn of the bushing or reseal. Refer to Table 7.

   Note: The synthetic oil is available in the following quantities:

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   Table 7

   Part Number	Part Description	Quantity
   242-3466	Gear Oil (75W-140)	19 L (5.0 US gal)
   242-3467	Gear Oil (75W-140)	208 L (55.0 US gal)

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   Illustration 77	g03777738

2. Use Tooling (F) plug installer to install the plastic plug in the rubber stopper.

   Note: Install the tapered end of the plug into the stopper first.

   Note: The plastic plug must protrude 0.0 mm to 5.0 mm (0.00 inch to 0.20 inch) out of the rubber stopper. The plug can vibrate into the oil reservoir of the track pin if the plug is pushed fully into the stopper hole.

3. Fill the remaining track joints with the same procedures.

   Note: If Tooling (J) Test and Fill Cart is not available, use the alternative method below to test and fill the track joint.

Alternative Method for Test and Fill

Refer to Undercarriage Reconditioning Bulletin, SEBF8594, "Nitrogen Pressure Test Unit".

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Illustration 78	g03777760
Tooling (K) Gauge Connection.

1. Introduce nitrogen into the oil cavity to a pressure of 138 kPa (20.0 psi) with Tooling (K) gauge connection.

   Note: The cavity must be sealed and pressure must be observed for10 seconds.

   Note: A pressure drop of 3.5 kPa (0.50 psi) or less is acceptable.

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   NOTICE
   Do not allow a surge of air to enter the track joint and do not use pressure in excess of 138 kPa (20 psi).

2. Fill the track joints with oil. Refer to Undercarriage Reconditioning Bulletin, SEBF8577, "Oil Volumes for Track Link Assemblies".

Preparation and Installation of the Track Shoes

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Illustration 79	g03748015

1. 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 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 master track links. The high temperatures can cause damage to the track seals.

   • 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 cause damage to 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 of the track nuts must be in good condition.

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   Illustration 80	g03748019
   Caterpillar Track Torque Wrench

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   Illustration 81	g03748113
   443-7801 Pneumatic Wrench Gp

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   Illustration 82	g03748113
   385-7874 Hydraulic Torque Wrench

2. Place the track on the conveyor of the Caterpillar Track Torque Wrench to install the track shoes.

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

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

4. 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.

5. Place a track bolt in each hole and start the nut by hand.
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   Illustration 83	g03748114

6. Turn the switch on the side of the Caterpillar Track Torque Wrench to the "120 Degree" position.
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   Illustration 84	g03748116

7. Press the "Set Pre Torque" button. Enter the correct preliminary torque value into the display panel. Press "Enter". Refer to Table 8 for the correct preliminary torque values.

8. Press the "Check Set Values" button to display and check the values that have been set.
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   Illustration 85	g01236312

9. Follow the correct pattern in Illustration 85 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".