Shop Repair Procedure for D6 and D7 Size Track with Positive Pin Retention 2 {4169, 4170, 4171, 4174, 4175, 4180} Caterpillar

Track-Type Tractor

D6 (S/N: AG91-UP; GZ91-UP; HR91-UP; LF91-UP; RA91-UP; SA91-UP; RDC1-UP; HNK1-UP; RBP1-UP; KMT1-UP; KEW1-UP; KTW1-UP)

D6 XE (S/N: B721-UP; ES91-UP; LNC1-UP; XEC1-UP; HFE1-UP; LRG1-UP; HMH1-UP; HZL1-UP; TPL1-UP; D5M1-UP; HLY1-UP; WGY1-UP)

D6M (S/N: 9ZM1-UP; 2RN1-UP; 3WN1-UP; 4JN1-UP; 5NR1-UP; 5WR1-UP; 6LR1-UP; 2YS1-UP; 4GS1-UP; 4HS1-UP)

D6N (S/N: MG51-UP; GB61-UP; SC61-UP; DJA1-UP; PBA1-UP; CBF1-UP; CCG1-UP; SGG1-UP; ALH1-UP; JAH1-UP; CBJ1-UP; CCK1-UP; CBL1-UP; AKM1-UP; NJN1-UP; ALR1-UP; LJR1-UP; PER1-UP; CCS1-UP; GHS1-UP; P5S1-UP; P5T1-UP; MLW1-UP; P5W1-UP; ALY1-UP; DJY1-UP)

D6R (S/N: EMM1-UP; 2HM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; JEN1-UP; 2YN1-UP; 3ZN1-UP; 4HN1-UP; 4MN1-UP; 5LN1-UP; 6JN1-UP; 7KN1-UP; 8LN1-UP; 8XN1-UP; 9MN1-UP; 9PN1-UP; DMP1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6GR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; S6T1-UP; S6X1-UP; S6Y1-UP)

D6R Series II (S/N: BNC1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-UP)

D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP)

D6R2 (S/N: PPP1-UP; SSS1-UP; TTT1-UP)

D6T (S/N: 2D21-UP; CR31-UP; 2B31-UP; MB51-UP; AK71-UP; MH71-UP; CG81-UP; 7C91-UP; SGA1-UP; JHB1-UP; KSB1-UP; ZEB1-UP; ZJB1-UP; JZC1-UP; SMC1-UP; DTD1-UP; JWD1-UP; LBD1-UP; RAD1-UP; LAE1-UP; STE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; EJJ1-UP; LKJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; JML1-UP; KJL1-UP; MEL1-1; SKL1-UP; JNM1-UP; TSM1-UP; WLM1-UP; WRN1-UP; K1R1-UP; KMR1-UP; PLR1-UP; WES1-UP; GCT1-UP; HYT1-UP; SGT1-UP; JRW1-UP; RCW1-UP; RLW1-UP; LAY1-UP; NDY1-UP; TMY1-UP; HTZ1-UP; PEZ1-UP; SGZ1-UP)

D7E (S/N: HKA1-UP; TJA1-UP; MDB1-UP; SCG1-UP; SSH1-UP; TAN1-UP)

D7R (S/N: R7B1-UP; R7C1-UP; DSH1-UP; R7H1-UP; 9HM1-UP; DLN1-UP; 2EN1-UP; 3DN1-UP; DJR1-UP; 2HR1-UP; 3ZR1-UP; 4SR1-UP; 5MR1-UP; 6ER1-UP; 5KZ1-UP)

D7R Series II (S/N: KNA1-UP; AEC1-UP; AFG1-UP; ABJ1-UP; BPK1-UP; BNM1-1; BRM1-UP; AGN1-UP; BRP1-UP; ACS1-UP; BPT1-UP; DJT1-UP; ADW1-UP)

Introduction

© 2019 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 technical questions when using this document, work with your Dealer Technical Communicator (TC).

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

Safety

Illustration 1	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 ones below is used to identify a hazard.

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

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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.

Summary

The information in this guideline covers the servicing procedures in the shop for D6 and D7 size Heavy-Duty Extended Life (HDXL) Track with Positive Pin Retention 2 (PPR2). The new HDXL undercarriage is offered for D6N/M, D6T/R, D6, D6 XEand D7E/RTrack-Type Tractors. The PPR2 design locks the pin and link together, which maintains more consistent seal compression and oil retention over the life of the track. 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. A list of important reference and training materials is listed in this guideline. The operator of the track press should become familiar with this material prior to servicing the track.

Each track pin has an oil reservoir in the center of the track pin. A rubber stopper and a plastic plug are used to close the oil cavity. The track pin contains a cross-hole to allow the oil to flow to the outside of the track pin. The oil lubricates the track pin, the bushing, and the seal face. If the seal face is wet with oil, the seal prevents dirt from entering the track joint. The seal and the end of the bushing will wear if there is no oil film. The seal will no longer retain oil in the track joint. A good press fit between the track pin and the pin bore of the track link also prevents loss of lubrication.

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

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"

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System Website (SIS Web) 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 (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: Dimension C is measured once the shims / spacers are in place and tooling is attached to tool bar.

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 metal smearing and peening of the track pin.
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   Illustration 5	g03750937

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   Illustration 6	g01212271

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   NOTICE
   When using Tooling (B) deburring tool, do not plunge tooling directly into the center of the oil reservoir of the track pin. The tool can 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 in.) 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 Service Handbook, PEKP9400, "Caterpillar Custom 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	g06400461

2. Use wire wheel to remove rust/dirt around pin OD to prevent link bore scoring at disassembly.

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 12	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.
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   Illustration 13	g03745727

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

   Note: If the contact surfaces of the tooling are not flat or if the surfaces are peened, grind the contact surfaces so the surfaces are flat. Replace any tooling that is beyond repair.

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 for track link offset dimensions (B).
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   Illustration 14	g03780110

9. Measure the height of the track pin disassembly tooling use tooling (D) calipers.
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   Illustration 15	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 track link offset dimensions for the tooling are incorrect, spacers / shims can be used to the correct tooling dimensions. Refer to Table 4 for contact tooling modifications.

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

13. Follow Steps 13a through 13e 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 16	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.

       Refer to Illustration 16.

       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 17	g06362980

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 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 18	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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   Illustration 19	g06411603

2. Inspect PPR grove on pins for cleanliness.
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   Illustration 20	g06363003

3. Use wire wheel to clean debris or rust that may interfere with final swaging of link to pin.
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   Illustration 21	g03745754

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   Illustration 22	g03745044

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

   Note: The stopper must be installed 7.0 - 15.0 mm (0.28 ± 0.59 in.) 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.

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   Illustration 23	g06411614

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   Illustration 24	g06396173

5. Remove any burrs, material, and any paint from the spot face of track link that will interfere with the tooling on the track press.
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   Illustration 25	g03745758

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   Illustration 26	g06411618

6. Thoroughly clean the counter-bores and pin bores of the track links with Tooling (A) die grinder and Tooling (F) end brush.

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

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   Illustration 27	g03745759

7. Wipe the counterbore of the track link with a lint free cloth.
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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 28	g03745782

8. 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 29	g03745840

9. Use Tooling (T) end groove gauge to check the end grooving of the bushing.
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   Illustration 30	g03757277

10. Place the seal into Tooling (P) seal installer.
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    Illustration 31	g03757317

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

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

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    Table 5

    Rigid Track Seal Installers
    Sales Model	Part Number
    D6N D6M	4C-8616
    D6T, D6R, D6, D6 XE	4C-8617
    D7E D7R	4C-8619

First and Second Assembly Side Concept

The Caterpillar assembly contact tooling requires that you press only one link at a time onto the assembly. 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, ensure 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, the joint must be assembled 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 rub against one another.

Setup of the Track Press

Illustration 32	g03757401

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 Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts" or Reference Table 4 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 33	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 4 for the correct dimensions.
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   Illustration 34	g03780149

4. Use Tooling (D) calipers to measure the height of the tooling for the track pin.
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   Illustration 35	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 track link offset dimensions for the tooling are incorrect, spacers / shims can be used to correct tooling dimensions. Refer to table 4 for contact tooling modifications.

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   Illustration 36	g03787624

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   Illustration 37	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 bushing projection dimensions for the tooling are incorrect, spacers / shims can be used to the correct tooling dimensions.

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   Illustration 38	g03745923

8. Assemble the bushing tooling including the spring, plunger, and base.
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   Illustration 39	g03787981

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   Illustration 40	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 pin projection dimensions for the tooling are incorrect, spacers / shims can be used to the correct tooling dimensions. Reference Table 4 for contact tooling modifications.

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    Illustration 41	g03745943

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

13. Perform a final check to verify that the tooling is set up properly. Refer to Step 14 through Step 20.
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    Illustration 42	g03745960

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

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 43	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 44	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 45	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 46	g01347392

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

    Refer to Table 6 for maximum allowed assembly force.

    Other References:

    Undercarriage Reconditioning Bulletin, SEBF8566, "Track Data Charts"

    Decal, NEEG2430, "Track Assembly Specifications" reference Illustration 46

    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
    D6N, D6M	622 kN (70 tons)
    D6T, D6R, D6, D6 XE	711 kN (80 tons)
    D7R / D7E	756 kN (85 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 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	g01233892
   Bushing with the marks in the original position

2. If the bushing is not to be rotated, install the track pin and the bushing with the marks in the original position.
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   Illustration 49	g03747701
   Proper pin and bushing rotation.

3. If the pin and 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	g01212368

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	g03790969

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   Illustration 52	g03747707

5. Use a lint free cloth to clean the ends of the pin and bushing.

6. Bolt the split master links together to properly align the bushing ends.
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   NOTICE
   Use only half of the assembly pressure when assembling the master track links. 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. Alignment of the tooling / pin and bushing is critical and must be monitored during assembly.

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

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   Illustration 53	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.

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 54	g03747738
   Tooling (R) dial indicator.

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   Illustration 55	g01212377

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

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

    Refer to Table 4 or Undercarriage Reconditioning Bulletin, SEBF8566, "Track Data Charts" for the correct dimensions.

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    Illustration 56	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.
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    NOTICE
    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 57	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 58	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.

14. 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.

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

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

17. Use force from each ram to press the right side track link onto the track pin and bushings

    The assembly force may vary based on part conditions and dimensions

    Refer to Table 6 for the maximum assembly forces.

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

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

19. Repeat Steps 15 to 18 assemble the left-hand track link.
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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 59	g03791877

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

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

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

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

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    Illustration 60	g03792805

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    Illustration 61	g01233961

21. 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 3 or Table 4 for the correct dimensions.

    Other Reference:

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

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    Illustration 62	g03792805

22. Use Tooling (F) dial indicator 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 63	g03793779

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    Illustration 64	g03793703

23. 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 65	g03747850

24. Install the anvil assembly tooling onto both sides of the track press.
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    Illustration 66	g03747882

25. 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 67	g03793796

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    Illustration 68	g06396284

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

    Note: Verify that extruder assembly tooling is properly positioned 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 72 for the correct location.

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    Illustration 69	g03793808

27. Apply the recommended press force to swage the track joint. Reference Table 7 for swage press force.

    Note: Swage depth should be 0.7 mm (0.028 inch) minimum to 1.2 mm (0.05 inch) maximum.

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    Illustration 70	g03709353

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    Illustration 71	g03709357

28. Material from the link will be swaged into the pin groove.
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    Table 7

    Specifications for Swaging Force
    Sales Model	Maximum PPR2 Swaging Force
    D6N, D6M	622 kN (70 Tons)
    D6T, D6R, D6, D6 XE	711 kN (80 Tons)
    D7R D7E	756 kN (85 Tons)

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    Illustration 72	g03793821
    The darker shaded extruded area is from previous assembly swaging procedure. The lighter shaded extruded area is from current assembly swaging procedure.

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    Illustration 73	g06402063

29. Inspect the extruded area of the track joint.

    Note: Swage depth should be 0.7 mm (0.02 inch) minimum - 1.2 mm (0.04 inch) maximum.

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    Illustration 74	g03748003

30. Check joints for flexibility / articulation.

    Flexibility is the ability for movement, from the joint weight.

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

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

    Reference steps 40through 46 for proper end play measuring procedures.

32. Unlock the assembled joints that display no flexibility.

    Reference Table 8 for unlocking force.

    Reference steps 33 through 37 for unlocking procedures.

    After unlocking the joint, reference steps 40 through 46 for proper end play measuring procedures.

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    Illustration 75	g03748006

33. 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.

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

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

36. Repeat Steps 33 through 37 for the other side of the track joint.
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    Illustration 76	g03748008

37. 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 8.

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

    The need to adjust continually 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 action 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 8

    Specifications for Unlocking Force
    Sales Model	Maximum PPR2 Unlocking Force
    D6N, D6M	622 kN (70 Tons)
    D6T, D6R, D6, D6 XE	711 kN (80 Tons)
    D7R D7E	756 kN (85 Tons)

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

39. Remove the pin unlocking tooling from the track press.
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    Illustration 77	g03794326

40. Check the end play of the track links.

41. 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 77.

42. 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 77.

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

44. 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 77.

45. Maintain the applied force between the track links. The Dial Indicator point of reference will display total end play generation. Refer to arrow (4) in Illustration 77.

46. Acceptable end play is 0.00 mm to 0.20 mm (0.000 inch to 0.008 inch).
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    Illustration 78	g03748003

47. Repeat Steps 40 through 46 for the remaining track joints until the track is assembled.

48. All link assembly joints must have flexibility, even with measurable end play of 0.0 mm (0.0 inch). Flexibility is the ability for movement, from joint 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 79	g03745125
Tooling (L) 170-5664 Test and Fill Cart

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Illustration 80	g03745129

1. Use Tooling (L) 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 reseals. Refer to Table 9.

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

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   Table 9

   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 81	g03780921

2. Use Tooling (H) 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 (L) 170-5664 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 82	g03780937

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

   Note: The cavity must be sealed and pressure must be observed for 10 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 83	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 84	g03748019
   Caterpillar Track Torque Wrench

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   Illustration 85	g03748022
   443-7801 Pneumatic Wrench Gp

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   Illustration 86	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 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 anti-seize 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 87	g03748114

6. Turn the switch on the side of the Caterpillar Track Torque Wrench to the 120° position.
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   Illustration 88	g03748116

7. Press the "Set Pretorque" button. Enter the correct preliminary torque value into the display panel. Press "Enter".

8. Press the "Check Set Values" button to display and check the values that have been set.
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   Illustration 89	g01234180

9. Follow the correct pattern in Illustration 89 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".