Field Repair of SystemOne Track with the Multi-Pitch Track Press {0354, 0685, 4170} Caterpillar

Caterpillar Products

Machines with SystemOne Undercarriage

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.

Summary

This guideline provides the procedure for the field repair of SystemOne track on the following machines.

• D8 through D3 Track-Type Tractors

• 963 and 953 Track-Type Loaders

• PL61 Pipelayer

• 527 Track Skidder

This Undercarriage Reconditioning Bulletin explains the Multi-Pitch Track Press. The Multi-Pitch Track Press will service all the machines with the SystemOne track. For the complete list of tools for your machine, refer to the "Required Tooling" section of this guideline.

Prior to installing the SystemOne track, the undercarriage must be converted to the SystemOne configuration. For more information on retrofitting your machine to the SystemOne undercarriage, refer to Special Instructions, REHS2350, "SystemOne Overview".

Do not perform any procedure in this guideline until you understand the information that is provided within this guideline. The SystemOne undercarriage is an undercarriage that is different from any other undercarriage that has been released. All the procedures should be followed to gain the full benefits of this system.

Do not perform any procedures in this guideline until all the information within the "References" section has been read.

Do not perform any procedures in this guideline until all the information within the "Safety" section has been read.

References

Reference: Undercarriage Reconditioning Guide, SEBF8599

Reference: Tool Operating Manual, NEHS0929, "Operation and Parts for Large Multi-Pitch SystemOne Track Press Tool"

Reference: Tool Operating Manual, NEHS0930, "Operation and Parts for the Small Multi-Pitch SystemOne Track Press Tool"

Reference: Tool Operating Manual, NEHS0931, "Operation and Parts for Large 267-2107 Multi-Pitch SystemOne Track Press Tool"

Reference: Tool Operating Manual, NEHS0933, "Operation and Parts for Small 267-2109 Multi-Pitch SystemOne Track Press Tool"

Reference: Undercarriage Reconditioning Bulletin, REHS2220, "Installation and Removal of SystemOne Clamp Masters"

Reference: Tool Operating Manual, NEHS0923, "Using the Clamp Master Tools to Separate and Connect SystemOne Undercarriage Track"

Reference: Undercarriage Reconditioning Bulletin, REHS2412, "Removing SystemOne Track Links"

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

Reference: Special Instructions, REHS2350, "SystemOne Overview"

Reference: Special Instructions, REHS1610, "Installation of Direct Conversion Center Tread Idlers"

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

Reference: Custom Track Service, PEKP9400

Reference: Parts Sales Kit, PECP3003

Reference: See Testing and Adjusting for your machine.

Reference: See Disassembly and Assembly for your machine.

Reference: See Operation and Maintenance Manual for your machine.

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. Hazardous steps will be identified by warning symbols like the ones.

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.

Note: The safety shield on the Multi-Pitch Track Press has been removed for photographic purposes. Always operate the Multi-Pitch Track Press with the safety shield.

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

For all the necessary undercarriage components, refer to Special Instructions, REHS2350, "SystemOne Overview".

Note: The force on the hydraulic cylinder should not exceed 75 tons. If the force of 75 tons is not sufficient, refer to Undercarriage Reconditioning Bulletin, REHS2412, "Removing SystemOne Track Links" to remove the track link.

Procedure to Replace SystemOne Track Components

Illustration 2	g01436222
(1) Offset track link box (2) Outer track link (3) Track link box (4) Cartridge (5) Inner track link

The following components can be serviced on the SystemOne track:

• Outer track link

• Track link box

• Offset track link box

Cartridge (4) and inner track links (5) are nonserviceable as a separate item from track link box (3).

The offset track link box is for machines that have an odd number of joints in the link assembly.

The procedure to replace SystemOne track components requires separating the track. Removing the track from the machine to replace components is not necessary . The SystemOne track can be serviced on the machine. If the track has been removed from the machine, the track components can still be replaced. Use blocks to support the track to allow the tooling to be installed on the track.

If the track separated during operation, review the "Separate the SystemOne Track" section of this guideline. Make sure that the necessary steps have been performed before replacing the damaged components.

Identify the components that will be replaced. Refer to the "Procedure to Replace a SystemOne Track Link" section to replace an outside track link. Refer to the "Procedure To Replace a SystemOne Track Link Box" section to replace a track link box and an offset track link box. The track link box includes two cartridge pins and two inner track links.

Procedure to Replace a SystemOne Track Link

Illustration 3	g01132630

Follow the procedure below to replace a track link.

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Illustration 4	g01132699
Track link that will be removed on machines with an elevated sprocket

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Illustration 5	g01236860
Track link that will be removed on machines with an oval track

1. Remove the track links that will be replaced. Refer to the "Separate the SystemOne Track" section of this guideline.

   Note: Refer to Undercarriage Reconditioning Bulletin, REHS2412, "Removing SystemOne Track Links" if the track links become rusted or corroded. The rusted or corroded link can generate a force during removal that is greater than the force provided by the tooling.

2. Inspect the components of the track link box to make sure that the cartridges and links are reusable. Refer to Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts".

3. The height of the new track link should be machined or trimmed to match the wear of the link assembly.

   1. Measure the height of the track links on the link assembly.
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      Illustration 6	g01132701

   2. Mark the new track link to reflect the height of the link assembly that is being repaired.

   3. Prior to installation of the track links use a suitable method to machine or trim the track links. The preferred methods are, metal milling machine or an abrasive saw. Use a cutting torch to cut the track links prior to installation in circumstances that do not allow the preferred methods.

4. Install the track links refer to the "Connect the SystemOne Track" section of this guideline. Follow steps 4 through 27 to install the track links.

5. The SystemOne clamp master may be installed onto the track link assembly for all models except the D8. The clamp master would replace the standard track link. Refer to Undercarriage Reconditioning Bulletin, REHS2220, "Installation and Removal of SystemOne Clamp Masters".

6. Repeat Steps 1 through 4 for additional outer track links that will be replaced.

Procedure To Replace a SystemOne Track Link Box

Follow the procedure below to replace a track link box.

1. Identify and mark the track link box that will be replaced.

2. Remove the track shoe that is bolted directly to the track link box that is to be removed.

3. Remove the two track shoes on the right side and the two track shoes on the left side of the track shoe that was removed in Step 2. A total of five track shoes should be removed.

4. Remove the two outer track links on one side of the track link box that is being replaced. Refer to the "Separate the SystemOne Track" section of this guideline to remove the outside links.

5. Remove the two outer track links on the other side of the track link box that is being replaced. Refer to "Separate the SystemOne Track" and follow Step 5 through Step 48.

6. Remove the track link box.

7. Evaluate the track links to make sure that the track links can be reused. Refer to Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts".

8. Use 168-7720 Ultrasonic Wear Indicator or the manual 6V-9413 Tool Kit to determine the amount of wear on the track link box and the track links. Refer to Custom Track Service, PEKP9400 for the percentages of wear.
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   NOTICE
   A cutting torch should not be used to trim a track link box. Using a cutting torch to trim a track link box can cause damage to the internal components of the cartridge. The service life of the components can be reduced from the heat from the cutting torch.

9. Measure the link wear and determine the track link box that should be used for replacement. Refer to Table 11 and Table 12 to determine the replacement track link box.

   For some models, a new 70 percent worn track link box is offered for link assemblies that have 40 percent or greater wear.

   If the link assembly has less than 40 percent wear, use a new track link box.

   A track link box that is worn 70 percent will not be necessary for the D8.

10. Connect the SystemOne track refer to "Connect the SystemOne Track"section of this guideline.

Replacement Track Components

Note: Track link boxes are serviced as being worn zero percent or 70 percent worn. The track link box that is worn zero percent is equal to a new track link box. A new track link box that is worn 70 percent has been machined to match a link assembly that is worn 70 percent. A new track link box that is 70 percent should be used on link assemblies that have 40 percent wear or more. Refer to Table 11 for the track links that are worn 70 percent. Refer to Table 12 for the percent of wear depths.

Note: On some models, the machine performance can be affected if a new track link box that has a zero percent wear is used to replace a link box on a link assembly that has 40 percent wear or more. The bogie system on the D8 will compensate for the wear differences. A new track link box that is worn 70 percent will not be necessary for the D8.

Separate the SystemOne Track

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Illustration 7	g01226071

1. Relieve the tension on the track roller frame. For more information on adjusting the track tension, refer to Operation and Maintenance Manual, "Track - Adjust" for your machine.
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   Illustration 8	g01227782
   Track with the elevated sprocket

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   Illustration 9	g01227783
   Oval track

2. Position the track link that will be removed between the final drive and the rear idler on machines with the elevated sprocket. Position the track link that will be removed between the front idler and the carrier roller on machines with the oval track.
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   Illustration 10	g01226926

3. Block the track assembly with cribbing.
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   Illustration 11	g01227785
   Track with the elevated sprocket

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   Illustration 12	g01227787
   Oval track

4. Remove three track shoes at the location of the track link that will be removed. Remove the shoe that is directly bolted on the track links that will be removed. Remove one track shoe on either side of the track link that will be removed.

5. Clean the bushings and the track links. Any large amounts of dirt or rust may inhibit the tool from aligning properly.
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   Illustration 13	g01227788

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   Illustration 14	g01443029
   273-8788 Plate for the D8T, D8R, and D8N (B) Puller plate

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   Illustration 15	g01263861

6. Install top plate (N) onto the track link that will be removed first Refer to Illustration 13. Use the existing track bolts to locate top plate (N), tighten track bolts. Refer to Table 13 for the correct hole spacing.

   Note: Washers may need to be added between top plate (N) and the track link to align plate (A) Refer to Illustration 15 for location of washer. Refer to Table 14 for the correct flat washers.

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   Table 13

   Hole Spacing for Top Plate As-Link (N)
   Sales Model	Pitch	Part Number of Top Plate (N)	Hole Spacing
   D8T D8R D8N	218.0 mm (8.58 inch)	272-6559	Either Hole
   D6T D6R D6R2 D6H 963 527	202.81 mm (7.985 inch)	264-5771	Inside Holes
   D6N D6M D5R D5H 953	190.0 mm (7.48 inch)	264-5771	Outside Holes
   D6K2 D6K D5K D5K2 953 PL61	190.0 mm (7.48 inch)	271-5523	Inside Holes
   D6K D5N D5M D5G D4K D4K2 D4H D4G D4C D3K D3K2 D3G D3C	171.07 mm (6.735 inch)	268-5658	Outside Holes
   D4G D4C D3K D3K2 D3G D3C	175.41 mm (6.906 inch)	268-5658	Inside Holes

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   Table 14

   Flat Washers for Spacing Plate (N)
   Sales Model	Part Number
   D8T D8R D8N D6T D6R D6R2 D6H 963 527	5P-8249
   D6N D6M D5R 953	8T-3282
   D6K2 D6K D5K D5K2 D5N D5M D5G D4K D4K2 D4H D4G D4C D3K D3K2 D3G D3C PL61	5P-8247

7. Install threaded rods (E) through top plate (N). Refer to Illustration 13.

8. Install plate (B) onto threaded rods (E). Refer to Illustration 13.

   Note: For the D8, plate (B) also includes 273-8788 Plate. This plate is necessary to fit the profile of the D8 track link. Refer to Illustration 14.

9. Install two nuts (C) onto threaded rods (E) to a distance of approximately 127 mm (5.0 inch.) Refer to Illustration 13
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   Illustration 16	g01437008

10. Position the second top plate (N) onto the track links. Locate top plate (N) with the track bolts and the track nuts. Use the existing track bolts to locate top plate (N), tighten track bolts. Refer to Illustration 16

    Note: Washers may need to be added between top plate (N) and the track link to align Tooling (A). Refer to Table 14 for the correct flat washers.

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    NOTICE
    Nuts (C) will keep the tooling from falling to the ground after the track link has been removed.

11. Install two nuts (C) onto threaded rods. Verify the full thread engagement of nuts (C) but do not tighten. Refer to Illustration 16.

12. Ensure enough space between nuts (C) and top plate (N) to allow the threaded rods to travel the distance needed to remove the link. This space should be greater than the length of the end cap of the cartridge pin or greater than the width of the track link that is about to be removed. Refer to Illustration 16.
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    Illustration 17	g01227790

13. Install two nuts (C) onto the remaining two threaded rods (E) to a distance of approximately 127 mm (5.0 inch). Refer to Illustration 17

14. Install threaded rods (E) and nuts (C) through plate (B). Refer to Illustration 17.
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    Illustration 18	g01436291
    The two arrows pointing to the spotfaces on plate (A) represents the location for the removal contact tooling (F) for the D6T, D6R, D6H, 963and the 527.

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    Illustration 19	g01436293
    Location of the removal contact tool (F) according to pitch.

15. Install contact tool (F) for removal onto plate (A). Refer to Table 15 for the correct location of removal contact tool (F) depending upon pitch.
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    Table 15

    Location for Contact Tool (F) for Removal
    Sales Model	Pitch	Location
    D8T D8R D8N	218.0 mm (8.58 inch)	(CC)
    D6T D6R D6R2 D6H 963 527	202.81 mm (7.985 inch)	Use the spotfaces on plate (A).
    D6K2 D6K D6N D6M D5R D5K D5K2 D5G D5H 953 PL61	190.0 mm (7.48 inch)	(DD)
    D5H D5N D5M D5C D5G D4H	171.07 mm (6.735 inch)	(EE)
    D4K D4K2 D4G D4C D3K D3K2 D3G D3C	175.41 mm (6.906 inch)	(EE)

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    Illustration 20	g01227799

16. Install plate (A) onto threaded rods (E).
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    Illustration 21	g01437010

17. Install blocks (H) onto threaded rods (E).
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    Illustration 22	g01227706

18. Adjust blocks (H) so that the cylinder will be located properly. Refer to Illustration 22.

19. Install a minimum of two nuts (C) onto threaded rods (E). The nuts should be installed diagonally as shown in Illustration 21.

    Note: While you tighten nuts (C), locate the removal contact tool (F) onto the cartridge pins. Refer to Illustration 21.

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    Illustration 23	g01227707

20. If necessary, a 1/4-20 bolt can be installed into plate (A). The bolt will keep the hydraulic cylinder from falling during removal.
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    Illustration 24	g01227805

21. Install another plate (A) onto threaded rods (E).

22. Install four nuts (C) onto threaded rods (E) as shown in Illustration 24.
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    Illustration 25	g01227756

23. Locate the center of the hydraulic cylinder and indicate center with a visible line/mark. On some hydraulic cylinders, the cylinder is not located in the center of the housing. It is critical that the hydraulic cylinder is located centrally for easier removal of the track link.
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    NOTICE
    Damage to the cylinder may occur if the cylinder is not installed properly.

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    Illustration 26	g01227807

24. Install hydraulic cylinder (K) between both of plates (A).

    Note: Verify that hydraulic cylinder (K) is centered within the tooling.

25. Tighten nuts (C) until plate (A) supports hydraulic cylinder (K). Refer to Illustration 26.
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    NOTICE
    Failure to remove the track bolts will result in damage to the tooling.

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    Illustration 27	g01227808

26. Remove the track bolts from top plate (N) of the track link that is being removed.Top plate (N) and plate (B) will be traveling along with the track link that is being removed. Refer to Illustration 27. Plate (B) will be forcing off the track link of the cartridges.

    Note: Do not remove the track bolts from the other top plate (N). This top plate (N) will be supporting the tooling after the link has been removed from the cartridges.

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    Illustration 28	g01227811

27. Connect hydraulic pump (M) hose to hydraulic cylinder (K).

28. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps.
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    To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noise generating tools. To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component.

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    To prevent personal injury or even death from ejected parts or flying objects never remove the upper rigid guard or the lower flexible guard during operation of the portable track press. Never remove either guard when the tool is under pressure.

    Note: The force on the hydraulic cylinder should not exceed 75 tons. If the force of 75 tons is not sufficient refer to Undercarriage Reconditioning Bulletin, REHS2412, "Removing SystemOne Track Links" to remove the track link.

29. Turn on the hydraulic pump. Apply pressure in small amounts. The track link will be removed from the ends of the cartridge pins. Watch carefully to ensure that the track link is removed evenly.

    1. The track link must be removed from the ends of the cartridge pins evenly. If one end of the track link is leading more than 6 mm (0.24 inch) from the other trailing end of the track link turn off the pump. Release the hydraulic pressure from the hydraulic cylinder and remove the guard.

    2. Move the hydraulic cylinder to the side of the track link that is trailing behind. Do not move the centerline of the hydraulic cylinder to the outside of the threaded rods. If the centerline of the hydraulic cylinder is outside the threaded rods, the tooling may become damaged. Realign the tooling and tighten nuts.

    3. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Apply pressure in small amounts. Continue to remove the track link.

    4. Once the track link is even. Release the hydraulic pressure from the hydraulic cylinder and remove the guard. Center the hydraulic cylinder to the track link. Realign the tooling and tighten nuts. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Continue to remove the track link.

    5. If necessary, use tool spacers (T) to realign uneven track links being removed. Refer to Table 9. Release the hydraulic pressure from the hydraulic cylinder and remove the guard. Move the hydraulic cylinder to the side of the track link that is trailing behind. Install three of the tool spacers (T) on each contact tool (F). The tool spacers will limit how far the track link can come off each cartridge pin. If only one end of the track link starts to move off a cartridge pin the tool spacers holds the leading track link until the other trailing track link also moves off that cartridge pin an equal amount. Realign the tooling and tighten nuts.

    6. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Continue to remove the track link. Apply pressure in small amounts.

    7. Once the track link is even. Release the hydraulic pressure from the hydraulic cylinder and remove the guard. Remove one spacer (T) from each contact tooling. Center the hydraulic cylinder to the track link. Realign the tooling and tighten nuts.

    8. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Continue to remove the track link. Repeat the procedure and continue to remove shims until link is removed.

       Note: 265-8034 Hydraulic Cylinder and 265-8035 Hydraulic Cylinder have a 12.7 mm (0.50 inch) stroke. It will be necessary to stroke the hydraulic cylinder several times during the removal process. 360-6967 Hydraulic Cylinder has a 60.5 mm (2.381 inch) stroke. This hydraulic cylinder may complete the removal process with a single stroke.

       Note: If there is enough clearance between the machine and the track link assembly to install the Multi-Pitch Track Press, follow Steps 30 through 48 to remove the inside track link. If there is not enough clearance between the machine and the track link assembly to install the Multi-Pitch Track Press, refer to the "Alternate Method for Separation of the SystemOne Track" section of this guideline to remove the inside track link.

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    Illustration 29	g01437012

30. After the first track link has been removed, a hoist may be used to place the tooling onto the ground. Support the tooling with a suitable lifting device. Remove nuts (C).

    Note: If a hoist is not available, the tooling can be disassembled one component at a time. The heaviest components are plates (A). One plate (A) weighs approximately 180 N (40.0 lb). The total weight of the Multi-Pitch Track Press is approximately 710 N (160.0 lb).

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    Illustration 30	g01227814

31. Place the tooling onto the ground. Remove nuts (C). Remove plate (B). Remove the track link.
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    Illustration 31	g01227815

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    Illustration 32	g01443029
    273-8788 Plate for the D8T, D8R, and D8N (B) Puller plate

32. Position threaded rods (E) through top plate (N). Refer to Illustration 31.

33. Install plate (B) onto threaded rods (E). Refer to Illustration 31

    Note: For the D8, plate (B) also includes 273-8788 Plate. This plate is necessary to fit the profile of the D8 track link. Refer to Illustration 32.

34. Install four nuts (C) onto threaded rods (E). Refer to Illustration 31.
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    Illustration 33	g01437013

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    Illustration 34	g01226931

35. Install the other top plate (N) onto the track links. Locate plate (N) with the track bolts and the track nuts. Tighten the track bolts to secure the top plate (N) to the track links. Refer to Illustration 33

    Note: Washers may need to be added between Tooling (N) and the track link to align Tooling (A). Refer to Illustration 34 for location of washers. Refer to Table 16 for the correct flat washers.

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    Table 16

    Flat Washers for Spacing Plate (N)
    Sales Model	Part Number
    D8T D8R D8N D6T D6R D6R2 D6H 963 527	5P-8249
    D6N D6M D5R 953	8T-3282
    D6K2 D6K D5K D5K2 D5N D5M D5G D4K D4K2 D4H D4G D4C D3K D3K2 D3G D3C PL61	5P-8247

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    NOTICE
    Nuts (C) will keep the tooling from falling to the ground after the track link has been removed.

36. Install two nuts (C) onto threaded rods (E). Verify the full thread engagement of nuts (C) but do not tighten. Refer to Illustration 33.

    Note: Ensure enough space between nuts (C) and top plate (N) to allow the threaded rods to travel the distance needed to remove the link. This space should be greater than the length of the end cap of the cartridge pin or greater than the width of the track link that is about to be removed.

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    Illustration 35	g01437014

37. Tighten nuts (C) to locate contact tool (F) onto the cartridge pins. refer to Illustration 35
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    NOTICE
    Damage may occur to the cylinder if the cylinder is not installed properly.

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    Illustration 36	g01227819

38. Install hydraulic cylinder (K) between both of plates (A).

    Note: Verify that hydraulic cylinder (K) is centered within the tooling. Refer to Illustration 36

39. Tighten nuts (C) until plate (A) supports hydraulic cylinder (K). Refer to Illustration 36
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    NOTICE
    Failure to remove the track bolts will result in damage to the tooling.

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    Illustration 37	g01227820

40. Remove the track bolts from top plate (N) of the track link that is being removed. Top plate (N) and plate (B) will be traveling along with the track link that is being removed. Plate (B) will be forcing off the track link of the cartridges.

    Note: Do not remove the track bolts from the other top plate (N). This top plate (N) will be supporting the tooling after the link has been removed from the cartridges.

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    Illustration 38	g01227821

41. Connect hydraulic pump (M) hose to hydraulic cylinder (K).

42. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps.

43. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps.
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    To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noise generating tools. To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component.

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    To prevent personal injury or even death from ejected parts or flying objects never remove the upper rigid guard or the lower flexible guard during operation of the portable track press. Never remove either guard when the tool is under pressure.

    Note: The force on the hydraulic cylinder should not exceed 75 tons. If the force of 75 tons is not sufficient refer to Undercarriage Reconditioning Bulletin, REHS2412, "Removing SystemOne Track Links" to remove the track link.

44. Turn on the hydraulic pump. Apply pressure in small amounts. The track link will be removed from the ends of the cartridge pins. Watch carefully to ensure that the track link is removed evenly.

    1. The track link must be removed from the ends of the cartridge pins evenly. If one end of the track link is leading more than 6 mm (0.24 inch) from the other trailing end of the track link turn off the pump. Release the hydraulic pressure from the hydraulic cylinder and remove the guard.

    2. Move the hydraulic cylinder to the side of the track link that is trailing behind. Do not move the centerline of the hydraulic cylinder to the outside of the threaded rods. If the centerline of the hydraulic cylinder is outside the threaded rods, the tooling may become damaged. Realign the tooling and tighten nuts.

    3. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Apply pressure in small amounts. Continue to remove the track link.

    4. Once the track link is even. Release the hydraulic pressure from the hydraulic cylinder and remove the guard. Center the hydraulic cylinder to the track link. Realign the tooling and tighten nuts. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Continue to remove the track link.

    5. If necessary, use tool spacers (T) to realign uneven track links being removed. Refer to Table 9. Release the hydraulic pressure from the hydraulic cylinder and remove the guard. Move the hydraulic cylinder to the side of the track link that is trailing behind. Install three of the tool spacers (T) on each contact tool (F). The tool spacers will limit how far the track link can come off each cartridge pin. If only one end of the track link starts to move off a cartridge pin the tool spacers holds the leading track link until the other trailing track link also moves off that cartridge pin an equal amount. Realign the tooling and tighten nuts.

    6. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Continue to remove the track link. Apply pressure in small amounts.

    7. Once the track link is even. Release the hydraulic pressure from the hydraulic cylinder and remove the guard. Remove one spacer (T) from each contact tooling. Center the hydraulic cylinder to the track link. Realign the tooling and tighten nuts.

    8. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Continue to remove the track link. Repeat the procedure and continue to remove shims until link is removed.

       Note: 265-8034 Hydraulic Cylinder and 265-8035 Hydraulic Cylinder have a 12.7 mm (0.50 inch) stroke. It will be necessary to stroke the hydraulic cylinder several times during the removal process. 360-6967 Hydraulic Cylinder has a 60.5 mm (2.381 inch) stroke. This hydraulic cylinder may complete the removal process with a single stroke.

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    Illustration 39	g01437017

45. Remove the guard.

46. Remove hydraulic cylinder (K).

47. Support the tooling with a suitable lifting device. Remove nuts (C).

48. Place the tooling on the ground. Disassemble the tooling.

Alternate Method for Separation of the SystemOne Track

The following procedure should be used to separate the SystemOne track if the clearance between the machine and the track link assembly will not allow installation of the Multi-Pitch Track Press.

Shims (S) will be used to remove the inside track link.

1. Remove all the tooling except for the inner top plate (N) that is positioned directly above the link that is to be removed. Install the upper threaded rods (E).
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   Illustration 40	g01227824

2. Install plate (A) with contact tools (F) on threaded rods (E) to remove the inside track link. Refer to Illustration 40

3. Install the lower threaded rods (E) and four nuts (C).
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   Illustration 41	g01261493

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   Illustration 42	g01446455
   273-8788 Plate for the D8T, D8R, and D8N (B) Puller plate (S) Shim (E) Threaded rods

4. Install plate (B) on threaded rods (E) against the inside track link.

   Note: For the D8, plate (B) also includes 273-8788 Plate. This plate is necessary to fit the profile of the D8 track link. Refer to Illustration 42.

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   Illustration 43	g01227826

5. Install shim (S) from the upper threaded rods (E).
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   Illustration 44	g01227827

6. Install the other top plate (N) on the outer track links.
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   Illustration 45	g01227829

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   Illustration 46	g01437019

7. Install shim (S) from the upper threaded rods (E).

   Note: Distance (FF) should be greater than the length of the end cap of the cartridge pin or greater than the width of the track link that is about to be removed.

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   Illustration 47	g01436952

8. Install blocks (H) onto the threaded rods (E). Adjust blocks (H) so that the cylinder will be located properly. Refer to Illustration 47

9. Install plate (A) and install nuts (C) on each of threaded rod (E).
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   NOTICE
   Damage may occur to the cylinder if the cylinder is not installed properly.

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   Illustration 48	g01227840

10. Install hydraulic cylinder (K) so the ram faces inward toward the track link that is to be removed.
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    NOTICE
    Failure to remove the track bolts from the top plate will result in damage to the tooling.

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    Illustration 49	g01441366

11. Remove the track bolts from top plate (N) of the track link that is being removed. Top plate (N) and plate (B) will be traveling along with the track link that is being removed. Plate (B) will be forcing off the track link of the cartridges.

    Note: Do not remove the track bolts from the other top plate (N). This top plate (N) will be supporting the tooling after the link has been removed from the cartridges.

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    Illustration 50	g01227821

12. Connect hydraulic pump (M) hose to hydraulic cylinder (K).

13. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps.

14. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps.
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    To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noise generating tools. To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component.

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    To prevent personal injury or even death from ejected parts or flying objects never remove the upper rigid guard or the lower flexible guard during operation of the portable track press. Never remove either guard when the tool is under pressure.

    Note: The force on the hydraulic cylinder should not exceed 75 tons. If the force of 75 tons is not sufficient refer to Undercarriage Reconditioning Bulletin, REHS2412, "Removing SystemOne Track Links" to remove the track link.

15. Turn on the hydraulic pump. Apply pressure in small amounts. The track link will be removed from the ends of the cartridge pins. Watch carefully to ensure that the track link is removed evenly.

    1. The track link must be removed from the ends of the cartridge pins evenly. If one end of the track link is leading more than 6 mm (0.24 inch) from the other trailing end of the track link turn off the pump. Release the hydraulic pressure from the hydraulic cylinder and remove the guard.

    2. Move the hydraulic cylinder to the side of the track link that is trailing behind. Do not move the centerline of the hydraulic cylinder to the outside of the threaded rods. If the centerline of the hydraulic cylinder is outside the threaded rods, the tooling may become damaged. Realign the tooling and tighten nuts.

    3. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Apply pressure in small amounts. Continue to remove the track link.

    4. Once the track link is even. Release the hydraulic pressure from the hydraulic cylinder and remove the guard. Center the hydraulic cylinder to the track link. Realign the tooling and tighten nuts. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Continue to remove the track link.

    5. If necessary, use tool spacers (T) to realign uneven track links being removed. Refer to Table 9. Release the hydraulic pressure from the hydraulic cylinder and remove the guard. Move the hydraulic cylinder to the side of the track link that is trailing behind. Install three of the tool spacers (T) on each contact tool (F). The tool spacers will limit how far the track link can come off each cartridge pin. If only one end of the track link starts to move off a cartridge pin the tool spacers holds the leading track link until the other trailing track link also moves off that cartridge pin an equal amount. Realign the tooling and tighten nuts.

    6. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Continue to remove the track link. Apply pressure in small amounts.

    7. Once the track link is even. Release the hydraulic pressure from the hydraulic cylinder and remove the guard. Remove one spacer (T) from each contact tooling. Center the hydraulic cylinder to the track link. Realign the tooling and tighten nuts.

    8. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps. Continue to remove the track link. Repeat the procedure and continue to remove shims until link is removed.

       Note: 265-8034 Hydraulic Cylinder and 265-8035 Hydraulic Cylinder have a 12.7 mm (0.50 inch) stroke. It will be necessary to stroke the hydraulic cylinder several times during the removal process. 360-6967 Hydraulic Cylinder has a 60.5 mm (2.381 inch) stroke. This hydraulic cylinder may complete the removal process with a single stroke.

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    Illustration 51	g01437017

16. Remove the guard.

17. Remove hydraulic cylinder (K).

18. Support the tooling with a suitable lifting device. Remove nuts (C).

19. Place the tooling on the ground. Disassemble the tooling.

Connect the SystemOne Track

Perform the following steps to connect the SystemOne track.

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Illustration 52	g01226073
Track with the elevated sprocket

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Illustration 53	g01226074
Oval track

1. Position the ends of the track assembly between the final drive and the rear idler on machines with the elevated sprocket. Position the ends of the track assembly between the front idler and the carrier roller on oval track.

   Note: Minimal track sag will help during installation.

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   Illustration 54	g01226926

2. Block the track assembly with the appropriate cribbing.

3. If the track is new, remove the protective covers from the ends of the cartridge pins. If the track is used, make sure that the bushings and the ends of the cartridge pins are free of dirt, paint, and rust.
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   Illustration 55	g01226928

4. Check the location of marking (AAA) on the ends of the cartridge pin. The marking should be located near the link rail of the outer track link that will be installed and opposite the track shoe. If the orientation is not correct, use a chain/strap wrench to rotate the cartridge pin to the correct position. See Illustration 55.
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   Illustration 56	g01226929

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   Illustration 57	g01226931

5. Use the track bolts and the track nuts to install top plates (N). The track bolts should be installed into top plates (N) in the correct holes for the model of tractor that is being serviced. Refer to Table 17 for the correct hole spacing. Tighten the track bolts to straighten the track assembly.

   Note: The holes in top plate (N) are used to maintain the correct pitch for the corresponding sales models. Failure to use the correct holes and bolts will result in not maintaining the correct pitch.

   Note: Washers may need to be added between plate (N) and the track link to align plate (A). Refer to Illustration 57 for the location of washers. Refer to Table 18 for the correct flat washers.

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   Table 17

   Hole Spacing for Top Plate As-Link (N)
   Sales Model	Pitch	Part Number of Top Plate (N)	Hole Spacing
   D8T D8R D8N	218.0 mm (8.58 inch)	272-6559	Either Hole
   D6T D6R D6R2 D6H 963 527	202.81 mm (7.985 inch)	264-5771	Inside Holes
   D6N D6M D5R D5H 953	190.0 mm (7.48 inch)	264-5771	Outside Holes
   D6K2 D6K D5K D5K2 953 PL61	190.0 mm (7.48 inch)	271-5523	Inside Holes
   D6K D5N D5M D5G D4K D4K2 D4H D4G D4C D3K D3K2 D3G D3C	171.07 mm (6.735 inch)	268-5658	Outside Holes
   D4G D4C D3K D3K2 D3G D3C	175.41 mm (6.906 inch)	268-5658	Inside Holes

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   Table 18

   Flat Washers for Spacing Plate (N)
   Sales Model	Part Number
   D8T D8R D8N D6T D6R D6R2 D6H 963 527	5P-8249
   D6N D6M D5R 953	8T-3282
   D6K2 D6K D5K D5K2 D5N D5M D5G D4K D4K2 D4H D4G D4C D3K D3K2 D3G D3C PL61	5P-8247

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   Illustration 58	g01266182

   Note: If it is difficult to install top plates (N), a starter link (L) may be used.

6. Install two of threaded rods (E) through top plates (N).
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   Illustration 59	g01226933

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   Illustration 60	g01437501
   Contact Plate (R) 268-1699. For the D8T, D8R, and D8N

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   Illustration 61	g01226934
   Contact Plate (R) 268-1699.

7. Install plate (A) and nuts (C) onto threaded rods (E). For the D6T, D6R/H, D6M/N, 963, and 953, plate (A) must be installed so that the spotfaces are facing the cartridge pins. For the D8T, D8R, and D8N, plate (R) needs to be installed onto plate (A) with two 8H-3127 Bolts. For the D6K, D5K, D5K2, D5M/N, D5G, D4K, D4K2, D4H, D4G, D4C, D3K, D3K2, D3G, D3C, PL61, and 527 plate (R) needs to be installed onto plate (A) with two #10-24 machine screws. Plate (A) must be installed so plate (R) faces the cartridge pins. Refer to Table 19.

   Note: Leave enough room between plate (A) and the cartridge pins to install the track link.

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   Table 19

   Contact Plate (R) for Installation
   Sales Model	Part Number	Qty
   D8T D8R D8N	289-5146	4
   D6K2 D6K D5K D5K2 D5N D5M D5G D4K D4K2 D4H D4G D4C D3K D3K2 D3G D3C PL61 527	268-1699	2
   D6T D6R D6R2 D6H D6N D6M D5R 963 953	264-5768 The face of the contact plate (A) with the spotfaces/counterbore facing the track link during installation.	2

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   Illustration 62	g01437025

8. Install another plate (A) onto threaded rods (E).

9. Install the remaining two threaded rods (E) through both of plates (A) and install nuts (C) onto threaded rods (E).
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   Illustration 63	g01227703

10. Install two blocks (H) onto threaded rods (E).
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    Illustration 64	g01227706

11. Orient blocks (H) so the cylinder will be located properly.
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    Illustration 65	g01227707

12. If necessary, a 1/4-20 bolt can be installed into plate (A). The bolt will keep the hydraulic cylinder from falling during installation.
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    Illustration 66	g01437027

13. Apply 222-3114 Anti-Seize Compound to the bore of the track link and the cartridge pins. Install track link (AA) into the tooling. Tighten nuts (C) to properlylocate track link (AA).
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    Illustration 67	g01227753

14. Install plate (B) onto threaded rods (E). Install four nuts (C) onto threaded rods (E).
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    Illustration 68	g01227756

15. Locate the center of the hydraulic cylinder. On some hydraulic cylinders, the cylinder is not located in the center of the housing. It is critical that the hydraulic cylinder is located centrally for easier installation of the track link.
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    NOTICE
    Damage may occur to the cylinder if the cylinder is not installed properly.

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    Illustration 69	g01227759

16. Install hydraulic cylinder (K) between plate (B) and plate (A). Tighten nuts (C) to secure the hydraulic cylinder.

    Note: Verify that the hydraulic cylinder is located in the center of the tooling.

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    Illustration 70	g01227760

17. Connect hydraulic pump (M) to hydraulic cylinder (K).
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    Illustration 71	g01227761

18. Install guard (J) over the tooling. Fasten the buckles. Tighten the straps.
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    To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noise generating tools. To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component.

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    To prevent personal injury or even death from ejected parts or flying objects never remove the upper rigid guard or the lower flexible guard during operation of the portable track press. Never remove either guard when the tool is under pressure.

19. Turn on the hydraulic pump. The track link will be pulled onto the ends of the cartridge pins. Watch carefully to ensure that the track link is pulled evenly. When the track link is in place, plate (A) will contact the ends of the cartridge pins. The gauge on the pump will indicate a sharp rise in pressure.

    1. The track link must be pulled evenly onto the ends of the cartridge pins. Turn off the pump if one end of the track link is offset more than 6.0 mm (0.24 inch) from the other end of the track link.

    2. If one side of the track link has been installed farther, release the hydraulic pressure from the hydraulic cylinder. Move the hydraulic cylinder to the side of the track link that is trailing behind. Do not move the centerline of the hydraulic cylinder to the outside of the threaded rods. If the centerline of the hydraulic cylinder is outside the threaded rods, the tooling may become damaged. Once the track link is even, center the hydraulic cylinder to the track link. Continue to install the track link.

       Note: 265-8034 Hydraulic Cylinder and 265-8035 Hydraulic Cylinder have a 12.7 mm (0.50 inch) stroke. It will be necessary to stroke the hydraulic cylinder several times during the removal process. 360-6967 Hydraulic Cylinder has a 60.5 mm (2.381 inch) stroke. This hydraulic cylinder may complete the removal process with a single stroke.

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    Illustration 72	g01437029

20. Once track link (AA) is installed, remove the hydraulic cylinder. Loosen nuts (C).

21. Apply 222-3114 Anti-Seize Compound to the bore of track link (BB) and the cartridge pins.

22. Install track link (BB) between plate (A) and the cartridge pins. Tighten nuts (C) to locate track link (BB) onto the ends of the cartridge pins.

23. Repeat Step 18 and Step 19 to install the other track link.
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    Illustration 73	g01227764

24. If necessary, remove the track bolts. Plates (N) can be slid inward on the threaded rods to verify that both track links have been installed. There should be a gap of approximately 1.5 mm (0.06 inch) between the outside track link and the inside track links.
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    Illustration 74	g01227765

25. After the track links have been installed, all the tooling can be lifted with a hoist from the tapped holes that are provided on the tooling. The tapped holes are 3/8-16. If a hoist is not available, each component of the tooling can be disassembled. The heaviest components are plates (A). One of plate (A) weighs approximately 180 N (40.0 lb). The total weight of the Multi-Pitch Track Press is approximately 710 N (160.0 lb).

    Note: If the tooling will be removed with a hoist, the bottom threaded rods (E) will need to be removed first.

26. Install the three remaining track shoes. Torque the track shoe bolts to the correct torque. Refer to Table 20 for the correct torque specifications. Then, tighten each bolt by an extra turn of 120 ± 5 degrees.
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    Table 20

    Model	Pitch	Preliminary Torque Specifications
    D8T D8R D8N	218.0 mm (8.58 inch)	650 ± 70 N·m (480.0 ± 50.0 lb ft)
    D6T D6R D6R2 D6H 963 527	202.81 mm (7.985 inch)	500 ± 70 N·m (370.0 ± 50.0 lb ft)
    D6N D6M D5R 953	190.0 mm (7.48 inch)	400 ± 70 N·m (300.0 ± 50.0 lb ft)
    D6K2 D6K D5K D5K2 D5G D4H PL61	190.0 mm (7.48 inch)	200 ± 25 N·m (150.0 ± 20.0 lb ft)
    D5N D5M D5G D4C	171.07 mm (6.735 inch)	145 ± 40 N·m (110.0 ± 30.0 lb ft)
    D4K D4K2 D4G D3K D3K2 D3G D3C	175.41 mm (6.906 inch)	145 ± 40 N·m (110.0 ± 30.0 lb ft)

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    Illustration 75	g01227766

27. Adjust the track tension. For more information on adjusting the track tension, refer to Operation and Maintenance Manual, "Track - Adjust" for your machine.