Track Service Evaluation Checklist {4169, 4170, 4171, 4172, 4174, 4175, 4176} Caterpillar


Track Service Evaluation Checklist {4169, 4170, 4171, 4172, 4174, 4175, 4176}

Usage:

D6D 01Y
Caterpillar Products
Machines with Grease Lubricated Track with Swage
Machines with Greased Lubricated Track (GLT)
Machines with Positive Pin Retention (PPR) Track
Machines with Positive Pin Retention 2 (PPR2) Track
Machines with Rotating Bushing Track
Machines with Sealed Positive Pin Retention (PPR) Track
Machines with Sealed Track
Machines with Sleeve Bearing Track
Machines with non-PPR Sealed and Lubricated Track
Track Drills
MD5150C (S/N: SEY1-UP)

Introduction

Table 1
Revision  Summary of Changes in SEBF8565 
20–23  Added serial number prefixes for New Product Introduction.Added serial number prefixes for New Product Introduction. 
19  Added serial number prefixes for New Product Introduction.
Updated introduction information. 
18  Added serial number prefixes for New Product 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.

Canceled Part Numbers and Replaced Part Numbers

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

References

Reference: Undercarriage Reconditioning Bulletin, SEBF8599, "Undercarriage Reconditioning Guide"

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

Reference: Servicing Handbook, PECP3003, "Parts Sales Kit Undercarriage"

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8557, "Shop Repair Procedure for Non-PPR Sealed and Lubricated Track"

Reference: Undercarriage Reconditioning Bulletin, SEBF8546, "Shop Repair Procedure for Positive Pin Retention Track"

Reference: Undercarriage Reconditioning Bulletin, SEBF8609, "Shop Repair Procedure for Sleeve Bearing Track"

Reference: Special Instruction, SEHS8957, "Field Servicing Procedure for Non-PPR Sealed and Lubricated Track"

Reference: Undercarriage Reconditioning Bulletin, SEBF8612, "Field Service for Positive Pin Retention Track"

Reference: Undercarriage Reconditioning Bulletin, SEBF8613, "Field Service Procedure for Sleeve Bearing Track"

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8553, "Reusability Guidelines and Installation Procedures for Split Master Links"

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

Reference: Special Instruction, SEHS8881, "Repair Procedure For Quad Track"

Reference: Special Instruction, SEHS9371, "Track Seal Installers And Track Bushing Groove Gauges For Rigid Track Seals"

Reference: Video, PEVN4322, "Track Shop Servicing Procedure for Non-PPR Sealed and Lubricated track"

Reference: Video, PEVH4776, "Undercarriage Test and Fill Machine"

Tooling

Table 2
Track Seal Installers and Bushing Groove Gauges For Rigid Track Seals 
Sales Model  Seal Installer  End Groove Gauge 
D11T
D11R
D11N 
4C-8623
241-1854(1) 
4C-8613 
D10T
D10R
D10N 
4C-8622
262-9822(1) 
4C-8612 
D10  4C-8622  4C-8611 
D9T
D9R
D9N 
4C-8621  4C-8610 
D9L
589 
4C-8621  4C-8609 
D8T
D8R
D8N
D8L
583
578 
4C-8619  4C-8607 
D7E
D7R
D7H
572 
4C-8619  4C-8605 
D6T
D6R
D6H 
4C-8617  4C-8604 
D6K
D6M
D6N
D5R
D5H 
4C-8616  4C-8603
133-1538 
D5M
D5N
D4H 
133-1532  133-1535 
D5K
D5G
D5C 
4C-8615  4C-8602 
D4K
D3K
D4G
D3G
D4C
D3C 
165-2571  165-2572 
(1) Post Turn Seal Installer

Undercarriage Shop

Table 3
Description 
(1) Is the undercarriage shop clean and orderly? 
 
 
(2) Is the contact tooling clearly identified, stored orderly, and easily accessible? 
 
 
(3) Are racks or cabinets installed near the track press to store the tooling? 
 
 
(4) Are the shelves or drawers clearly labeled? 
 
 
(5) Is the tooling organized by track pitch or part number? 
 
 
(6) Are the necessary hand tools accessible and stored near the track press? (Impact wrench, electric drill, PPR extruders, unlocking tools, and so forth) 
 
 
(7) Does the operator of the track press wear eye protection? 
 
 
(8) Does the operator of the track press wear ear protection? 
 
 
(9) Is the undercarriage shop equipped with adequate lighting for effective operation of the equipment? 
 
 
(10) Is adequate floor space available for servicing the track efficiently? 
 
 
(11) Does the layout of the undercarriage shop allow for efficient workflow processing? 
 
 
(12) Are the rebuild processes free from bottlenecks in the undercarriage shop? 
 
 
(13) Is the track press equipped with a drip pan to contain the oil during disassembly? 
 
 
Comments: 
 
 
 
 

Track Service

Preparation for Disassembly

Table 4
Description 
(1) Is the track group thoroughly washed before the track is brought into the undercarriage shop? 
 
 
(2) Are the plastic plugs and the rubber stoppers removed using a 12.7 mm (0.50 inch) drill bit? 
 
 
(3) Are the oil cavities chamfered to remove any burrs or smeared metal? 
 
 
(4) Is the oil drained or vacuumed from each track joint? The track may need to be washed again to remove the oil residue. 
 
 
(5) Is the track measured for wear and the wear measurements recorded? 
 
 
(6) Is the track service documented in a work order? (dry joints, assembly measurements, reuse information, CTS inspection report) 
 
 
(7) Are the track shoes removed using a shoe lifter or fabricated lifting device? 
 
 
(8) Are the track pins and bushings marked and numbered with a permanent paint pen? 
 
 
(9) Is the disassembly tooling checked for proper dimensions, condition, and alignment with the pin and bushing? 
 
 
Comments: 
 
 
 
 

Disassembly and Inspection

Table 5
Description 
(1) Are the shop personnel using Wall Chart, SENR1788, "Non-PPR Sealed and Lubricated Track Reconditioning" and Wall Chart, SENR1838, "Positive Pin Retention Sealed and Lubricated Track Reconditioning" for the correct procedures and specifications? 
 
 
(2) Are the track links inspected for cracks, broaching in the pin bore, and damage to the counterbore during disassembly? 
 
 
(3) Are the track links measured and dimensions recorded? 
 
 
(4) Are the bushings, pins, and thrust rings cleaned? 
 
 
(5) Is the number of dry joints recorded? 
 
 
(6) Are the bushings inspected for end cracks, internal cracks, and end grooving? Refer to Table 2 for the correct end grooving gauges. 
 
 
(7) Are the bushings measured and dimensions recorded? 
 
 
(8) Are the track pins inspected for spalling, galling, wear steps, and plugged crossholes? 
 
 
(9) Are the thrust rings inspected for cracks, chips, and wear? 
 
 
Comments: 
 
 
 
 

Preparation for Assembly

Table 6
Description 
(1) Are small burrs removed from the pin ends with light grinding on PPR track? 
 
 
(2) Is a 10 degree chamfer ground onto the pin ends on Non-PPR track? 
 
 
(3) Are the rubber stoppers lightly lubricated and installed to the proper depth using the correct installation tooling? 
 
 
(4) Are the damaged seals removed and the link counterbores thoroughly cleaned with a wire brush and a lint-free cloth? 
 
 
(5) Are new seals installed in clean counterbores using the correct seal installer? Refer to Table 2 for the correct seal installers. 
 
 
(6) Is the contact tooling inspected and properly setup? (pin projection, bushing projection, link offset) 
 
 
Comments: 
 
 
 
 

Assembly

Table 7
Description 
(1) Are the shop personnel using Wall Chart, SENR1788, "Non-PPR Sealed and Lubricated Track Reconditioning" and Wall Chart, SENR1838, "Positive Pin Retention Sealed and Lubricated Track Reconditioning" for the correct procedures and specifications? 
 
 
(2) Is the assembly force on the track press adjusted to the specification for the model being assembled? 
 
 
(3) Is an identification number welded on the master link of each track serviced and recorded in the logbook? 
 
 
(4) Is the track pin and bushing rotated horizontally by 180 degrees and the bushing rotated around the track pin by 180 degrees? 
 
 
(5) Is the track pin installed with the crosshole towards the wear surface of the track links? 
 
 
(6) Are thrust rings installed over each track pin?
(a) For PPR track, the facing ring is optional to achieve proper joint articulation.
(b) For Non-PPR track, apply molykote grease on the bushing side of the thrust ring. 
 
 
(7) Is the contact tooling properly setup for the correct assembly dimensions? 
 
 
(8) Are the pin and bushing projections and end play measured on the first joint that is assembled? 
 
 
(9) Is each track joint checked for articulation? 
 
 
(10) Is a retaining ring installed on each pin end on PPR track? 
 
 
(11) Are the retaining rings extruded using the correct extruders on PPR track? 
 
 
(12) Is each track joint unlocked with the correct force to give the track joint end play and the ability to articulate? 
 
 
(13) Is each track joint pressure tested using nitrogen to ensure proper sealing using either 170-5664 Test and Fill Cart or FT-2724 Pressure Gauge Tool? 
 
 
(14) Is each track joint filled with 75W-140 synthetic gear oil? 
 
 
(15) If not using 170-5664 Test and Fill Cart, is the track joint evacuated to obtain the desired partial fill? 
 
 
(16) Is the plastic plug installed into the rubber stopper to the proper depth using 5P-7419 Installer Tool? 
 
 
(17) Is any paint and debris removed from all the mating surfaces of the shoes, bolts, nuts, nut seats, and track links? 
 
 
(18) Are the track shoe bolts tightened to the correct torque specification? Refer to Undercarriage Reconditioning Bulletin, SEBF8566, "Track Data Charts" for the correct torque. 
 
 
(19) Are the track bolts smaller than 28.58 mm (1.125 inch) lubricated with SAE 30 oil? 
 
 
(20) Are the track bolts from 28.58 mm (1.125 inch) and 34.93 mm (1.375 inch) lubricated with anti-seize? 
 
 
(21) Are the track bolts being forced into the bolt holes? 
 
 
(22) Are the track bolts tightened in a criss-cross pattern? 
 
 
(23) Are the track bolts turned an additional 120 degrees? 
 
 
Comments: 
 
 
 
 

Accessory Equipment

Cleaning

Table 8
Description 
(1) Are the tracks cleaned using either high-pressure wash or steam? 
 
 
(2) Is the washing of the tracks a one-man operation? (One man should be able to perform this function) 
 
 
(3) Is the wash area located near the track press to ensure efficient workflow? (minimum steps and time between operations) 
 
 
(4) Are the track pins and bushings cleaned using one of the following methods?
(a) Solvent tank
(b) Agitating hot tank
(c) Steam
(d) Wash cabinet 
 
 
(5) Is the washing equipment used for cleaning the track components also used for cleaning the roller and idler components? (Minimum steps and time between operations) 
 
 
Comments: 
 
 
 
 

Integrity of the Track Joints

170-5664 Test and Fill Cart Gp

Table 9
Description 
(1) Is the compressed shop air filtered and pressure regulated at 552 kPa to 690 kPa (80.0 psi to 100.0 psi?) 
 
 
(2) Is the oil pressure regulated at 28 kPa to 41 kPa (4.0 psi to 6.0 psi?) 
 
 
(3) Is the nitrogen regulated at 275 kPa to 345 kPa (40.0 psi to 50.0 psi) at the nitrogen tank? 
 
 
(4) Is the nitrogen regulated at 10 kPa to 14 kPa (1.5 psi to 2.0 psi) at the fill nozzle? 
 
 
(5) Is the oil heated for at least 10 minutes? 
 
 
(6) Is the system purged? 
 
 
(7) Are the service indicators for the oil filters checked periodically? 
 
 
(8) Is the overall condition of the machine good? 
 
 
Comments: 
 
 
 
 

FT-2724 Pressure Gauge Tool Gp

Table 10
Description 
(1) Is the nitrogen pressure maintained at 138 kPa (20.0 psi) throughout test cycle? 
 
 
(2) Is the ball valve and pressure differential valve closed? 
 
 
(3) Is the pressure observed for 10 seconds without a pressure drop of 3.4 kPa (0.5 psi?) 
 
 
Comments: 
 
 
 
 

Filling

Table 11
Description 
(1) Are the shop personnel using Wall Chart, SENR1788, "Non-PPR Sealed and Lubricated Track Reconditioning" and Wall Chart, SENR1838, "Positive Pin Retention Sealed and Lubricated Track Reconditioning" for the correct oil fill volumes? 
 
 
(2) Is the rubber stopper lubricated with a light-weight oil to promote expansion and installed with the proper stopper installer? 
 
 
(3) Is the track joint filled to 80% to 90% with 75W-140 synthetic oil and the plastic plug installed? 
 
 
(4) Is the oil filtered properly to prevent contamination? 
 
 
(5) Do air bubbles exist in the stream of oil? Air bubbles can be caused by a worn out pump, low oil level, and broken pipes. 
 
 
(6) Is there a loss of vacuum? Create a vacuum with finger over the lubricator tip, release the vacuum button, and check for loss of vacuum by viewing the gauge. (If loss of vacuum is observed, check all connections between the button (valve) and the tip.) 
 
 
(7) Check the accuracy of gauges. Do the gauges zero? Are the gauges broken or have a broken glass? Replace any damaged gauges. 
 
 
(8) Is the overall condition of the hoses and related equipment in good condition? 
 
 
(9) Does the fill and vacuum button have an over center finger or palm pad to reduce fatigue? 
 
 
(10) Is the regulator set at a maximum of 552 kPa (80.0 psi?) Pressure above 552 kPa (80.0 psi) will blow the seals. 
 
 
(11) Electrical controls auto lubricator
(a.) Is vacuum set at a minimum of 138 kPa (20.0 psi?)
(b.) Is pressure set at a minimum of 379 kPa (55.0 psi?)
(c.) Is partial vacuum set at zero? 
 
 
Comments: 
 
 
 
 

Quality and Contamination

Table 12
Description 
(1) Do the current methods and procedures comply with the procedures outlined in the Undercarriage Reconditioning Bulletins and Wall Charts? 
 
 
(2) Are the disassembled components protected from contamination of dirt or debris? 
 
 
(3) Is the general condition of the work area clean and orderly? 
 
 
(4) Is any welding or grinding separated from the Disassembly and Assembly area? 
 
 
(5) Are the work benches neat and clean? 
 
 
(6) Do all the components being reconditioned meet the specifications that are outlined in the Undercarriage Reconditioning Bulletins? 
 
 
(7) Are periodic inspections performed during the pin and bushing turn in a sealed and lubricated track link assembly? 
 
 
(8) Is the track cleaned with high-pressure water before disassembly? 
 
 
(9) Are the track pins and bushings marked and numbered prior to disassembly? 
 
 
(10) Is the track press and contact tooling properly setup to ensure correct alignment and assembly dimensions? 
 
 
(11) Is the link counterbore cleaned with a high-speed rotary wire brush? 
 
 
(12) Do the pin and bushing projections equal the correct dimensions for the link assembly being rebuilt? 
 
 
(13) Is the end play allowance on each assembled joint held to 0.03 mm to 0.20 mm (0.001 inch to 0.008 inch) for a wet turn? 
 
 
(14) Is the track pin and bushing rotated horizontally by 180 degrees? Is the bushing rotated around the track pin by 180 degrees to achieve a correct pin and bushing turn? 
 
 
(15) Is the proper assembly force being set and maintained on the track press? 
 
 
(16) Is a pressure test performed on each track joint prior to lubrication? 
 
 
Comments: 
 
 
 
 

Literature and Materials

Table 13
Description 
(1) Is Undercarriage Reconditioning Guide, SEBF8599 current and complete? 
 
 
(2) Is Servicing Handbook, PEKP9400, "Custom Track Service Handbook" current and available to the track press operator? 
 
 
(3) Is Parts Sales Kit, PECP3003 current and available to the track press operator? 
 
 
(4) Is the track press operator or supervisor maintaining a Track Service Logbook? (Other methods include service report, track form, and so forth) 
 
 
(5) Is the media listed in the "References" section current and available? 
 
 
Comments: 
 
 
 
 

Recommendations

Table 14
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Notes

Table 15
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

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