NEHS1249 100T Track Repair Group {0374, 0599, 0700, 0729, 4169, 4170} Caterpillar

Excavator

All

Track-Type Tractor

All

Introduction

Important Safety Information

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Think Safety

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.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety Section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts Section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

No Smoking

Hazard Avoidance

Crushing Hazard (foot)

Crushing Hazard (hand)

Pinch Point

Fire Hazard

Electrical Shock - Hazard

Fire Hazard

Safety Section

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

Introduction

© 2017 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. This Tool Operating Manual contains information to allow a dealer to operate the 100T Track Repair Group and service typical track groups except for SystemOne. Do not use this Track Repair Group to service SystemOne link assemblies without the proper tooling. Refer to Reuse and Salvage Information to determine when to repair and when to replace track group components. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might cause changes to product that is not included in this publication. This Tool Operating Manual must be used along with the latest technical information that is available from Caterpillar. See the Referenced Publications below. For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Cat Repair Process Engineering: · Cat Dealer Technical Communicator · Dealer Solution Network · Cat Technical Representative · Knowledge Network

Contact Information

For product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

USA: 1-800-542-8665, Option 1

International: 1-309-578-7372

Summary

This guideline provides the procedure for removal and installation of track pins to repair or replace dry joints in the shop or field. Note: The procedure in this guideline repairs the damaged track joint on the ground not on the machine.

References

Refer to the Operation and Maintenance Manual for your equipment. Additional Information may be found in:

Literature Information

This manual should be stored with the 492-1988 Track Repair Group. It contains information regarding safety, operation, and maintenance. Some photographs or illustrations in this publication show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your service tool which are not included in this publication. Read, study, and keep this manual with the Track Repair Group. Whenever a question arises regarding your service tool or this publication, consult your Cat dealer for the latest available information.

Safety Signs and Labels

There are several specific safety signs on this product. The exact location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety signs.

Make sure that all of the safety signs are legible. Clean the safety signs or replace the safety signs if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the safety signs, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety signs. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety sign. Loose adhesive will allow the warning sign to fall.

Replace any safety sign that is damaged or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. Any Cat dealer can provide new safety signs.

Read the Safety section to completely understand the warnings.

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The decal above warns about high pressure.

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The decal above warns against operating the tool without the guard in place and is on top of the guard and the bolster. Read the Safety Section completely to understand the warnings.

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The decal above warns against hearing and eye damage and is on top of the tool case. Read the Safety Section to completely understand the warnings.

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This decal warns against bodily injury if the tool is operated without fully reading and understanding this and other related manuals. The decal is on top of the tool case.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by Caterpillar is not used, you must satisfy yourself that it is safe for you and for others. You should ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance, or repair procedures that you choose. The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material. Do not weld on the tool components. Welding can reduce the strength of the tool and cause failures resulting in explosively ejected parts. Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.

Safety

To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment or tools. Do not operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals. Contact Dealer Service Tools for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

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.

Do not place any part of your hand or body between the hydraulic cylinder or tooling and the track chain. The track repair group uses pressures up to 700 bar (10,000 psi) which will cause bodily injury (crushing).

The hydraulic system can be pressurized to 700 bar (10,000 psi). Make sure that all hydraulic pressure has been relieved before disconnecting hoses or servicing the unit. Personal injury can result from removing hoses or quick disconnect fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.

General Hazard Information

This unit is designed for a maximum pressure of 700 bar (10,000 psi). Use care when this unit is connected to a portable hydraulic supply. Do not exceed the maximum pressure ratings. Overloading causes equipment failure and possible personal injury. Do not connect this unit to a pump or power supply with a higher pressure rating. Check high-pressure hydraulic hoses carefully. DO NOT use your bare hand to check for potential leaks. Always use a board or cardboard when checking for a leak. Escaping hydraulic fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

To prevent personal injury or even death from ejected parts or flying objects, never remove guards during operation of the track repair group. Never remove guards when the tool is under pressure.

Personal Protection

Wear proper personal protective gear, such as gloves, when operating hydraulic equipment or working around the track link assembly. Wear protective shoes when handling, installing, or removing this track links, track repair group, or tooling. Personal injury can result from falls. DO NOT leave tools, hoses, or components lying around the work area. Sharp corners or burrs on track links, or sharp threads on track bolts, can cause cuts. Wear gloves for protection when handling sharp objects. Personal injury can result from slips. Clean up all spilled fluids immediately. The track repair group is heavy and can cause back injury if not handled properly. Use a crane or other lifting device to move the track repair group as needed. To prevent personal injury, avoid pinch points when assembling the tool and/or when positioning the tool onto the track. The portable track press weighs enough to cause personal injury if dropped onto your hand or foot. Always wear protective shoes and use care when handling the unit. Know how to safely shut-off the hydraulic power supply (energy source). If an emergency situation occurs, immediately shut down and lock out the equipment.

Inspection

Inspect all components of this tool before each use. Check for damage or wear on any part. Replace all damaged or worn parts immediately. Do not reuse bent or deformed threaded components. Failure of these parts may produce flying objects, which could result in serious injury or even death. Refer to the "Inspection Guide" in this manual for additional inspection information.

Hydraulic Power Supply (Energy Source)

Hydraulic equipment must only be serviced by a qualified hydraulic technician. For repair service, contact Dealer Service Tools.

This unit is designed to work with a hydraulic power supply (energy source) equipped with a 700 bar (10,000 psi) maximum pressure relief valve and hoses rated for that working pressure. The hydraulic power supply should be compliant with European Union Directives and Requirements. Refer to Cat NENG2500 Tools and Shop Products Guide for possible power supply units.

The hydraulic system can be pressurized to 700 bar (10,000 psi). Make sure that all hydraulic pressure has been relieved before disconnecting the hoses. Personal injury can result from removing hoses in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved (zero pressure).

Pressure can be trapped in a hydraulic system. Trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings. High-pressure oil that is released can cause a hose to whip while oil is spraying. Relieve all pressure before any lines, any fittings, or any related items are disconnected or removed.

High-pressure hoses [700 bar (10,000 psi) maximum pressure], are required to be used with this Track Repair Group. Connect the Track Repair Group to a recommended hydraulic power supply.

457-0818 Hydraulic Power Supply (115V - 5 Gal Tank) 457-0819 Hydraulic Power Supply (230V - 5 Gal Tank)

Illustration 7	g03740575

Fluid Penetration

Check hoses carefully. Tighten all connections to the recommended torque. When you check for a leak, use a board or cardboard. Fluid penetration can cause serious injury and possible death. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. Pin hole leaks can cause severe injury. If fluid is injected into your skin, you must obtain treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Oils

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At operating temperature, the hydraulic power supply is hot. Hot oil and components can cause personal injury. Do not allow hot oil to contact the skin.

Oil Cleanliness

Always place dust caps onto quick-disconnect fittings when the unit is not in use to helps prevent contamination of the hydraulic power supply and related components.

Hoses

Avoid damaging hydraulic hoses. Avoid sharp bends and kinks when routing hydraulic hoses. Using a bent or kinked hose will cause severe back-pressure. Sharp bends and kinks will internally damage the hose, leading to premature hose failure resulting in personal injury. Do not drop heavy objects on hoses. Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install bent hoses. Do not install damaged hoses. Keep this unit and high-pressure hoses away from flames and excessive heat. Excessive heat will soften packings and seals, resulting in fluid leaks. Heat also weakens hose materials and packings. For optimum performance, do not expose equipment to temperatures of 65°C [150°F] or higher. Protect hoses and cylinders from weld spatter. Do not handle pressurized hoses. Escaping oil under pressure can penetrate the skin, causing serious injury. If oil is injected under the skin, see a doctor immediately. Never operate equipment with a known malfunction or leak.

Containing Fluid Spillage

Care must be taken to ensure that hydraulic oil is contained during installation and removal of hoses. Be ready to collect the oil before removing any hoses. Obey all local regulations for the disposal of liquids.

Operation

492-1988 Track Repair Group (100T) General Information

The 492-1988 Track Repair Group and related tooling allows qualified service personnel to remove or install track pins into track link assemblies on track chain. This group can be used in the shop or in the field. Each track size and type requires specific track tooling. To avoid personal injury or death, carefully read and understand all instructions in this and all other applicable manuals before attempting to operate this tool.

This tooling should never be used for any other application other than the intended use of removing and installing track pins. Using this tooling for any other purpose can result in serious injury or even death.

This Track Repair Group is compliant to the European Union Directives and Requirements. The required Declaration of Conformity document is included in this manual.

Note: The sound level of this tool without hydraulic supply does not exceed 70 dB(A). However, the actual sound levels, when in use, can be much higher depending on the hydraulic power supply and track-generated noise during pressing.

Unpack and Inspect

Remove the lid from the top of the shipping crates by removing the screws in the top panel. Remove and inspect the flexible guard lying on the top tool tray. Remove blocking from the crate. Inspect for missing or damaged parts. Remove any protective film from the guard to create an unobstructed view.

Setup

Connect the hydraulic power supply to the cylinders using the hose group. Make sure Hose A is connected to Cylinder Port A, and Hose B is connected to Cylinder Port B. Remove all trapped air from the high-pressure hoses and cylinders by fully extending and retracting the cylinders several times. Connect the two high-pressure hydraulic hoses the cylinders. Power Supply ports are labeled with an "A" and "B". Make sure that the correct hose is connected to the corresponding port.

Note: Make sure that all connections are clean and tight. Connect hose assembly to the hydraulic power supply (energy source).

492-1988 Track Repair Group (100T) Nomenclature

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Contact Tooling

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Shown above, is a general guide to help identify the different contact tooling that may be required.

Removal of Track Pin

Pinch Point

1. Use a CE Compliant Load Positioner Group to suspend the track repair group. Load Positioners make it easier to handle the track repair group.
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2. Use wooden blocks to provide clearance for the Track Repair Group. Place the blocking perpendicular to and below the bottom of the track link assembly. Blocking height should be so that the center line of the pin is at or slightly below the center of the hydraulic cylinder rod. Center line of the Track Repair Group is 181.0 mm (7.13") above the bottom of the Track Repair Group.
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3. Remove the Acme threaded nuts (7) and Back Plate (1) from the track repair group.

4. Install correct forcing pin (A) by threading it completely onto the threaded adapter (11). Failure to thread the forcing pin completely onto the adapter may cause deformation of the threads and make it difficult to remove. The forcing pin must be slightly smaller in diameter than the track pin in order to pass through the pin boss of the link to fully disassemble the track pin.

5. Use a Load Positioner to locate the Track Repair Group so that the tie rods are above and below the link assembly that is to be serviced.
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6. Connect the hydraulic lines to the Track Repair Group. The hose from valve port "A" (Extend) must be attached to the piston end of the hydraulic cylinder. The hose from valve port "B" (Retract) must be attached to the quick coupler that is on the rod end of the cylinder. Connect the hydraulic lines to the Track Repair Group. The hose from valve port "A" (Extend) must be attached to the piston end of the hydraulic cylinder. The hose from valve port "B" (Retract) must be attached to the quick coupler that is on the rod end of the cylinder. Connect the hydraulic lines to the Track Repair Group.

7. Set proper pressures on the hydraulic power supply. Only use minimum pressure required to perform the disassembly process. Excessive pressure could lead to damage to contact tooling or the link assembly.
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8. Install the correctly sized Pin Receiver (C) into the Back Plate (1). Magnets are permanently installed into the Back Plate to help retain the Pin Receiver. Inside diameter of the Pin Receiver (C) must be larger than the track pin being removed.

9. Install Back Plate (1) onto the ends of the all of the Tie Rods (2) and secure with ACME Nuts (7) that are hand tightened only.
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10. Carefully align Tooling (A) and Tooling (C) on the track link assembly. Carefully align the center line of the track pin with the tooling.
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    Illustration 17	g03741623

11. Install the Top Guard Assembly, Nut Guard (4), and Pin Basket (5) onto the Back Plate (1). Extend the ram and assembled tooling slowly until the track pin is trapped between the Forcing Pin and the Removal Adapter. Slowly extend the cylinder rod to push the track pin completely through the opposite side link and into the pin basket. Once track pin has been removed, remove the pin basket. Basket cannot be removed unless pin has been pressed through the pin boss of the opposite side link.
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    Illustration 18	g03741666

12. As the cylinder is retracted, insert Alignment / Pilot Pins (B) through the pin bosses of both the Right-Hand and Left-Hand links.

13. Repeat the process to remove additional track pins as needed to perform service.

Track Pin Installation

1. Use the 6V-3160 Double Acting Cylinder between the raised links to spread the links apart. Rotate the mating links to the full extent of the upward arc. Carefully align the bushing with the seals and lower the hoist to position the link airs together, at the same time. Allow the joint to fold together.

2. After the two link pairs are in alignment, install a guide pin. Release the hydraulic pressure and remove the 6V-3160 Double Acting Cylinder.

3. Lubricate the new stopper with lightweight oil and install the stopper in the pin end.

4. Use a CE Compliant Load Positioner Group to suspend the Track Repair Group. A Load Positioner will make it easier to handle the Track Repair Group.
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   Illustration 19	g03741209

5. Use wooden blocks to provide clearance for the Track Repair Group. Place the blocking perpendicular to and below the bottom of the track link assembly. Blocking height should be so that the center line of the pin is at or slightly below the center of the hydraulic cylinder rod. Center line of the Track Repair Group is 181.0 mm [7.13"] above the bottom of the Track Repair Group.
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   Illustration 20	g03741690

6. Remove the Acme threaded nuts (7) and Back Plate (1) from the track repair group

7. Install the new track pin with the cross hole towards the wear surface of the links, and position the pin with the oil hole facing the same side of the track as the other pins.
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   Illustration 21	g03741705

8. Align Track Pin, the tooling with the links as close as possible. Press the pin into the link pin bores.
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9. Do not remove the guide pin from the link bore until the guide pin is pushed out completely. Once the pin is installed completely, increase the hydraulic pressure to the proper assembly force. This pressure ensures that the joint is properly assembled to "ZERO" end play.

10. Pin projection is set by the counter bore in the Piston Rod Cap. Remove all foreign material such as burrs and cold-flowed material from the counter bore and the pin boss of the links.

11. Move the tooling to the second joint and install the track pin, following the same procedure.

12. Remove the track repair group.

Maintenance and Repair

Inspect all component of this tool before each use. Check for damage or wear on any part. Replace all damaged or worn parts immediately. Do not reuse bent or deformed threaded components. Failure of these parts may produce flying objects, which could result in serious injury or even death.

Refer to the "Inspection Guide" in this manual for additional inspection information.

Parts

When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material. Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.

Note: Current tools are found in the Dealer Service Tool Catalog NENG2500.

Troubleshooting Chart

Declaration of Conformity

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Note

Current tools are found in the Dealer Service Tool Catalog NENG2500.