Caterpillar 242-5360 Portable Track Press D6H,D6R & 963 SystemOne Undercarriage Operating Manual

R

NEHS0915-02 October 2004

TOOL OPERATING MANUAL 242-5360 Portable Track Press, D6H, D6R, and 963 SystemOneTM Undercarriage Operation, Maintenance, and Parts CE Compliant SMCS: 4150

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Important Safety Information

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 also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

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.

The information, specifications, and illustrations in this publication are on the basis of 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.

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 operation, lubrication, maintenance, and repair information.

WARNING 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.

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.

Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.

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.

WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

2

Contents

Literature Information

Literature Information. . . . . . . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Signs and Labels . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Hazard Information . . . . . . . . . . . 5 Personal Protection . . . . . . . . . . . . . . . . . . 5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Pressure Air . . . . . . . . . . . . . . . . . . . . . . . . 7 Trapped Pressure . . . . . . . . . . . . . . . . . . . 7 Fluid Penetration . . . . . . . . . . . . . . . . . . . . 7 Containing Fluid Spillage. . . . . . . . . . . . . . 7 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Portable Track Press . . . . . . . . . . . . . . . . . 7 Hydraulic Power Supply . . . . . . . . . . . . . . 7 Portable Track Press Color Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Portable Track Press To Track Link Chart . . . 9 Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . 9 Additional Contact Information . . . . . . . . . . 11 References. . . . . . . . . . . . . . . . . . . . . . . . . . 11 Specifications. . . . . . . . . . . . . . . . . . . . . . . . 11 Unpack and Inspect . . . . . . . . . . . . . . . . . . 11 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Contact Tooling . . . . . . . . . . . . . . . . . . . . . . 13 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Operating Procedures . . . . . . . . . . . . . . . 14 Pinch Points . . . . . . . . . . . . . . . . . . . . . . . 14 Oil Cleanliness . . . . . . . . . . . . . . . . . . . . . 15 Flow Control Valves . . . . . . . . . . . . . . . . . 15 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Track Connect Procedure . . . . . . . . . . . . . . 16 Required Parts . . . . . . . . . . . . . . . . . . . . . 16 Connect Procedure . . . . . . . . . . . . . . . . . 17 Track Separate Procedure . . . . . . . . . . . . . . 22 Required Parts . . . . . . . . . . . . . . . . . . . . . 22 Separate Procedure. . . . . . . . . . . . . . . . . 22 Maintenance and Repair . . . . . . . . . . . . . . . 27 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Hydraulic Schematic . . . . . . . . . . . . . . . . . . 27 Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Part Numbers and Descriptions . . . . . . . 28 Replacement Decals . . . . . . . . . . . . . . . . 32 Inspection Guide . . . . . . . . . . . . . . . . . . . . . 33 Troubleshooting Chart . . . . . . . . . . . . . . . . . 33 Declaration of Conformity . . . . . . . . . . . . . . 34

This manual should be stored with the portable track press tool.

This manual contains safety information, operation instructions, and maintenance information.

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 portable track press tool.

Whenever a question arises regarding your service tool or this publication, please consult your Caterpillar dealer for the latest available information.

Safety The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning signs and labels used on the service tool.

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

Operation 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 SystemOne™ track links.

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

Maintenance The maintenance section is a guide to equipment care.

3

This decal warns against operating the tool without the guard in place and is located on top of the tool case. Read the Safety section to completely understand the warnings.

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. Please 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.

261-7492

0915-53

This decal warns against hearing and eye damage and is located on top of the tool case.

Read the Safety section to completely understand the warnings.

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 Caterpillar dealer can provide new safety signs.

This decal warns against high pressure and is located on top of the tool case. Read the Safety section to completely understand the warnings.

261-7493

261-7491

0915-52

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

The decal is located on top of the tool case.

Read the Safety section to completely understand the warnings.

0915-54

0915-55

4

General Hazard Information

Safety

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.

WARNING 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.

Do not exceed the portable track presses 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 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.

Personal Protection

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

Wear protective shoes when handling, installing, or removing this track link tooling.

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.

Sharp corners or burrs on track links, or sharp threads on track bolts, can cause cuts. Wear gloves for protection when handling sharp objects.

Wear proper personal protective gear, such as gloves, when operating hydraulic equipment or working around the track link.

Personal injury can result from falls. DO NOT leave tools, hoses, or components laying around the work area.

Personal injury can result from slips. Clean up all spilled fluids immediately.

261-7491

The portable track press is heavy and can cause back injury if not handled properly. Use two people to move and install the track press if necessary.

To prevent personal injury, avoid pinch points such as when assembling the upper cover onto the lower tool tray and/or when installing the unit onto the track.

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.

261-7492

5

Personal Protection (continued)

Hoses

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.

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.

Know how to safely shut-off the hydraulic power supply (energy source). If an emergency situation occurs, immediately shutdown and lock out the equipment.

Do not drop heavy objects on hoses. A sharp impact may cause internal damage to hose wire strands. Applying pressure to a damaged hose may cause it to rupture, resulting in personal injury.

Inspection Inspect all component parts of this tool before each daily use. Check for damage or excess wear on any part. Replace all damaged or worn parts immediately.

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

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 reuse bent threaded components.

Failure of these parts may produce flying objects, which could result in serious injury or even death.

Tooling Do not strike the tooling or any components with a hammer or other similar hand tool when it is pressurized.

Failure to follow this recommendation could result in tool failure causing ejected parts, which will result in personal injury or death.

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.

Do not weld on tool, master link, or any other part of this tooling. Welding can reduce the strength of the tool and/or create a location where cracks can start. Welding can cause tooling failure, resulting in explosively ejected parts.

Do not bend high pressure lines. Do not strike high pressure lines. Do not install bent hoses.

Do not install damaged hoses.

Repair damaged hoses. Leaks can cause fires.

See your Caterpillar dealer for repair or for replacement parts.

Never operate the unit if the plastic viewing window in the rigid guard is cracked or damaged.

Replace the viewing window immediately with a new Caterpillar part.

Check hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. See “General Hazard Information” section in this manual for more details. Tighten all connections to the recommended torque.

Remove plastic pins before installing track link.

Never use steel pins in place of plastic pins.

Replace the parts if any of the following conditions are present: - End fittings that are damaged or leaking - Outer coverings that are chafed or cut - Wire shields that are exposed - Outer coverings that are ballooning - Flexible part of the hoses that are kinked - End fittings that are displaced 6

Pressure Air

Introduction

Pressure air can cause personal injury. When pressure air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.

Portable Track Press The 242-5360 Portable Track Press allows service personnel to remove or install Caterpillar’s SystemOneTM track (234-9699) onto a machine without a master link. The unit can also replace track links at any location around the track chain.

The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.

The portable track press can be used in the shop or out in the field for on-site repairs.

Using this tooling, the track can be disassembled and the track sections can be replaced as needed. Each size and type of track requires specific track tooling. Do not try to repair other types or sizes of track with this tooling.

Trapped 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. Fluid penetration can cause serious injury and possible death.

WARNING This tooling should never be used for any other application other than its intended use; disassembly and assembly of SystemOneTM track.

Using this tooling for any other purpose can result in serious injury or even death.

Fluid Penetration When you check for a leak, use a board or cardboard. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak 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.

This portable track press is compliant to the European Union 98/37/EC Directive and EN 982 requirements. The required Declaration of Conformity document is included in this manual.

Containing Fluid Spillage

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.

Care must be taken in order 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.

Hydraulic Power Supply This unit is designed to work with a dealersupplied 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 to the European Union 98/37/EC Directive and EN 982 requirements.

Oils Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin.

At operating temperature, the hydraulic power supply is hot.

Relieve all pressure before any lines, any fittings, or any related items are disconnected or removed.

7

NOTICE Each size and type of track requires specific track tooling. Do not try to repair other types or sizes of track with this tooling or damage to the tooling or the track could result.

High-pressure hoses [700 bar (10,000 psi) maximum pressure], which are part of this group, connect the portable track press to the dealer-supplied hydraulic power supply.

Refer to Caterpillar’s NENG2500 Tools and Shop Products Guide for possible power supply units.

4a

4b

B

2b A

2a

3a 3b

1 0915-10

Hydraulic System.

(1) 700 bar (10,000 psi) Hydraulic Power Supply.

(2a) Hose A. (2b) Hose B. (3a) Flow Control Valve A. (3b) Flow Control Valve B. (4a) Cylinder A. (4b) Cylinder B.

8

Portable Track Press Color Identification Chart Model

Part No.

Description

Color

D6H, D6R 242-5368

Aluminum Plate As.

Silver

963

Starter Link

Silver

Aluminum Plate As.

Red

Starter Link

Red

D6M, D6N 252-9964

Aluminum Plate As.

Blue

953 T2

Starter Link

Blue

D5G, D5M, 252-9932

Aluminum Plate As.

Green

D5N

Starter Link

Green

242-5369

D3G/D4G 242-5388 242-5362 252-9979 252-9942

Portable Track Press to Track Link Chart Model TTT1

Model TTL2

Track Press Part No.

Pitch

Pitch in Inches

Track Link No.

D3G/D4G

NA

242-5400

175.4

6.91

260-6740

D5G, D5M, D5N NA

252-9918

171.1

6.75

235-2514

D6M, D6N

953 T2

252-9960

190

7.5

235-2501

D6H, D6R

963

242-5360

202.8

8

234-9699

1TTT - Track-Type Tractor 2TTL - Track-Type Loader

Nomenclature 242-5360 Portable Track Press Nomenclature Item Part No.

9

Description

1

242-5393

Flexible Guard Group

2

152-0788

Plastic Storage Bag (hose group and flexible guard)

3

242-5380

Hydraulic Hose Group

4

8S-4757

Bolt (link removal)

5

242-5356

Contact Tool (link removal)

6

252-9911

Contact Tool (link installation)

7

242-5357

Hex Socket Bolt

8

252-9951

Stud (link installation)

9

242-5369

Starter Link

10

2M-5656

Nut (link installation)

11

242-5381

Plate (link removal)

12

242-5379

Plate (link installation)

13

0S-0509

Bolt (flex guard to rigid guard)

14

242-5377

Plastic Locating Pin

15

9W-4381

Track Nut

16

242-5358

Link Support Plate

17

9Y-9024

Track Bolt

18

242-5372

Yoke Plate Group

19

242-5360

Hydraulic Press Group

20

242-5371

Installation Plate

21

1D-4646

Guide Bolt

22

252-9917

Case Group

1 242-5393

®

®

2 152-0788 (2) 242-5380

3

5

242-5356 (2)

6

252-9911 (2)

7 242-5357 (10)

8

4

252-9951 (4)

8S-4757 (4)

9 242-5369

10

12

2M-5656 (8)

242-5379

13 0S-0509

11 242-5381

14

15

242-5377 (6)

9W-4381 (2)

16 242-5358

17 18

9Y-9024 (2)

242-5372

21 1D-4646 (2)

493 261-7

261 -74 91

261-7492

19 242-5360 242-5371

20

22 252-9917

10

0915-01

Additional Contact Information

Unpack and Inspect 1. Remove the shipping box.

For further assistance for ordering or for information on other specialized tooling available for your service operation, contact: Dealer Service Tools 8900 N. Pioneer Road Peoria, IL U.S.A. 61615-1522 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1475 CSTG_Hotmail@cat.com

References NEHS0923

Master Link Tools for SystemOne

REHS1110

Installation and Removal of SystemOneTM Track (elevated sprocket)

REHS2221

Installation and Removal of SystemOneTM Track (oval)

REHS2412

SystemOneTM Link Removal (Link Cutting)

SERF8620

SystemOneTM Service Training (electronic)

SEBF8552

Procedure for Idler Weld Rebuild

SEBF8571

Reconditioning Dimensions for Idlers

SEBF8516

Equipment and Tools for Undercarriage Rebuilding and Reconditioning Stations

SEBF8558

Guidelines for Reusable Track Parts

SEBF8599

Undercarriage Reconditioning Guide

SEBF8619

Field Service Procedure for SystemOneTM Track

TM

2. Remove the four bolts securing the upper rigid guard from the lower tray.

Track

Specifications Hydraulic Power Supply (Energy Source) Type of oil

CAT HYDOTM 10W oil

Maximum hydraulic pressure

700 bar (10,000 psi)

Maximum pump flow

3 lpm (.8 gpm)

Maximum cylinder stroke

38 mm (1.5 in)

Maximum travel speed

2.5 cm/second (1.0 inch/second)

Recommended operating oil temperature

104 to 300°C (40 to 150°F)

11

3. Remove and inspect the flexible guard laying on the top tool tray. Remove each tool tray and inspect for missing or damaged parts.

4. Remove the white protective film from both sides of the viewing window.

12

Setup

Contact Tooling

1. Connect the upper rigid guard (22) to the lower flexible guard (1) using two 0S-0509 Bolts (13).

There are two types of contact tooling; installation and removal. The removal contact tooling has a thicker diameter flange (ring) on the face of the tool (shown on the left).

Installation contact tooling (shown on the right) has a thinner diameter flange (ring).

2. Connect the hydraulic power supply to the cylinders using the hose group. Make sure Hose A is connected to Cylinder A, and Hose B is connected to Cylinder B. 3. Remove all trapped air from the high-pressure hoses and cylinders by fully extending and retracting the cylinders at least three times.

0915-11

Removal

Installation

The removal contact tooling presses on the outer ring of the track pin while the installation contact tooling presses on the inner surface of the track pin.

0915-08

4. Release all pressure from the hoses and the portable track press before moving the unit or removing the hoses.

1

3

NOTE: Make sure there is no pressure in the hoses before disconnecting them. When the cylinders are fully retracted, the pressure inside the cylinders and hose should be zero.

Also make sure the pressure gauge on the hydraulic power supply is reading zero pressure.

WARNING 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).

2

0915-07

(1) Removal contact tooling presses against outer surface of track pin. (2) Installation contact tooling presses against inner surface of track pin. (3) Track pin.

261-7491

13

Pinch Points

WARNING To prevent personal injury, avoid pinch points when installing the unit onto the track, as shown below.

When installing the track press, if the plastic pins do not align with the holes in the track shoe, the pins can be pushed upward, pinching your fingers.

Installation Contact Tooling

Removal Contact Tooling

Operation Operating Procedures

WARNING 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.

Follow the procedures in the REHS1110 or REHS2221 Special Instructions for the specific SystemOneTM track being serviced.

Refer to the “References” chart in this manual for additional operating information.

14

Oil Cleanliness

(–)

Always replace dust caps onto quick-disconnect fittings when the unit is not in use. This will help to prevent oil contamination of the hydraulic power supply.

4

X

A

R

00

M

BA

I/7

0

PS

00

10

1

0915-09

0915-17

Clockwise decreases flow.

(1) From hydraulic power supply (energy source). (4) To hydraulic cylinders.

Flow Control Valves Each hydraulic hose is equipped with a flow control valve. These valves can increase or decrease oil flow to each portable track press cylinder depending on the valve setting. For normal operation, open both valves completely (counterclockwise).

WARNING

261-7491

(+) 4 X

A

R

00

M

BA

I/7

00

PS

0

10

1

0915-16

Counterclockwise increases flow.

(1) From hydraulic power supply (energy source). (4) To hydraulic cylinders.

15

Never leave the flow control valves in a fully closed position when the track press is not being used. A closed control valve can hold stored hydraulic pressure in the track press cylinder and hoses, causing bodily injury if released.

Inspection

Track Connect Procedure

Inspect and clean all the parts of the portable track press before and after each use. Refer to the “Inspection” chart in this manual for additional inspection information.

Perform the following steps in order to connect the SystemOneTM track. The position of the track links that will be installed must be between the final drive and the rear idler.

Three track shoes, at the location of the track link connection, must be removed. Refer to Special Instruction, REHS1110, Installation and Removal of SystemOneTM Track (elevated sprocket) or REHS2221, Installation and Removal of SystemOneTM Track (oval) for additional information on track removal and installation.

WARNING Inspect all component parts of this tool before each daily use. Check for damage or excess wear on any part. Replace all damaged or worn parts immediately.

Required Parts 17

22 3

261-749

7491

If parts are worn or damaged, they must be replaced. All repair/replacement work must be performed by a certified hydraulic technician.

261-

16 15 261-7492

9

8 3

WARNING 12 14

20

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

18

7 19

1

21

6 10 0915-18

16

Item Part No.

Description

1

242-5393

Flexible Guard Group

3

242-5380

Hydraulic Hose Group

6

252-9911

Contact Tool

7

242-5357

Socket Head Screw

8

252-9951

Stud

9

242-5369

Starter Link

10

2M-5656

Nut

12

242-5379

Plate

14

242-5377

Plastic Locating Pin

15

9W-4381

Track Nut

16

242-5358

Link Support Plate

17

218-3274

Track Bolt

18

242-5372

Yoke Plate Group

19

242-5360

Hydraulic Press Group

20

242-5371

Installation Plate

21

1D-4646

Guide Bolt

22

252-9917

Case Group (rigid upper guard)

4. Verify that the correct contact tool is installed onto the hydraulic press. The 252-9911 Contact Tool is used to install the track links.

Connect Procedure NOTE: Some photos may show machines/models different from the actual machine being serviced. The photos represent a typical connect procedure. Refer to REHS1110, Installation and Removal of SystemOneTM Track (Elevated Sprocket) or REHS2221, Installation and Removal of SystemOneTM Track (Oval) for complete connect details.

5. Install yoke plate (18) onto bushings (A). It may be necessary to remove paint, rust, or dirt to install the yoke.

1. Position the ends of the track assembly between the final drive and the rear idler.

Block the track assembly with the appropriate cribbing.

WARNING The plastic locating pins (14), when installed with the portable track press, can create a pinch point during installation. Use care to prevent hand or finger injuries.

2. Check the location of marking (AAA) on the ends of the cartridge pins. The marking should be located near the link rail and opposite the track shoe. If the orientation is not correct, use a strap wrench in order to rotate the cartridge pin to the correct position.

3. Relieve the tension on the track roller frame and then install starter link (9) over cartridge pins.

17

8. Install four threaded rods (8) into plate (20).

The threaded rods should be installed into the recessed counterbore side of the plate.

Install the threaded rods through the plate at least 6.0 mm (.24 in).

6. Use two people or a suitable lifting device in order to position portable track press (19) on starter link (9). Portable track press (19) weighs approximately 19 kg (42 lbs).

Install plastic locating pins (14).

6 mm (.25 in)

0912-48

9. Apply 4C-5598 High Temperature Anti-Seize to the bore of the track link and the cartridge pins. Place track link (B) onto the threaded rods.

NOTE: Portable track press (19) and starter link (9) can fall to the ground before guide bolts (21) are installed. Caution should be taken until Step 7 is performed.

WARNING 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.

7. Install guide bolts (21) through the top plate of portable track press (19). Thread the guide bolts at least 25 mm (1.0 in.) into yoke plate (18).

10. Install plate (20) and track link with four threaded rods through yoke plate (18) and through portable track press (19).

18

14. Before tightening the four nuts, verify that track link (B) is centered over the ends of the cartridge pins. Verify that plate (20) is centered on track link (B). Tighten nuts (10) evenly in order to hold the track link in the proper assembly position.

11. Install plate (12) onto the four threaded rods.

12. Install four nuts (10) onto the threaded rods, finger tight.

15. Install upper rigid guard (22) and lower flexible guard (1) over the portable track press.

13. Remove plastic locating pins (14). Failure to remove the pins will result in destroying the pins. Do not use pins made of any other type of material.

19

16. Insert the two high-pressure hydraulic hoses (3) through the flexible guard (1) and connect them to their respective cylinders. Both the hoses and cylinder ports are labeled with an “A” and “B”.

Make sure the correct hose is connected to the corresponding port.

18. Bolt the guard assembly (upper rigid guard and lower flexible guard) to the track chain in all four locations (two on each side of the guard).

NOTE: Make sure that all connections are clean and tight.

19. View of completely assembled tooling ready to separate a track link.

17. Attach the snaps of flexible guard (1) to rigid guard (22). The flexible guard must be attached at all attachment points.

20. Connect hose assembly (3) to the hydraulic power supply (energy source).

21. Make sure that both flow control valves (C) are in the open position.

20

25. Push the portable track press towards the track link so that the tool is firmly seated on the track. This will reduce the load on the top guide bolts. Reinstall plastic locating pins (14) for added support.

WARNING Never operate without a guard. Do not stand near the portable track press while it 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.

26. Remove four nuts (10). Remove plate (12).

27. Remove plate (20) with four threaded rods (8).

28. Remove guide bolts (4).

22. Turn on hydraulic power supply (energy source). The track link will be pulled onto the ends of the cartridge pins. Watch carefully in order to ensure that the track link is pulled evenly. When the track link is in place, plate (20) will contact the end of the cartridge pins. The gauge on the hydraulic power supply (energy source) will indicate a sharp rise in pressure.

29. Use two people or a suitable lifting device in order to remove portable track press (19). The portable track press weighs approximately 19 kg (42 lbs). Remove starter link (9). Do not remove yoke plate (18).

30. Move portable track press (19) to the opposite side of the track in order to install the second track link.

NOTE: The track link must be pulled evenly onto the ends of the cartridge pins. Turn off the hydraulic power supply (energy source) if one end of the track link is offset more than 6 mm (.24 inch) from the other end of the track link. If one side of the track link has been installed farther, close the valve on the same side. Restart the hydraulic power supply (energy source). When the track link is straight, turn off the hydraulic power supply (energy source). Open both flow control valves (C). Continue the process.

31. Repeat Steps 6 through 29.

32. After installing the second track link and removing the portable track press, remove yoke plate (18).

NOTE: If the track link is pulling onto the ends of the cartridge pins more on the top or the bottom, shut off the hydraulic power supply (energy source) immediately. Remove the tooling. Remove the track link. Inspect the track link for damage to the bores. If the bores of the track link have been damaged, replace the track link with a new track link.

23. Turn off the hydraulic power supply (energy source) when the track link is in place. Open the flow control valves completely. Allow the oil to return to the reservoir. Springs will force the hydraulic cylinders of the main service tool to return to the start position.

24. Remove the two high-pressure hoses from the cylinders. Remove the upper rigid and lower flexible guard.

21

Required Parts

Track Separate Procedure

9

22 261-74

93

Perform the following steps in order to separate the SystemOneTM track. The position of the track links that will be removed must be between the final drive and the rear idler.

Three track shoes, at the location of the track link separation, must be removed. Refer to Special Instruction, REHS1110, Installation and Removal of SystemOneTM Track (Elevated Sprocket) or REHS2221, Installation and Removal of SystemOneTM Track (Oval), for additional information on track removal.

2617491

261-7492

11

14 3

18

5

12 7

1

21

4

19

0915-19

Item Part No.

Description

1

242-5393

Flexible Guard Group

3

242-5380

Hydraulic Hose Group

4

8S-4757

Bolt

5

242-5356

Contact Tool

7

242-5357

Socket Head Screw

9

242-5369

Starter Link

11

242-5381

Plate

12

242-5379

Plate

14

242-5377

Plastic Locating Pin

18

242-5372

Yoke Plate Group

19

242-5360

Hydraulic Press Group

21

1D-4646

Guide Bolt

22

252-9917

Case Group (rigid upper guard)

Separate Procedure NOTE: Some photos may show machines/models different from the actual machine being serviced. The photos represent a typical connect procedure. Refer to REHS1110, Installation and Removal of SystemOneTM Track (Elevated Sprocket) or REHS2221, Installation and Removal of SystemOneTM Track (Oval) for complete connect details.

22

1. Position the ends of the track assembly between the final drive and the rear idler.

Block the track assembly with the appropriate cribbing.

WARNING The plastic locating pins (14), when installed with the portable track press, can create a pinch point during installation. Use care to prevent hand or finger injuries.

2. Relieve the tension on the track roller frame.

NOTE: Remove three track shoes at the location of the track links that will be removed.

Remove the shoe that is directly on the track links that will be removed. Remove one track shoe on either side of the track links that will be removed. Clean the bushings. Clean the track links. Any large amounts of dirt or rust may inhibit the tool from aligning properly.

5. Use two people or a suitable lifting device in order to position portable track press (19) on track link (D). Portable track press (19) weighs approximately 19 kg (42 lbs).

Install plastic locating pins (14) in order to secure the portable track press to the track link.

3. Install yoke plate (18) onto the bushings.

4. Verify that the correct contact tool is installed on the hydraulic press. The 242-5356 Contact Tool is used for removing the track links.

NOTE: Portable track press (19) can fall to the ground before guide bolts (21) are installed. Caution should be taken until Step 6 is performed.

23

9. Insert plate (11) between yoke plate (18) and portable track press (19). Thread bolts (4) into plate (11).

6. Install two guide bolts (21) through portable track press (19) and into yoke plate (18).

7. Remove the two plastic locating pins (14).

Failure to remove the pins will result in destroying the pins. Do not use pins made of any other type of material.

10. Make sure the portable track press is firmly in place and tighten the bolts.

11. Install upper rigid guard (22) and lower flexible guard (1) over the portable track press.

8. Install four bolts (4) through plate (12) and portable track press (19).

24

12. Insert the two high-pressure hydraulic hoses (3) through the flexible guard (1) and connect them to their respective cylinders. Both the hoses and cylinder ports are labeled with an “A” and “B”.

Make sure the correct hose is connected to the corresponding port.

14. Bolt the guard assembly (upper rigid guard and lower flexible guard) to the track chain in all four locations (two on each side).

NOTE: Make sure that all connections are clean and tight.

15. View of completely assembled tooling ready to separate a track link.

13. Attach the snaps of flexible guard (1) to rigid guard (22). The flexible guard must be attached at all attachment points.

16. Connect the hose assembly (3) to the hydraulic power supply (energy source).

17. Make sure that both flow control valves (C) are in the open position.

25

NOTE: Remove top and bottom bolts (4) first.

Then remove one of the middle two bolts. The remaining bolt will hold back plate (12) and the track link in place until you are ready to remove them.

WARNING

261-7492

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.

23. Remove top guide bolts (21).

24. Use two people or a suitable lifting device in order to remove portable track press (19). Portable track press (19) weighs approximately 19 kg (42 lbs). Do not remove yoke plate (18).

25. Move portable track press (19) to the opposite side of the track in order to remove the second track link.

18. Turn on hydraulic power supply (energy source). The track link will be pulled off the ends of the cartridge pins. Watch carefully in order to ensure that the track link is removed evenly.

26. Repeat Steps 4 through 24 on the opposite track link.

NOTE: The track link must be pulled evenly off the ends of the cartridge pins. Turn off the hydraulic power supply (energy source) if one end of the track link is offset more than 6 mm (.24 inch) from the other end of the track link.

Close the valve on the side of the track link that is farther off the end of the cartridge pin.

Restart the hydraulic power supply (energy source). When the track link is straight, turn off the hydraulic power supply (energy source).

Open both flow control valves (C). Continue the process.

27. After installing the second track link and removing the portable track press, remove yoke plate (18).

28. Follow the instructions in REHS1110 or REHS2221 Special Instructions or appropriate Service Manual to reinstall the track.

19. Turn off the hydraulic power supply (energy source) when the track link is removed. Open the flow control valves completely. Allow the oil to return to the reservoir. Springs will force the hydraulic cylinders of the main service tool to return to the start position.

20. Remove the two high-pressure hoses from the cylinders. Remove the upper rigid and lower flexible guards.

21. Push the portable track press toward the track link so that the tool is firmly seated on the track. This will reduce the load on the top guide bolts. Reinstall plastic locating pins (14) for added support.

22. Remove four bolts (4), front plate (11), and back plate (12). Remove one of the center bolts last. This holds the link in place while removing the back plate.

Remove track link (D).

26

Maintenance and Repair

Hydraulic Schematic

There are no parts that require periodic maintenance.

4a

If, after inspection, the hydraulic cylinder(s) shows signs of leakage, the cylinder(s) should be replaced. Use the following procedure.

4b

1. If attached, disconnect the hydraulic hoses.

2. Unscrew the cylinder from the track press housing in a counterclockwise direction.

3. Fully thread a new cylinder into the housing until it is fully seated into the threaded bore.

2a

4. If necessary, the cylinders can then be unscrewed in the counterclockwise direction to align the quick disconnect fittings to point downward.

2b 3b

3a 1

0912-18

Storage All the parts of the portable track press are designed to fit inside the metal case using the foam inserts provided with the tooling and should be stored in the case when not in use.

4a

4b

B

2b A

2a

3a 3b

1 0915-10

Hydraulic Schematic.

(1) 700 bar (10,000 psi) Hydraulic Power Supply.

(2a) Hose A. (2b) Hose B. (3a) Flow Control Valve A. (3b) Flow Control Valve B. (4a) Cylinder A. (4b) Cylinder B.

27

Parts WARNING 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.

Part Numbers and Descriptions

B

A

A

B

7

B A

0915-06

242-5360 Portable D6H, D6R, and 963 Track Press Tooling Item Part No.

Description

A

Sub As. Hydraulic Group

242-5370

See page 29

B

242-5390

Hardware Group

See page 30

7

242-5380

Hydraulic Hose Group

See page 31

28

5

7

6

19a 19b 19c 22

19d

1

0915-05

242-5370 Sub-Assembly Hydraulic Group “A” Item Part No.

Description

1

242-5393

Flexible Shield Group

5

242-5356

Rod End Contact (Removal)

6

252-9911

Rod End Contact (Installation)

7

242-5357

Socket Head Screw

19a 242-5368

Retainer Plate As.

19b 242-5355

Cylinder Plate

19c

Hydraulic Cylinder

242-5354

19d 3F-7147

Bolt

22

Case Group

252-9917

29

0915-03

8 20

18

14

4

9 10 21 15, 17 16

12

242-5390 Hardware Group “B” Item Part No.

Description

4

8S-4757

Bolt

8

252-9951

Stud

9

242-5369

Starter Link

10

2M-5656

Nut

11

242-5381

Plate

12

242-5379

Plate

14

242-5377

Locating Pin

15

9W-4381

Track Nut

16

242-5358

Link Support Plate

17

9Y-9024

Track Bolt

18

242-5372

Yoke Plate Group

20

242-5371

Installation Plate

21

1D-4646

Bolt

30

12

11

7 7d

7c

7f

A

7b 7a 7e

B 7f

7g

0915-04

242-5380 Hydraulic Hose Group (7) Item Part No.

Description

7a

1P-2375

Connector Coupler As.

7b

242-5364

Pipe Nipple

7c

242-5366

Straight Elbow

7d

242-5365

Shut Off Valve (Flow Control)

7e

242-5361

Pipe Tee

7f

242-5359

Hose As.

7g

242-5363

Dust Cap

31

Replacement Parts 22c

0915-02

22 261-7491

22b 22d

261-7492

22d 22a 22f

22c

261-7492

261-7491

261-7493

22e

22e 261-7493

22f 22b

Replacement Parts Item

Part No.

Description

22

252-9917

Case Group

22a 242-5397

Plastic Viewing Window1

22b 156-3815

CE Decal

22c

261-7491

Do Not Operate Without Guard Decal

22e 261-7493

Safety Glasses/Ear Protection Decal

22f

Read Manual Decal

22g 252-9899

22m

22h

22i 22g

Foam Group (includes 22h through 22k and two 152-0788 Plastic Storage Bags)

22h 252-9936

Foam Block Group (Top, Layer 1)

22i

252-9935

Foam Block Group (Layer 2)

22j

252-9946

Foam Block Group (Layer 3)

22k

252-9945

Foam Block Group (Bottom, Layer 4)

22m 152-0788

®

Remove Pressure Warning Decal

22d 261-7492

224-0554

®

22j

22k 0915-61

Plastic Storage Bags

1 Service replacement part.

32

Inspection Guide Inspection Guide Item

Visual Inspection

Possible Solution

Plates

Check for cracks.

Replace the plate if cracks are found.

Bolts

Check bolt threads for damaged or galled threads.

Replace any damaged bolts.

Hydraulic hoses

Inspect all hoses for damage, cracks or abrasions to the outer covering, and/or leaks.

Replace any damaged hoses.

Hydraulic cylinders

Check the fittings for leakage.

Replace the fittings. If this does not correct the leakage, replace the cylinder(s).

Contact tooling

Inspect the tooling for excessive wear or cracks.

If any damage is found, replace the tooling.

Safety window

Make sure the window is securely held in place. Also check for cracks or discoloration of the plastic.

Replace the window if any of these conditions are found.

Rigid guard

Check the rigid guard for tears or cracks.

Replace the rigid guard if damaged.

Flexible guard

Check the guard for tears.

Replace the guard if damaged.

Troubleshooting Chart Troubleshooting Chart Problem Hydraulic force not applied by cylinders.

Parts of tool will not assemble.

Tool is operated at full operating pressure but link does not disassemble.

Hydraulic leakage.

Viewing window is not clear.

Possible Cause

Possible Solution

Hydraulic power source malfunctioning.

Check oil level. If oil level is correct, fix or repair hydraulic power source.

Needle valves closed.

Open needle valves.

Hydraulic leak.

Repair leak.

Quick disconnect fitting is not completely seated.

Completely connect or seat the fitting.

Damaged threads.

Replace threaded items.

Check part numbers.

Use correct part numbers.

Misaligned tooling.

Align tooling.

Check condition of link.

Replace link.

Damaged threads.

Replace threads.

Worn contact tool.

Replace contact tooling.

Link is stuck.

Apply light, hydraulic oil to the inside bore of the track link. Contact CPI.

Leaky cylinder(s).

Replace cylinder.

Leaky hose(s).

Replace hose.

Leaky fitting(s).

Tighten or replace fitting.

Age or chemical damage.

Replace viewing window

33

Declaration of Conformity

34

Notes

35

For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 8900 N. Pioneer Road Peoria, IL U.S.A. 61615-1522 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1475 CSTG_Hotmail@cat.com

©2004 Caterpillar All Rights Reserved

36

NEHS0915-02 Printed in U.S.A.