Caterpillar 300T Track Press Maintenance Tool Operating Manual - PDF DOWNLOAD

R

TOOL OPERATING MANUAL Caterpillar 300T Track Press Maintenance SMCS: 0729, 4169

NEHS0827 December 2002

Contents

Safety

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . 7 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Small Hydraulic Cylinder . . . . . . . . . . . . . 10 Large Hydraulic Cylinder . . . . . . . . . . . . . 10 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic System. . . . . . . . . . . . . . . . . . . . 16 Inspection . . . . . . . . . . . . . . . . . . . . . . . . 18 Motor and Pumps . . . . . . . . . . . . . . . . . . 18 Main Control Valve . . . . . . . . . . . . . . . . . . 19 Accessory Hydraulic Circuit . . . . . . . . . . 20 Hydraulic Rams . . . . . . . . . . . . . . . . . . . . 20 Hydraulic Tanks . . . . . . . . . . . . . . . . . . . . 21 Relief Valves . . . . . . . . . . . . . . . . . . . . . . 21 Adjustments. . . . . . . . . . . . . . . . . . . . . . . . 21 Calibrate Tonnage . . . . . . . . . . . . . . . . . . 21 Pressure Switch . . . . . . . . . . . . . . . . . . . . 22 Indexer Belt . . . . . . . . . . . . . . . . . . . . . . . 22 Lubrication Points . . . . . . . . . . . . . . . . . . . 23 Electrical Control Boxes . . . . . . . . . . . . . . . 24 Operator Control Box . . . . . . . . . . . . . . . . 25 Transformer Control Box. . . . . . . . . . . . . . 25 Pendant Control Box . . . . . . . . . . . . . . . . 28 Electrical Control Functions . . . . . . . . . . . . 28 Power Disconnect Switch. . . . . . . . . . . . . 28 Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Start Hydraulics . . . . . . . . . . . . . . . . . . . . 29 Pendant Power. . . . . . . . . . . . . . . . . . . . . 29 Pad Lift Up. . . . . . . . . . . . . . . . . . . . . . . . 29 Pad Lift Down . . . . . . . . . . . . . . . . . . . . . 29 Winch In . . . . . . . . . . . . . . . . . . . . . . . . . 30 Winch Out . . . . . . . . . . . . . . . . . . . . . . . . 30 Door Switch . . . . . . . . . . . . . . . . . . . . . . . . 30

Most accidents involving product operation, maintenance, and repair occur through failure to observe basic safety rules or operations. An accident can often be avoided by being alert and recognizing potentially hazardous situations before an accident occurs. Any individuals performing product operation, maintenance, or repair should have the necessary training, skills, and tools required to perform the functions properly and safely. The safety information in this manual serves as a basic guide in an attempt to prevent injury or death.

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 mentioned by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. Make sure the product or machine will not be damaged or be made unsafe by any operation, lubrication, maintenance, or repair procedures that you choose.

If any doubt arises about the correct, safe method of performing any steps of these procedures, DO NOT proceed. Seek out expert assistance from a qualified person.

NOTE: Caterpillar reserves the right to make technical changes for product improvement.

This manual may contain illustrations and photographs, for demonstration purposes, which slightly deviate from the actual product design.

2

To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment. 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 CSTG for replacement manuals.

Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

Personal injury can result from hydraulic oil pressure or hot oil. DO NOT remove a hydraulic tank filler cap unless it is cool enough to touch with your bare hands. Relieve all pressure in a hydraulic system before any caps, lines, fittings, or related items are disconnected or removed.

Contact with hot oil or hot components can result in severe burns.

D O NOT touch any hot oil or

Always wear protective clothing while operating any machinery. DO NOT wear loose clothing, jewelry, watches, or anything else that might catch on controls, tooling, side bars, or any other part of the track press.

components.

To prevent personal injury, make sure all protective guards and covers are in place and secured before operating any equipment.

Keep fingers away from any moving parts or pinch points to prevent pinching and crushing. When operating the track shoe pad lift, keep hands away from the conveyor rails, because the track shoe support structure passes between the outer rails of the conveyor.

To prevent hand injury, DO NOT use a winch cable that is kinked or frayed. Wear protective gloves while handling the winch cable.

Make sure all limit switches are in proper working order (one for each hydraulic ram and one for the safety door).

Components or debris can be violently propelled when placed under extreme pressure, resulting in personal injury.

To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying debris before striking any object.

To prevent personal injury, use the minimum pressure required to continuously assemble/disassemble the track. Excessive pressure can be hazardous to the operator and damage the track components and tooling.

Check hydraulic oil lines, tubes, and 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.

Personal injuries can occur as a result of using pressurized air.

Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes. Wear protective clothing, protective glasses, and a protective face shield when using pressure air.

3

• three Emergency Stop buttons — these buttons are used to shut down the power to the track press, especially in an emergency situation.

Personal injury or death can result from a fire. Oil leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled oil immediately.

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately.

EMERGENCY STOP

Contact with electrical components can cause injury or death. Always completely disconnect the main power before working on the instrument and before opening an electrical control box.

Remove all jewelry and avoid any contact with electrical components. Use properly insulated tools when maintaining electrical equipment.

0826-50

Illustration 1. Emergency Stop Button.

NOTE: An Emergency Stop button is located on the operator control box, the transformer control box, and the pendant control box.

• Power Disconnect switch — shuts down all electric power to the track press for maintenance operations.

Features The Caterpillar 300T Track Press includes several safety features, including: • a safety door — a 9.65 mm (.380 in), three-piece polycarbonate sliding door equipped with door stops, operating on a “Dual-Vee” rail and roller system.

• a safety door switch — a proximity switch is programmed to indicate when the safety door is closed so the track press may attain ram force above 24 tons.

Illustration 2. Power Disconnect Switch.

NOTE: The track press WILL NOT operate correctly if the safety door switch is tampered with to indicate it is always shut.

NOTE: The Power Disconnect switch is located on the transformer control box.

4

Nomenclature

Illustration 1. 300T Track Press (Front View).

Illustration 2. 300T Track Press (Back View).

5

Illustration 3. 300T Track Press Left-Hand View (Back) With Indexer Table.

Illustration 6. 300T Track Press Operator Station.

(1) Operator Control Box. (2) Hydraulic Controls.

Illustration 4. 300T Track Press Center View (Back) With Indexer Table.

Illustration 7. 300T Track Press Work Table.

Illustration 8. 300T Track Press Work Table (Close Up).

Illustration 5. 300T Track Press Right-Hand View (Back) With Indexer Table.

6

Hydraulic Cylinders Parts List Chart A. 300T Track Press Parts List Item Qty.

Part No.

Description

1

1

0808-07-01

Base Frame

2

1

0808-07-03

Left-Hand Side Plate

3

1

0808-07-02

Right-Hand Side Plate

4

20

6V-7977

Bolts

5

20

3S-6162

Washer

6

1

0808-07-06

Top Plate Assembly (Not Shown)

7

2

0808-07-07

Rod Wiper

8

2

0808-07-08

Wear Ring, 38.1 mm (1.50 in) wide x 254 mm (10.0 in) diameter

91

4

0808-07-09

101

4

8L-6059

111

4

0808-07-11

Wear Ring, (3x1)

121

16

0808-07-12

Tie Rods, 5/8-11

131

16

4K-0367

Nut, 5/8-11

141

16

2J-3506

Washer, 5/8-11

151

4

0808-07-15

Tube

161

4

0808-07-16

Cylinder Rod

171

4

0808-07-17

Gland

181

8

0808-07-18

O-ring

191

4

0808-07-19

Poly-Pak Seal

201

8

0808-07-20

Backup Seal

211

4

0808-07-21

End Cap

221

4

0808-07-22

Piston

231

4

0808-07-23

Piston Wear Ring

241

8

0808-07-24

Piston Poly-Pak Seal

252

2

0808-07-25

Tube

262

2

0808-07-26

Press Ram

272

2

0808-07-27

End Cap

282

2

0808-07-28

O-ring

292

20

4L-8515

Bolt, 1/2-13 x 76.2 mm (3.00 in) long

302

20

8B-7979

Bolt, 1/2-13 x 63.5 mm (2.50 in) long

312

2

0808-07-31

Piston Adapter, 108 mm (4.25 in)

322

1

0808-07-32

Piston

332

2

0808-07-33

Wear Ring, 38.1 mm (1.50 in) wide x 362.0 mm (14.25 in) diameter

342

2

0808-07-34

Poly-Pak Seal

352

16

0808-07-35

Tie Rod, 44.5 mm (1.75 in)

362

16

0808-07-36

Nut

373

2

170-2503

Connecting Bar Assembly

38

12

0808-07-38

Bolt, 1-8 x 114.3 mm (4.50 in) long

C79781T1

Illustration 1. 170-2503 Connecting Bar Assembly.

Chart B. 170-2503 Connecting Bar Assembly Serviceable Parts

Bushing

Part No.

Bolt, 1-8 x 63.5 mm (2.50 in) long

1 Part of the small cylinder assembly.

2 Part of the large cylinder assembly.

3 Refer to Chart B for serviceable parts.

7

Description

170-2504

Bar, Slide Tool Mounting

170-2505

Bar Assembly, Connecting

170-2506

Bar, Slide

170-2507

Bar, Connecting

170-2508

Pin

171-5890

Screw, Thumb

170-5891

Nut, Thumb

171-5892

Bolt, Swing

171-5893

Washer, Thrust

0827-48

Illustration 2. 300T Track Press Hydraulic Cylinders.

8

36

35

27

34

32 33 34

28

13 12

33

14 21 22

13 14 18

24 20 23 20

12

29

31

30

24

22 24 20 23 20 24 10

26 15

15

16 18

16 17

17

3

19

1

9 11

8 7 38

37

0827-42

Illustration 3. Small And Large Cylinder (Cut-Away View, Close-Up).

9

Small Hydraulic Cylinder

Illustration 4. Small Hydraulic Cylinder.

(9) Bushing. (10) Bolt. (11) Wear Ring. (12) Tie Rods. (13) Nut. (14) Washer. (15) Tube. (16) Rod. (17) Gland.

(18) O-ring. (19) Poly Pak Seal. (20) Backup Seal. (21) End Cap. (22) Piston. (23) Wear Ring. (24) Piston Poly Pak Seal.

Large Hydraulic Cylinder

Illustration 5. Large Hydraulic Cylinder.

(25) Tube. (26) Rod. (27) End Cap. (28) O-ring. (29) Bolt (Piston Adapter to Rod). (30) Bolt (Piston Adapter to Piston).

(31) Piston Adapter (32) Piston. (33) Wear Ring. (34) Poly Pak Seal. (35) Tie Rod. (36). Nut.

10

Assembly Use these steps to reassemble the track press after a cylinder rebuild.

C

D 45

NOTE: Apply assembly grease to seals and wear rings before installation.

54 6 3

2 1

1. Assemble the track press frame.

45

a. Use 6V-7977 Bolts (4) and 3S-6162 Washers (5) and apply anti-seize to threads on 6V-7977 Bolts (4).

54 A

B 0805-31

b. Attach left-hand side plate (2) and right-hand side plate (3) to base frame (1) and top plate (6). Hand tighten 6V-7977 Bolts (4).

Illustration 7. Tighten Each Row Of Bolts In Sequence.

(1) Base Frame. (2) Left-Hand Side Plate.

(3) Right-Hand Side Plate. (4) 6V-7977 Bolts.

(5) 3S-6162 Washers. (6) Top Plate.

c. Tighten each bolt within a row in the proper sequence. Begin with center bolt (1) and finish with outside bolt (5) before moving to the next row.

5

3

1

2

4 0805-30

Illustration 6. Install Top Plate Between Side Plates.

(1) Base Frame. (2) Left-Hand Side Plates.

(3) Right-Hand Side Plates. (4) 6V-7977 Bolts.

(5) 3S-6162 Washers. (6) Top Plate.

Illustration 8. Tighten Each Bolt In Sequence.

NOTICE DO NOT skip any bolts, this can warp the track press, causing it to function improperly.

2. Tighten each 6V-7977 bolt (4) to 12010 N·m (2700 ft lb). a. Tighten each bolt to 25% of final torque, 3403 N·m (675 ft lb).

c. Tighten each bolt to 50% of final torque, 6005 N·m (1350 ft lb).

b. Tighten each row of bolts in sequence: (A) bottom left-hand row, (B) bottom right-hand row, (C) top left-hand row, and (D) top right-hand row.

d. Tighten each bolt to 75% of final torque, 9008 N·m (2025 ft lb). e. Tighten each bolt to 100% of final torque, 12010 N·m (2700 ft lb).

11

3. Install rod wiper (7) into seal groove (A) and wear ring (8) into groove (B).

5. Assemble each large hydraulic cylinder prior to being attached to a side plate. a. Attach piston adapter (31) to press ram (26) with 8B-7979 bolts (30). b. Tighten bolts (30) to 120 N·m (27 ft lb).

Illustration 9. (7) Rod Wiper. (8) Wear Ring.

(A) Seal Groove. (B) Groove.

4. Install wear ring (11) in the inside bore and bushing (9) in the outside bore of each side plate (2 and 3).

Illustration 12. Attach Piston Adapter (31) To Press Ram (26) With 8B-7979 Bolts (30).

c. Attach piston (32) to piston adapter (31) with 4L-8515 bolts (29). d. Tighten bolts (30) to 120 N·m (27 ft lb). e. Install poly-pak seal (34) and wear ring (33) onto piston (32).

Illustration 10. Install Bushing (9).

NOTE: Use 1P-0510 Bearing and Seal Driver Group to make sure bushing (9) contacts the shoulder of the bore.

Illustration 13. Attach Piston (32) to Piston Adapter (31) With 4L-8515 Bolts (29).

(26) Press Ram. (33) Wear Ring. (34) Poly-Pak Seal.

Illustration 11. Installed Bushing (9).

12

f. Place tube (25) over assembled parts.

c. Pull press rams (26) inward to the end of their stroke by attaching an eye-bolt to each ram. Attach a ratchet puller and chains to each eye bolt and ratchet the chains tighter until each hydraulic ram reaches the end of the stroke.

Illustration 14. Place Cylinder Tube (25) Over Assembly.

6. Install large cylinder assemblies into side plates (2 and 3).

Illustration 17. Pull Press Rams (26) To End Of Stroke.

(A) Ratchet Puller.

a. Install six tie rods (35) into each side plate (2 and 3).

7. Install end cap (27). a. Insert O-ring (28) into end cap (27).

1

4

2

5 3

6 0805-34

Illustration 15. Install Six Tie Rods Into Each Side Plate.

b. Insert each large hydraulic cylinder into the groove of a side plate (2 and 3).

Illustration 18. Install O-Ring (28) Into Cylinder Cap (27).

Illustration 16. Insert Large Hydraulic Cylinders Into Side Plates (2 and 3).

13

b. Install end cap (27) over tie rods (35).

e. Tighten nuts (36) in sequence to the incremental values shown in Chart D.

3

5

7

1

8

2 4

6 0805-35

Illustration 19. Install End Cap (27) Over Tie Rods (35).

Illustration 21. Tightening Sequence.

c. Insert the final two tie rods (35) through each end cap (27) and thread into side plates (2 and 3).

Chart D. Torque Values

d. Install nuts (36) onto tie rods (35) using a 175-7940 Torque Wrench (A).

Steps

Torque

kPa (psi)

N·m (ft lbs)

1

25%

10342 (1500)

1179 (825)

2

50%

13790 (2000)

2070 (1449)

3

75%

26200 (3800)

3039 (2127)

4

100%

34474 (5000)

4000 (2800)

8. Test rod (16) to make sure it slides smoothly into bushing (9).

NOTE: If rod (16) does not slide smoothly into bushing (9) and wear ring (11), the bore is too tight. Use a small hone or sandpaper to enlarge the bore for a proper fit.

Illustration 20. Secure Cylinder End Cap (27) Onto Tie Rods (35) Using 175-7940 Torque Wrench (A) To Tighten Nuts (36).

NOTICE Hand fit the cylinder rod into the bushing to prevent damaging the cylinder rod or bushing.

14

9. Install small hydraulic cylinders.

10. Attach 170-2503 Connecting Bar Assembly (37) to press ram (26).

37 A

0805-80

Illustration 22. Small Cylinder Assembly.

(9) Bushing. (10) Bolt. (11) Wear Ring. (12) Tie Rods.

(13) Nut. (14) Washer. (15) Tube. (16) Rod. (17) Gland.

(18) O-ring. (19) Poly-Pak Seal. (20) Backup Seal.

(21) End Cap. (22) Piston. (23) Wear Ring. (24) Piston Poly-Pak Seal.

Illustration 23. 170-2503 Connecting Bar Assembly (37).

(A) Slide Bar.

a. Remove slide bar (A) from connecting bar assembly (37). b. Attach connecting bar (37) to press ram (26) with socket head cap screws (38).

Tighten to 1050 N·m (777 ft lb).

a. Secure piston (22) to rod (16) using bolt (10) and tighten bolt (10) to 900 N·m (666 lb ft). b. Fit seals (20 and 24) and wear ring (23) onto piston (22). c. Insert O-ring (18) and seal (19) into gland (17). d. Attach gland (17) and tie rods (12) to side plates (2 and 3). e. Insert rod (16) into bushing (9) and slide tube (15) over rod (16) and piston (22). f. Insert O-ring (18) into end cap (21). g. Install end cap (21), washer (14), and nut (13) onto tie rods (12).

Illustration 24. Attach 170-2507 Connecting Bar (37) To Press Ram (26) Using Socket Head Cap Screws (38).

h. Tighten nuts (13) to 250 N·m (160 lb ft).

15

Hydraulic System

0.5 mm

Leave cartridge spring in

75 PSI

r/v 9T0704

53

54

54

r/v 9T0704

148-3351 127-4405

Illustration 1. 300T Track Press Hydraulic System Schematic.

16

r/v 6E6283

52

r/v 6E6282

Leave cartridge spring in 0.5 mm

75 PSI

r/v r/v 9T1465

44 r/v 9T1465

1689-200-005

50

50

49

44

51 1597568 r/v 1697-150-005

166-7950

r/v 1689-200-005

1597568 r/v 1697-050-005

MARGIN PRESSURE -------500 PSI MAX PUMP PRESSURE ---3650 PSI MAX VANE PRESSURE ----150 PSI SLOW EXTEND --------------25.5 IPM FAST EXTEND ----------------93 IPM

FAST RETRACT --------------190 IPM

Modifiy LR valve to 103-5519-M

0827-49

17

NOTE: Item numbers in this section refer to the hydraulic schematic (Illustration 1) and hydraulic pressures and adjustments have been set at the factory. Refer to NEHS0829, Caterpillar 300T Track Press Parts and Schematics manual for additional information.

2. Hydraulic pressure is supplied by a pump mounted to each end of the motor.

Inspection

4. A 100-3259 Piston Pump (left) provides high-pressure oil at 83 Lpm (22 gpm) and 31026 kPa (4500 psi).

3. The motor drives each pump using a keyed half-coupling at the motor, a rubber coupling insert in the middle, and a spline half-coupling at the pump.

WARNING

5. A 1U-3969 Vane Pump (right) is used for low-pressure components.

Check hydraulic oil lines, tubes, and 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.

a. The first (inboard) cartridge is a 227 Lpm (60 gpm) cartridge set at 2068 kPa (300 psi). This cartridge provides rapid ram pressure. The pump is activated by pressing the RAM FAST button, which energizes relief valve (11). b. The second (outboard) cartridge is a 42 Lpm (11 gpm) cartridge set at 10342 kPa (1500 psi). This cartridge provides accessory supply for the indexer, encoder, shoe hold down, and pad lift.

The pump is activated by pressing an accessory control button, which energizes relief valve (10).

The track press includes an intricate hydraulic system which needs to be inspected on a periodic basis.

1. Check all hydraulic lines, connections, and fittings for leaks.

NOTE: The 1U-3969 Vane Pump is turned ON at the pendant box.

2. Check hydraulic cylinders on the track press, indexer table, and conveyor for leaks and/or seal problems.

6. Use an 8T-0860 Gauge to read the output pressure at the two quick-disconnect pressure ports (30) located near the piston pump and the vane pump. Relief valve (10) includes a pressure port (30) for attaching an 8T-0860 Gauge with 39990 kPa (5800 psi) capacity.

3. Check all filters and/or replace filter elements at regular intervals.

Motor and Pumps 1. Power is supplied to the track press by a 30 horsepower, 1200 rpm, double-shaft electric motor.

Illustration 3. 8T-0860 Gauge Connected To Read Piston Pump Pressure.

Illustration 2. Electric Motor And Pumps.

18

Main Control Valve The main control valve (16) at the operator control station includes right hydraulic ram, left hydraulic ram, hold down shoe, indexer forward/reverse, indexer raise/lower, and indexer float valve stacks.

The main control valve also receives hydraulic fluid from 100-3259 Piston Pump (2) and the inbound cartridge of 1U-3969 Vane Pump (3).

Check valve (15) keeps the two supplies of hydraulic fluid separated and includes a pressure port (30) for an 8T-0860 Gauge.

Illustration 5. Hydraulic Ram Proximity Switches.

(1) Left Ram Control Lever. (2) Right Ram Control Lever.

(3) Left Ram Proximity Switch. (4) Right Ram Proximity Switch.

Hold Down Shoe Stack • Raises and lowers hold down shoe.

• Includes: directional control valve (43), flow control valve (47), pilot check valve (57), and pressure reducing valve (60).

Illustration 4. Main Control Valve (Close-Up).

• Flow control valve (57) holds the position of hydraulic cylinders (49).

Left Hydraulic Ram Stack • Extends and retracts the left hydraulic ram.

• Hydraulic cylinders (49) are mounted directly behind each end of the hydraulic motor.

• Controls the left hydraulic ram valves.

• Pull the left hydraulic ram lever to create oil pressure in the left hydraulic cylinder to extend the left hydraulic ram.

• Pressure reducing valve (60) is factory set to reduce this circuit to 3447 kPa (500 psi).

• Push left hydraulic ram lever to activate the left hydraulic ram proximity switch.

Indexer Up/Down Stack

• The left hydraulic ram proximity switch opens a dump valve to release oil pressure from the left hydraulic cylinder and retract the left hydraulic ram.

• Raises and lowers indexer table.

• Includes a ram spool relieve valve which was set at the factory. DO NOT adjust the ram spool relief valve.

• Flow control valve (56) is mounted directly on and controls the speed of hydraulic cylinder (49).

• Includes: directional control valve (42) and flow control valve (56).

• Hydraulic cylinder (49) is mounted directly behind the center of the hydraulic motor.

Right Hydraulic Ram Stack • Extends and retracts the right hydraulic ram.

• Controls the right hydraulic ram valves.

Indexer Belt Motion Stack

• Pull the right hydraulic ram lever to create oil pressure in the right hydraulic cylinder to extend the right hydraulic ram.

• Moves indexer belt forward and reverse.

• Includes: directional control valve (42) and flow control valve (47).

• Push right hydraulic ram lever to activate the right hydraulic ram proximity switch.

Indexer Belt Float Stack

• The right hydraulic ram proximity switch opens a dump valve to release oil pressure from the right hydraulic cylinder and retract the right hydraulic ram.

• Controls motor and belt float when the indexer motor is not operating to avoid damaging the belt and motor.

• Includes a ram spool relieve valve which was set at the factory. DO NOT adjust the ram spool relief valve.

• Includes: directional control valve (44) and altered plate (45).

19

Accessory Hydraulic Circuit

Hydraulic Rams

The accessory hydraulic circuit is attached to the back of the left-hand hydraulic tank.

1. A separate manifold block (20) connected to right main ram cylinder (22R) and left main ram cylinder (22L) control hydraulic pressure in the main ram cylinders.

2. A gauge isolator (31) and pressure switch (18) is attached to each manifold block (20). Gauge isolator (31) is set to 2068 kPa (300 psi) and pressure switch (18) is set to 690 kPa (100 psi) to limit pressure in the main ram cylinders to 2068 kPa (300 psi) when the safety doors are open.

NOTE: When the safety door is closed the pressure switch is overridden to allow pressure in the main ram cylinders to achieve the pressure set at operator relief valves (32).

3. The pressure switch prevents high-pressure operation by causing the piston pump to unload if contact with the safety door switch is not made. The left and right hydraulic ram pressure switches are on the end of each hydraulic cylinder.

Illustration 6. Accessory Hydraulic Circuit.

(43) Pad LIft Up Solenoid. (44) Winch In Solenoid.

(45) Pad Lift Down Solenoid. (46) Winch Out Solenoid.

(5) Relief Valves.

The accessory hydraulic circuit includes the pad lift control solenoids and winch control solenoids.

1. Pad lift control solenoids (43 and 45) activate hydraulic cylinders (53), which raise and lower the pad lift rails on the conveyor sections.

2. Winch valve solenoids (44 and 46) controls winch (23), which is located on the top (back) of the 300T Track Press.

Illustration 7. Hydraulic Ram Pressure Switch.

a. These solenoids control the operation of the winch valve and two spool relief valves set to 10342 kPa (1500 psi).

4. A pilot operated check valve (19) allows supercharged oil to fill the hydraulic rams and checks when high-pressure is reached.

b. The winch (right side) includes two pressure ports (30) for attaching gauge (25), which is capable of measuring to 24821 kPa (3600 psi).

5. When a hydraulic ram is being retracted, the pilot pressure from manifold block (20) opens a check poppet to allow a high volume of hydraulic oil to flow back into the hydraulic tank. Two pullback cylinders (21) receive a supply of hydraulic oil to assist the return stroke of the main hydraulic ram.

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Hydraulic Tanks

Relief Valves

Each hydraulic tank includes a sight tube, 9U-7032 Filler/Breathers, and a 102 mm (4.0 in) shutoff valve.

The operator can adjust the relief valves mounted on the front of the operator control station to control hydraulic ram pressure.

The relief valves are factory set to 31716 kPa (4600 psi).

NOTE: The shutoff valves must remain open, except when the hydraulic tanks are required to be isolated from other components for maintenance or replacement.

Illustration 8. 9U-7032 Filler/Breathers.

NOTICE

Illustration 9. Hydraulic Ram Relief Valves.

A hydraulic tank is properly filled when the hydraulic oil is half way up the sight tube. Watch the oil sight tubes to prevent over-filling the hydraulic tanks, which can cause oil to be blown out of the filler/breathers.

The operator relief valves are connected to two-way valves which control hydraulic oil flow and tonnage pressure. These valves open when the ram is advancing and close when the ram is retracting.

The left hydraulic tank also includes a 38 mm (1.5 in) shutoff valve; while the right hydraulic tank includes a 76 mm (3.0 in) shutoff valve, two 51 mm (2.0 in) shutoff valves (front and back), and a 9U-6989 Filter Head with a 9U-5870 Filter Element.

The operator can monitor hydraulic ram pressure with a pair of gauges mounted on the front of the operator control station and connected to the main control valve manifold.

Adjustments

The hydraulic tanks are connected through a 102 mm (4.0 in) diameter hose, which keeps the hydraulic oil level balanced between the two tanks.

Several adjustments to the Caterpillar 300T Track Press are required for proper operation.

These adjustments should be verified every six months for proper track press functions.

Calibrate Tonnage Periodically check the accuracy of the tonnage dial compared to the decal values.

NOTICE Inaccuracies in the dial calibration could result in excessive assembly pressures leading to damaged track assembly components and excessive tool wear.

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Pressure Switch

Indexer Belt

Hydraulic ram pressure switches control oil flow to the large hydraulic ram.

1. Loosen the mounting bolts on the left side of the indexer to allow slack in the drive chain.

2. Remove the slack from the installed indexer belt, making sure there is no tension on the belt.

3. Make two marks on the belt 2540 mm (100.0 in) apart.

4. Measure from the top of the conveyor to the top of the lower bracket of the tensioning screw on each side. Adjust the bases so they are each the same distance from the top of the indexer.

Illustration 1. Pressure Switch.

5. Lightly mark the top of each bracket of the tensioning screw. This mark will be used as a guide to tighten the belt.

Set the pressure activation point using a flat tip screwdriver to loosen set screw (A).

6. Loosen the locking nut on the top of the adjustment screw, and turn the small square nut counterclockwise until the base is about 1372 mm (54.0 in) below the mark.

Adjust the screw on the other side of the conveyor until its base is a similar distance below the mark.

7. Gradually lengthen the adjustment screws until the measurement between the two marks on the belt read 2565 mm (101.0 in).

At this point, the belt will have stretched about 1%. DO NOT STRETCH THE BELT IN EXCESS OF 2%.

8. Make sure the distance from the top of the indexer to the base of the screw assembly is the same on both sides. Slightly adjust both sides to equalize the distance and when they are the same, tighten the lock nuts on the adjustment screw.

Illustration 2. Loosen Set Screw (A).

Change the pressure switch setting using an allen wrench to turn the hydraulic flow control counterclockwise to lower and clockwise to raise the pressure activation point.

9. Move the indexer motor up to remove excess slack in the chain and tighten the four mounting bolts on the motor.

10. Reinstall the cover of the indexer belt motor.

Illustration 3. Adjust The Pressure Activation Point.

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• Indexer conveyor shafts.

Lubrication Points Several points on the Caterpillar 300T Track Press should be lubricated at regular intervals, approximately weekly depending on actual usage. Use a multi-purpose grease for any surface-to-surface applications, the indexer chain and sprockets, and the indexer and conveyor shafts.

• Indexer chain and sprockets.

Illustration 3. Grease Indexer And Conveyor Shafts Using Grease Zerk (B).

• Winch.

NOTE: Use 80W-90 gear oil or equivalent to lubricate the winch and check the gear oil level in the reservoir at regular intervals.

Illustration 1. Grease Indexer Chain And Sprockets.

• Indexer sprocket shaft.

Illustration 4. Lubricate Winch.

(C) Gear Oil Fill Plug.

Illustration 2. Grease Indexer Sprocket Shaft Using Grease Zerk (A).

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Transformer control box (2) is located on the back side of the track press.

Electrical Control Boxes Contact with electrical components can cause injury or death. Always disconnect the main power supply before before opening an electrical control box and/or working on the instrument.

Remove all jewelry and avoid any contact with electrical components. Use properly insulated tools when maintaining electrical equipment.

Illustration 2. 300T Track Press (Back View).

(2) Transformer Control Box.

The Caterpillar 300T Track Press has three electrical control boxes. Refer to NEHS0829 Caterpillar 300T Track Press Parts and Schematics manual for additional information.

Operator controls are at the operator control box (1), on the front side of the track press.

Hand-held pendant control box (3) allows the operator to work along the entire length of the conveyor system.

Illustration 1. Caterpillar 300 Track Press (Front View).

(1) Operator Control Box.

Illustration 3. Hand-Held Pendant Control Box (3).

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3. The interior of the operator control box includes terminal blocks and ground blocks.

Operator Control Station 1. The operator control station has operator control box (1), pressure gauges (2), pressure control dial (3) and hydraulic control levers (4).

Illustration 6. Operator Control Box (Interior) (7) Terminal blocks. (8) Ground Blocks.

Illustration 4. Operator Control Station.

(1) Operator Control Box. (2) Pressure Gauge.

(3) Pressure Control Dial. (4) Hydraulic Control Levers.

Transformer Control Box The transformer control box is located on the back of the right-hand hydraulic fluid tank.

2. The exterior of the operator control box includes Emergency Stop button (7) and Start Hydraulics button (8).

The exterior of the transformer control box includes Power Disconnect switch (1), Emergency Stop button (2), and Light switch (3) for the work table.

Illustration 5. Operator Control Box. (5) Emergency Stop. (6) Start Hydraulics.

Illustration 7. Transformer Control Box Exterior.

(1) Power Disconnect Switch. (2) Emergency Stop Button. (3) Light Switch.

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The interior of the transformer control box contains a motor starter, thermal overload, 24 Volt power supply, circuit breaker, power disconnect switch, programmable logic controller (PLC), terminal blocks, ground blocks and fuses.

• thermal overload (5).

Illustration 10. Thermal Overload (5).

• 24 Volt power supply (6).

Illustration 8. Transformer Control Box Interior.

(4) Motor Starter. (5) Thermal Overload. (6) 24 Volt Power Supply. (7) Circuit Breaker. (8) Power Disconnect Switch. (9) Programmable Logic Controller (PLC).

(10) Terminal Blocks. (11) Ground Blocks. (12) Fuses.

Illustration 11. 24 Volt Power Supply (6).

(A) Indicator Light.

• motor starter (4).

• circuit breaker (7).

Illustration 9. Motor Starter (4).

Illustration 12. Circuit Breaker (7).

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• power disconnect switch (8).

• ground blocks (11).

Illustration 13. Power Disconnect Switch (8).

(A) Power Disconnect Handle.

Illustration 16. Ground Blocks (11).

• fuses (12).

• programmable logic controller (PLC) (9).

Illustration 17. Fuses (12).

Illustration 14. Programmable Logic Controller (PLC) (9).

• terminal blocks (10).

Illustration 15. Terminal Blocks (10).

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Pendant Control Box

Power Disconnect Switch

The pendant control box connects to the transformer control box and eliminates the need for a second person. This control box operates the pad lifts and winch and allows an operator to work along the entire conveyor system. The pendant control box includes Emergency Stop (1), Pendant Power (2), Pad Lift Up (3), Pad Lift Down (4), Winch In (5), and Winch Out (6) controls.

WARNING Place a Do Not Operate tag on the power disconnect switch handle to prevent accidental engagement of the power disconnect switch.

WARNING

do not operate

signed by date

Pull the Power Disconnect switch handle down to shut OFF all power to the track press for maintenance. Add a Do Not Operate tag to prevent the power from being turned ON.

WARNING

do not operate

Illustration 18. Pendant Control Box. (1) Emergency Stop. (2) Pendant Power. (3) Pad Lift Up. (4) Pad Lift Down. (5) Winch In. (6) Winch Out.

signed by date

Illustration 2. Power Disconnect Switch Handle To OFF.

Electrical Control Functions Lights

An Emergency Stop button is located on the operator control box, the transformer control box, and the pendant control box.

1. Replace the lights above the track press table if the lights do not illuminate when the Power Disconnect switch is ON and Light switch on the transformer control box is ON

Each Emergency Stop button should shut OFF power to the track press motor. Turn the Emergency Stop button in the direction of the arrow to release it and push the hydraulics start button at the operator control box to restart the track press.

LIGHTS (OFF/ON)

Illustration 3. Track Press Table Lighting.

EMERGENCY STOP

0826-50

Illustration 1. Emergency Stop Button (1).

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Start Hydraulics

Pad Lift Up

Maintenance troubleshooting is required when the hydraulic pump fails to start after the Start Hydraulics button is pressed.

Maintenance troubleshooting is required when the pad lift rails fail to raise after the Pad Lift Up button is pressed.

Start Hydraulics Function

Pad Lift Up Function

• Set Power Disconnect switch to ON.

• Set Power Disconnect switch to ON.

• Set Pendant Power switch to OFF.

• Set Pendant Power switch to ON.

• Make sure all three Emergency Stop buttons are Out.

• Make sure all three Emergency Stop buttons are Out. • Press the Pad Lift Up button.

• Press the Start Hydraulics button.

• Solenoid 43 on the accessory manifold should become energized.

• The Hydraulic Pump should start.

START HYDRAULICS

NOTE: The track press automatically shuts down after it runs for several minutes without any accessories being used.

PAD LIFT UP

• The hydraulic cylinder on the conveyor should extend.

• The pad lift rails should raise up (from a lowered position).

Illustration 4. Start Hydraulics Button.

Illustration 6. Pad Lift Up Button.

Pendant Power

Pad Lift Down

Make sure the Pendant Power switch is set to OFF to maintain the pad lift up, pad lift down, winch in, and winch out functions.

Maintenance troubleshooting is required when the pad lift rails fail to lower after the Pad Lift Down button is pressed.

OFF

ON

Pendant Power Functions

Pad Lift Down Function

• Set Power Disconnect switch to ON.

• Set Power Disconnect switch to ON.

• Set Pendant Power switch to ON.

• Set Pendant Power switch to ON.

• Make sure all three Emergency Stop buttons are Out.

• Make sure all three Emergency Stop buttons are Out.

• Make sure the pendant control functions operate appropriately.

• Press the Pad Lift Down button.

• Solenoid 45 on the accessory manifold should become energized.

NOTE: The track press will not operate if the Pendant Power switch is ON and the pendant functions PENDANT POWER will not operate if the Pendant Power switch is OFF.

PAD LIFT DOWN

• The hydraulic cylinder on the conveyor should retract.

• The pad lift rails should lower (from a raised position).

Illustration 5. Pendant Power Switch.

Illustration 7. Pad Lift Down Button.

NOTE: Keep the Pendant Power switch in the OFF position unless power is required for operating the pad lift and winch functions.

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Winch In

Door Switch

Maintenance troubleshooting is required when the winch motor fails to turn clockwise after the Winch In button is pressed.

The track press has a safety door proximity switch, on the bottom right of the safety door track (A), that requires regular inspection for proper operation. The switch detects when the safety doors are closed and triggers X27 input to the PLC, allowing high-pressure to occur in the hydraulic rams.

Winch In Function • Set Power Disconnect switch to ON. • Set Pendant Power switch to ON. • Make sure all three Emergency Stop buttons are Out.

The track press program requires the safety door to be opened and closed throughout the operation. If this door switch is tampered with to indicate that the door is always shut, the track press WILL NOT operate correctly.

• Press the Winch In button.

• Solenoid 44 on the accessory manifold should become energized.

WINCH IN

• The winch motor should rotate clockwise.

• The winch motor should reel in the winch cable.

Illustration 8. Winch In Button.

Winch Out Maintenance troubleshooting is required when the winch motor fails to turn counterclockwise after the Winch Out button is pressed.

Winch Out Function

Illustration 1. Safety Door Proximity Switch.

(A) Safety Door Track.

• Set Power Disconnect switch to ON. • Set Pendant Power switch to ON. • Make sure all three Emergency Stop buttons are Out. • Press the Winch Out button.

• Solenoid 46 on the accessory manifold should become energized.

WINCH OUT

• The winch motor should rotate counterclockwise.

• The operator should pull the winch cable along the conveyor system.

Illustration 9. Winch Out Button.

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Notes

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For information on service tools or shop supplies, contact Caterpillar Service Technology Group on: Caterpillar Service Technology 501 S.W. Jefferson Ave. Peoria, Illinois 61630-2184 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6618 (Fax) CSTG_Hotline@cat.com (E-mail) or Caterpillar Service Technology Caterpillar Overseas S.A. P. O. Box 6000 1211 Geneva 6 Switzerland +41 (79) 217 27 45 (Geneva Phone) +41 (22) 849 49 29 (Geneva Fax) 36CSTG (COSA E-Mail Address)

©2002 Caterpillar All Rights Reserved

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NEHS0827 Printed in U.S.A.