Caterpillar Large 267-2107 Multi-Pitch SystemOne Track Press Tool Operating Manual - PDF DOWNLOAD

R

NEHS0931-01 April 2005

TOOL OPERATING MANUAL Operation and Parts for Large 267-2107 Multi-Pitch SystemOneTM Track Press Tool European Union 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 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 Inspection/Cleaning . . . . . . . . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety Messages . . . . . . . . . . . . . . . . . . . . 4 General Hazard Information . . . . . . . . . . . 6 Personal Protection . . . . . . . . . . . . . . . . . . 6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pressure Air . . . . . . . . . . . . . . . . . . . . . . . . 7 Trapped Pressure . . . . . . . . . . . . . . . . . . . 8 Fluid Penetration . . . . . . . . . . . . . . . . . . . . 8 Containing Fluid Spillage. . . . . . . . . . . . . . 8 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Multi-Pitch Track Press Tool . . . . . . . . . . . . 8 Hydraulic Power Supply . . . . . . . . . . . . . . 9 High-Pressure Hose. . . . . . . . . . . . . . . . . . 9 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . 9 Additional Contact Information . . . . . . . . . . 10 References. . . . . . . . . . . . . . . . . . . . . . . . . . 10 267-2107 Multi-Pitch Track Press Group . . . 10 Additional Multi-Pitch Track Press Tools . . . 12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Track Separate Procedure . . . . . . . . . . . . 13 Required Parts . . . . . . . . . . . . . . . . . . . 13 Using Optional Shim Plates . . . . . . . 22 Track Connect Procedure . . . . . . . . . . . . 24 Required Parts . . . . . . . . . . . . . . . . . . . 24 Inspection/Cleaning . . . . . . . . . . . . . . . . . . . 31 Assembling the Guard Group. . . . . . . . . . . . . 32 Inspection Guide . . . . . . . . . . . . . . . . . . . . . 35 Troubleshooting Chart . . . . . . . . . . . . . . . . . 35 Declaration of Conformity . . . . . . . . . . . . . . . . 36

This manual should be stored with the multi-pitch track press tooling.

This manual contains safety information, operation instructions, and inspection/cleaning 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 multi-pitch track press tool.

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

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

Also, read and understand the General Hazard Information listed in the Safety section before operating, performing maintenance, and/or repairing 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 removing and installing SystemOne™ track links.

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

Inspection/Cleaning The Inspection/Cleaning section is a guide to equipment care.

3

Safety Safety Messages There are several specific safety signs on the top of the clear plastic guard. 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, or 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 or damage the clear plastic guard. Loose adhesive can allow the safety sign to fall off of the guard.

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.

4

3

261-7493

93 -74 261

2

1 1 49 1-7 26

2 49 1-7 26

261-7492

261-7491

0931-47

4

Protective Guard (1)

High Pressure (2)

The 261-7492, Do Not Operate Without Guard Decal, warns against operating the tool without the guard in place. This warning message is located on the plastic portion of the guard in the lower left corner.

The 261-7491, Remove Pressure Warning Decal, warns against high pressure. This warning message is located on the plastic portion of the guard in the lower right corner.

261-7491 261-7492

0931-54

0931-55

WARNING

WARNING

The hydraulic system can be pressurized to a maximum of 700 bar (10,000 psi). Make sure that all hydraulic pressure has been relieved before disconnecting the hydraulic hose or servicing the unit. Personal injury can result from removing a hose or quick disconnect fitting in a pressure system. Failure to relieve pressure can cause personal injury.

Do not disconnect or remove a hose or fittings until all pressure in the system has been relieved.

Cover work with the protective guard. With high forces being exerted on the part being removed/installed, breakage may sometimes result. By covering the work with the protective guard, the mechanic reduces the danger of personal injury or death by flying parts.

Never apply pressure to the track press until the guard is in place.

261-7491

261-7492

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

Do not exceed the multi-pitch track press tool’s cylinder’s maximum pressure ratings.

Overloading causes equipment failure and possible personal injury. Do not connect a hydraulic cylinder to a pump or power supply with a higher pressure rating.

5

Do Not Operate (3)

Hearing and Eye Protection (4)

The 224-0554, Read Manual Decal, warns against bodily injury if the tool is operated without fully reading and understanding this and other related manuals. This warning message is located on the plastic portion of the guard in the upper center left.

The 261-7493, Safety Glasses/Ear Protection Decal, indicates that hearing and eye protection should be worn at all times when using this tooling. This warning message is located on the plastic portion of the guard in the upper center right.

261-7493

0931-57

WARNING

0931-56

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.

To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noisegenerating 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.

General Hazard Information Personal Protection Wear proper personal protective gear, such as gloves, when operating hydraulic equipment or working around the track.

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

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

Sharp corners or burrs on track links, or sharp threads on track bolts and nuts, can cause cuts.

Wear gloves for protection when handling sharp objects.

6

Personal Protection (continued)

Hoses

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

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. Replace a damaged hose.

To prevent personal injury, avoid pinch points.

The parts of the multi-pitch track press tool weigh enough to cause personal injury if dropped onto your hand or foot. Always wear protective shoes and use care when handling the unit.

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. Replace a damaged hose.

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

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

Inspection

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.

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.

Check hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque.

Do not reuse bent threaded components.

Failure of these parts may produce flying objects.

Replace hoses 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 hose is kinked - End fittings that are displaced

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.

Do not weld on any 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.

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

Never operate equipment with a known malfunction or leak.

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

7

Trapped Pressure

Introduction

Pressure can be trapped in a hydraulic system.

Trapped pressure can cause sudden tool movement or attachment movement. Use caution when disconnecting the hydraulic hose fitting. 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.

Multi-Pitch Track Press Tool The 267-2107 Multi-Pitch Track Press Tool is sold as a kit. Using these tools, the following machine models can be serviced: D6H, D6M, D6N, D6R Track-Type Tractors, and 953, 963 Tractor-Type Loaders.

For future releases of SystemOneTM track, individual parts can also be ordered to make the removal and installation of a link faster and more efficient. Using additional tools, D3G, D4G, D5G, D5M, and D5N models can be serviced (See Additional Multi-Pitch Tools section).

Fluid Penetration When checking 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 skin, obtain treatment immediately.

Seek treatment from a doctor that is familiar with this type of injury.

The multi-pitch track press tool allows service personnel to remove or install various Caterpillar SystemOneTM track links on a machine without a master link. The unit can also replace track links at any location around the track chain.

Containing Fluid Spillage Care must be taken in order to ensure that hydraulic oil is contained during installation and removal of the hose. Be ready to collect the oil before removing the hose.

NOTICE Each size and type of track link requires specific 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.

Obey all local regulations for the disposal of liquids.

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

Using this tooling, the track can be separated and the track sections can be replaced as needed. Do not try to repair other types or sizes of track with this tooling.

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

At operating temperature, some hydraulic power supplies are hot and can cause severe burns.

Relieve all pressure before any hose, any fitting, or any related item is disconnected or removed.

WARNING This tooling should never be used for any 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.

8

Hydraulic Power Supply

Hydraulic Cylinders

This unit is designed to work with a dealer-supplied hydraulic power supply (energy source) equipped with a 700 bar (10,000 psi) maximum pressure relief valve and hoses rated for that working pressure.

Several power supplies are available through Caterpillar; however, only CE approved power supplies can be used.

Also required to operate the multi-pitch track press tool is a hydraulic cylinder. A 265-8034 50 ton Cylinder is part of this tool group.

High-Pressure Hose A high-pressure hose [700 bar (10,000 psi) maximum pressure] must be supplied by the user to connect the multi-pitch track press tool to the hydraulic power supply. Only CE approved power supplies can be used.

NOTICE Do not exceed 75 tons of force for the cylinder being used.

9

Additional Contact Information

267-2107 Multi-Pitch Track Press Group

For further assistance for ordering or for information on other specialized tooling available for your service operation, contact:

Refer to the Track Connect or Track Separate Procedure in this manual for quantities of each part used in the procedure.

Dealer Service Tools 501 S.W. Jefferson Peoria, IL U.S.A. 61630-2184 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_Hotline@cat.com

Item Part No.

References NEHS0923

Master Link Tools for SystemOneTM Track

REHS1110

Installation and Removal of SystemOne (elevated sprocket)

REHS2221

TM

Track

Installation and Removal of SystemOneTM Track (oval)

Description

1

264-5768

Contact Plate

2

264-5770

Puller Plate

3

—

Not Used

4

264-5778

Removal Contact Tool (D6H, D6M, D6N, D6R, 953, 963)

5

4L-7124

Socket Head Cap Screw

6

—

Not Used

7

264-5774

Acme Threaded Rod

8

265-9028

Acme Half Nut

9

265-8989

Acme Nut

10

264-5777

Cylinder Centering Block

11

264-5771

Top Plate (D6H, D6M, D6N, D6R, 953, 963)

12

267-21081

Guard Group

12a

—

Clear Plastic Guard

12b

—

Flexible Guard (Upper Half)

12c

—

Flexible Guard (Lower Half)

12d

—

Bolt (holds 12b to clear plastic guard)

12e

—

Bolt (holds items 12b, 12c, 12i, and 12h to clear plastic guard)

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

12f

—

Flat Washer

12g

—

Nut

SEBF8558

Guidelines for Reusable Track Parts

12h

—

Retaining Strap

SEBF8599

Undercarriage Reconditioning Guide

12i

—

Retaining Strap with Clip

SEBF8619

Field Service Procedure for SystemOneTM Track

12j

—

13

265-8034

Retaining Strap Buckle 50 ton Cylinder

1 This guard group must cover the tool and track link area

whenever installing or removing a track link.

10

267-2107 Multi-Pitch Track Press Group 1 264-5768 (2)

2 264-5770 (1) 4 264-5778 (2) 8 265-9028 (4)

5 4L-7124 (2) 10 264-5777 (2) 11 264-5771 (2)

7 264-5774 (4)

9 265-8989 (8) 13 265-8034 (1)

12b

12c 12a

12d

12i 12f 12j

12e 12g

0931-01

12h

11

Additional Multi-Pitch Track Press Tools

Item Part No.

Use additional tools to increase the versatility of this tool group.

Description

A1 268-7895

Shim, 12.7 mm (.500 in) thick

A2 268-7897

Shim, 25.4 mm (1.00 in) thick

A3 268-7898

Shim, 38.1 mm (1.50 in) thick

A4 268-7899

Shim, 50.8 mm (2.00 in) thick

A5 268-7900

Shim, 63.5 mm (2.50 in) thick

A6 268-7901

Shim, 76.2 mm (3.00 in) thick

A7 268-1698

Removal Contact Tool (D5G, D5M, D5N)

A8 268-1700

Puller Plate (D3G, D4G, D5G, D5M, D5N)

A9 268-1699

Installation Contact Plate (D3G, D4G, D5G, D5M, D5N)

A10 266-8997

Removal Contact Tool (D3G, D4G)

A11 6V-3170

Cylinder (55 ton)

A12 265-8035

Cylinder (75 ton)

A13 268-5658

Top Plate (D3G, D4G, D5G, D5M, D5N)

A14 270-4487

Top Plate (Pre-production D6R)

A7

A1

A4

A10 A13 A8 A2

A5

A3

A6

A14

A12

A11 A9

0931-58

12

Operation

Track Separate Procedure

The contact plates of the multi-pitch track press tool are designed to be used on different models of track links. The counterbore side of the contact plate is used for track links with a pitch distance of 202.82 mm (8.0 in). Other pitches with distances of 190 mm (7.5 in), 218 mm (8.58 in), 240 mm (9.45 in), or 175.4/171.1 mm (6.91/6.75 in) are available using the holes on the flat side of the plate.

Required Parts Track Separate Parts List Item Part No.

Description

Qty.

1

264-5768

Contact Plate

2

2

264-5770

Puller Plate (D6H, D6M, 1 D6N, D6R, 953, 963) or Puller Plate (D3G, D4G, D5G, D5M, D5N)

4

264-5778

268-1700

NOTE: The correct side of the contact plate must be installed, facing the track link, according to the pitch of the model and contact tool.

Contact Tool (D6H, D6M, 2 D6N, D6R, 953, 963) or Contact Tool (D5G, D5M, D5N) or Contact Tool (D3G, D4G)

268-1698 266-8997 5

4L-7124

Socket Head Cap Screw

2

7

264-5774

Acme Threaded Rod

4

8

265-9028

Acme Half Nut

4

9

265-8989

Acme Nut

8

10

264-5777

Cylinder Centering Block

2

11

264-5771

270-4487

Top Plate (D6H, D6M, D6N, 1 D6R, 953, 963) or Top Plate (D3G, D4G, D5G, D5M, D5N) or Top Plate (Pre-production D6R)

267-21081

Guard Group

268-5658

12

1

1 This guard group must cover the tool and track link area

whenever installing or removing a link.

7 2 D3G, D4G, D5G, D5M, D5N

5

4

8

11

11

1

1

9

10 7 5 4 D6H, D6M, D6N, D6R, 953, 963

9 8

10 0931-48

13

1. Perform the following steps in order to separate the SystemOneTM track. 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 and installation.

NOTICE To prevent breakage of cap screw (5), only finger tighten the capscrew.

Completely tightening the cap screw can cause it to break off in the contact plate during the link separate procedure.

3. Attach two contact tools (4) to contact plate (1). The contact tools must be installed into the correct counterbores, for the specific machine model, using socket head cap screws (5).

2. Block the track assembly with the appropriate cribbing and remove three track shoes.

Model

Contact Tool Contact Plate Pitch mm (in)

D3G, D4G

266-8997

264-5768

175.4 (6.91)

D5G, D5M, D5N 268-1698

264-5768

171.1 (6.75)

D6M, D6N

264-5778

264-5768

190 (7.5)

D6H, D6R

264-5778

264-5768

202.81 (8.0)

218.0 (8.58) 268-1698 171.1 (6.75) 266-8997 175.4 (6.91)

264-5778 190.0 (7.5)

264-5778 202.81 (8.0)

14

240.0 (9.45)

0931-51

NOTE: The inside two holes (A) fit one model of track link while the outer two holes (B) are used for another model.

WARNING Proper alignment between the contact tool (removal or installation) and the cartridge pin is critical. If the tooling is not properly aligned, excessive pressure can be built-up causing possible tool damage or personal injury.

E

B A

D C E A B

4. Install the appropriate shim (flat washer) between the top of the track link and the top plate. Use the chart as a guide to select the appropriate shim.

C D

0931-52

NOTE: Use as many washers as necessary to center the tooling on the cartridge pins.

Item Part No. A

264-5771

Description D6H, D6R, 963

B

264-5771

D6M, D6N, 953

C

268-5658

D3G, D4G

D

268-5658

D5G, D5M, D5N

E

270-4487

Pre-production D6R

6. Install two threaded rods (7) through puller plate (2) and top plate (11). Thread one nut (9) onto each rod, as shown.

Model

Part No.

Description

D3G, D4G

5P-8247

Flat Washer

D5G, D5M, D5N

5P-8247

Flat Washer

D6M, D6N

8T-3282

Flat Washer

D6H, D6R

5P-8249

Flat Washer

5. Attach top plate (11) to the top of the track links using the previously removed track bolts and track nuts.

NOTICE Do not use top plate (11) as a lifting device attachment point. Attaching an overhead lifting device to the top plate to raise or align the track chain will cause tooling damage.

15

9. Slide the lower two threaded rods (7) through puller plate (2).

7. Install a second top plate (11) onto the other track links using the track bolts and nuts. Place the required spacer between the track link and top plate (see Step 4 for spacer specs).

10. Thread two nuts (9) onto the two lower threaded rods until they contact the puller plate. The ends of the lower rods must be parallel with the ends of the upper rods. If the four rods are uneven at the ends, the guard group may not fit over the track press assembly when it is fully assembled.

8. Thread one half nut (8) onto each threaded rod.

WARNING Contact plate (1) weighs approximately 17 kg (37 lbs.) and will cause crushing injury to hands or feet if it slides off of the threaded rods. Hold the plate in place until centering blocks are installed (Step 12) and at least one half nut is installed (Step 13).

NOTE: Make sure there is at least 51 mm (2.0 in) between the top plate and the inside surface of half nut (8). This distance is required because the rods move in the direction of the top plate as the track link is pushed off.

16

11. Slide contact plate (1) with the contact tooling onto the four threaded rods.

13. Place one half nut (8) onto two threaded rods, as shown.

12. Install two cylinder centering blocks (10) onto the threaded rods. Install the blocks with the larger offset of the block facing each other.

10

265-8034

50 ton 0931-53

17

15. Install a 1/4-20 bolt into one of the holes in the contact plate (lower side). This will prevent the hydraulic cylinder from sliding out of the tooling during the link removal procedure.

14. Position (center) the contact tool over the cartridge pin and tighten half nuts (8) to hold the contact plate and contact tool firmly against the track pin. Verify the proper alignment of the contact tool to the cartridge pin center line. If the center lines are not aligned, add or remove shims under the top plate to align the mating surfaces. The track link has been removed for clarity of explanation.

WARNING Contact plate (1) weighs approximately 17 kg (37 lbs.) and will cause crushing injury to hands or feet if it slides off of the threaded rods. Hold the plate in place until nuts (9) are installed (Step 16).

16. Slide the second contact plate (1) onto the threaded rods. Allow enough distance between the two contact plates to insert the hydraulic cylinder. Hold the contact plate in place while installing one nut (9) onto each of the threaded rods.

18

17. Mark the center line of the hydraulic cylinder rod onto the side of the cylinder.

This mark will help align the hydraulic cylinder to the center line of the contact plates during the removal process.

20. Remove the two track bolts from the top plate of the track link being removed, as shown. Do not remove the track bolts from the other top plate.

WARNING If the track bolts are not removed from the top plate during the link removal process, the top plate will be damaged. Personal injury or death can occur due to the high forces exerted on the tooling, causing possible flying parts if the bolts are not removed.

18. Place a hydraulic cylinder (13) (rod side facing the link) between the two contact plates, centered from side-to-side.

21. Make sure all eight nuts (9) on the threaded rods are completely tightened against the front contact plate and the puller plate.

22. Make sure contact tool (4) is centered on each cartridge pin.

19. Connect the cylinder to a hydraulic power supply using a high-pressure hose.

19

25. Remove the track link.

23. Using the center mark on the cylinder, make sure it is centered, side-to-side, between the two contact plates.

a. Apply pressure to the hydraulic cylinder.

NOTE: The cylinder can be moved side-toside if one end of the track link comes off first.

Never position the cylinder past the end of the contact plate.

WARNING Cover work with the protective guard. With high forces being exerted on the part being removed/installed, breakage may sometimes result. By covering the work with the protective guard, the mechanic reduces the danger of personal injury or death by flying parts.

Never apply pressure to the track press until the guard is in place.

261-7492

b. Extend the cylinder fully to begin pulling the track link off of the cartridge pin.

NOTE: Increasing the pressure in small amounts (hydraulic pump ON and then OFF) may help the track link to be removed evenly from the cartridge pin.

24. Install guard group (12) around the track press assembly. Make sure all the snaps are secured and it is firmly held in place using the retaining straps.

20

c. When the cylinder is completely extended, release the pressure, but do not retract the cylinder rod.

NOTICE To prevent tool damage, make sure the half nuts on the end of the rods do not contact the top plate as the track link is removed.

d. Remove the guard and tighten two half nuts (8) against cylinder centering block (10). This will hold the contact tools against the track pins.

26. Remove the tooling and repeat the process to the other track link.

e. Fully retract the cylinders. f. Retighten four nuts (9) on the outer contact plate. Install the guard group and re-apply pressure to the cylinder.

g. Repeat this process until the link is removed.

21

3. Install puller plate (2) against inner link.

Using Optional Shim Plates Using a combination of shim plates allows the inner track link to be removed without moving the tooling to the inner side of the track chain.

This procedure is useful when clearance between the machine and the track chain prohibits or makes installation of the tooling impractical.

Additional Multi-Pitch Track Press Tools Item Part No.

Description

A1 268-7895

Shim, 12.7 mm (.500 in) thick

A2 268-7897

Shim, 25.4 mm (1.00 in) thick

A3 268-7898

Shim, 38.1 mm (1.50 in) thick

A4 268-7899

Shim, 50.8 mm (2.00 in) thick

A5 268-7900

Shim, 63.5 mm (2.50 in) thick

A6 268-7901

Shim, 76.2 mm (3.00 in) thick

4. Install appropriate shims (A6). The shims should extend past the face of cartridge pin (A) by at least the thickness of cartridge pin (A). If the shim thickness is too small, the tooling will interfere with the track chain before the inner link has been removed. If the shim thickness is too great, there may not be sufficient threaded rod to assemble the contact tool and cylinder.

WARNING Cover work with the protective guard. With high forces being exerted on the part being removed/installed, breakage may sometimes result. By covering the work with the protective guard, the mechanic reduces the danger of personal injury or death by flying parts.

Never apply pressure to the track press until the guard is in place.

261-7492

1. Remove outer link using the standard procedure.

2. Remove outer contact plate, top plate, and cylinder.

NOTE: On small track press tooling, the shoulders on the shim plate provides clearance. The extended portion of the shim will be between the threaded rods on small track press tooling. The photos show shims installed on large track press tooling.

5. Install one centering block (10) on the lower threaded rods.

22

6. Install contact plate (1).

9. Typical installation as viewed from machine side.

7. Install the cylinder, rod-side facing inward.

10. Use the typical procedure to remove the inner link.

8. Remove the bolts from the inner top plate.

NOTICE To prevent tooling damage, remove bolts from top plate before applying pressure.

23

1. Perform the following steps in order to connect the SystemOneTM track. 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.

Track Connect Procedure Required Parts Track Connect Parts List Item Part No.

Description

1

264-5768

Contact Plate

2

2

264-5770

Puller Plate (D6H, D6M, D6N, D6R, 953, 963) or Puller Plate (D3G, D4G, D5G, D5M, D5N)

1

268-1700

Qty.

7

264-5774

Acme Threaded Rod

4

8

265-9028

Acme Half Nut

4

9

265-8989

Acme Nut

8

10

264-5777

Cylinder Centering Block

2

11

264-5771

Top Plate (D6H, D6M, D6N, 1 D6R, 953, 963) or Top Plate (D3G, D4G, D5G, D5M, D5N) or Top Plate (Pre-production D6R)

268-5658

270-4487 12

267-21081

Guard Group

19

268-1699

Installation Contact Plate 2 (D3G, D4G, D5G, D5M, D5N)

20

265-9109

Screw

1

4

1 This guard group must cover the tool and track link area

whenever installing or removing a link.

1

D6H, D6M, D6N, D6R, 953, 963

D3G, D4G, D5G, D5M, D5N

9

19 20 1 1 7

11

1 2

11 9

D6H, D6M, D6N, D6R, 953, 963 8 10

0931-49

24

2. Make sure the track assembly is securely blocked with the appropriate cribbing.

3. Install the appropriate shim (flat washer) between the top of the track link and the top plate. Use the chart as a guide to select the appropriate shim.

NOTE: Use as many washers as necessary to center the tooling on the cartridge pins.

NOTE: A starter link and yoke plate can be used to hold the track chain together in order to install the starter link and the two top plates.

Model

Starter Link

Yoke Plate

D3G, D4G

242-5362

242-5303

D5G, D5M, D5N

252-9942

252-9939

D6H, D6R, 963

242-5369

242-5312

D6M, D6N, 953

252-9979

252-9975

25

Model

Part No.

Description

D3G, D4G

5P-8247

Flat Washer

D5G, D5M, D5N

5P-8247

Flat Washer

D6M, D6N, 953

8T-3282

Flat Washer

D6H, D6R, 963

5P-8249

Flat Washer

4. Attach two top plates (11) to the top of the track links using four previously removed track bolts and track nuts.

5. After the top plates are installed, make sure the bore of the track link aligns with the two mating cartridge pins. Do not try to install the track link if the mating parts are not aligned.

NOTE: The inside two holes (A) fit one model of track link while the outer two holes (B) are used for another model.

6. Place two threaded rods (7) through top plates (11).

E

B A

D C E A B C D

0931-52

Item Part No.

Description

A

264-5771

D6H, D6R, 963

B

264-5771

D6M, D6N, 953

C

268-5658

D3G, D4G

D

268-5658

D5G, D5M, D5N

E

270-4487

Pre-production D6R

WARNING Contact plate (1) weighs approximately 17 kg (37 lbs.) and will cause crushing injury to hands or feet if it slides off of the threaded rods. Hold the plate in place until nuts (9) are installed (Step 8).

26

8. Thread the full nuts onto the end of each rod so approximately 12 mm (.5 in) of thread is exposed on the end, as shown.

7. Slide the contact plate (1) onto the two threaded rods. Make sure the correct side of the contact plate is facing toward the track link, depending on the machine model (pitch distance). Do not let go of the plate until a nut (9) is installed on each of the threaded rods.

NOTICE The face of contact plate (1) with the counterbore must be facing the track link when working on D6H, D6M, D6N, D6R, D6H, 953, and 963 models. On the D3G, D4G, D5G, D5M, and D5N models, the contact plate is installed using an installation contact plate (19), with the counterbore facing away from the track link.

Incorrect installation of the contact plate will result in damage to the tooling and/or the track link/cartridge pin.

NOTE: Leave enough space between the contact plate and the cartridge pins to insert a track link.

WARNING Contact plate (1) weighs approximately 17 kg (37 lbs.) and will cause crushing injury to hands or feet if it slides off of the threaded rods. Hold the plate in place until nuts (8) are installed (Step 9).

NOTICE The face of contact plate (1) with the counterbore must be facing the track link when working on D6H, D6M, D6N, D6R, D6H, 953, and 963 models. On the D3G, D4G, D5G, D5M, and D5N models, the contact plate is installed using an installation contact plate (19), with the counterbore facing away from the track link.

Incorrect installation of the contact plate will result in damage to the tooling and/or the track link/cartridge pin.

27

9. Slide the second contact plate (1) onto the two threaded rods. Again, make sure the correct counterbore in the contact plate is facing toward the track link. Do not let go of the plate until one half nut (8) is installed on the threaded rods.

11. Thread two additional nuts (9) onto the two lower threaded rods. The ends of all the threaded rods should extend past the contact plate the same distance. If the four rods are uneven at the ends, the guard group may not fit over the track press assembly when it is fully assembled.

10. Slide two lower threaded rods (7) through the lower holes of both contact plates.

12. Thread one half nut (8) onto the lower threaded rod, as shown.

28

13. Apply 4C-5598 High Temperature AntiSeize to the bore of the track link and cartridge pins. Insert the track link between the contact plate and the cartridge pins. Push the contact plate against the track link to hold it in place.

15. Install the two cylinder centering blocks (10) onto the threaded rods. Install the blocks with the smaller offset of the block facing the center.

10

14. Tighten half nuts (8) to hold the track link in position against the cartridge pins.

265-8034

50 ton 0931-53

29

18. Place a hydraulic cylinder (rod side facing the link) between the contact plate and the puller plate, centered from side-to-side.

WARNING Puller plate (2) weighs approximately 7 kg (19 lbs.) and will cause crushing injury to hands or feet if it slides off of the threaded rods. Hold the plate in place until nuts (9) are installed (Step 16).

16. Slide puller plate (2) onto the threaded rods. Allow enough distance between the contact plate and the puller plate to insert the cylinder. Hold the plate in place while installing four nuts (9) onto one of the threaded rods.

19. Connect the cylinder to a hydraulic power supply using a high-pressure hose.

17. Install a 1/4-20 bolt into one of the holes in the contact plate (lower side). This will prevent the cylinder from sliding out of the tooling during the link installation procedure.

20. Make sure the counterbores in both contact plates are centered on the track bores. If the surface of the contact plate touches the cartridge pin, the track link will not be completely installed and excessive pressure will be placed against the cartridge pin.

21. Make sure all eight nuts (9) are tight against the contact plate and the puller plate. If the nuts are not completely tight, the link may be pushed unevenly onto the cartridge pins.

30

24. Install the track link.

22. Using the center mark on the cylinder, make sure it is centered, side-to-side, between the contact plates and puller plate.

a. Apply pressure to the hydraulic cylinder. b. Extend the cylinder fully to begin pulling the track link onto the cartridge pin.

NOTE: Increasing the pressure in small amounts (hydraulic pump ON and then OFF) may help the track link to be installed evenly onto the cartridge pins. c. When the cylinder is completely extended, release the pressure, but do not retract the cylinder rod. d. Remove the guard and tighten two half nuts (8) against the contact plate (1).

This will hold the contact tools against the cartridge pins.

WARNING Cover work with the protective guard.

With high forces being exerted on the part being removed/installed, breakage may sometimes result. By covering the work with the protective guard, the mechanic reduces the danger of personal injury or death by flying parts. Never apply pressure to the track press until the guard is in place.

261-7492

e. Fully retract the cylinder.

23. Install guard group (12) around the track press assembly. Make sure all the snaps are secured and it is firmly held in place using the retaining straps.

f. Retighten four nuts (9) on the contact plate. Install the guard and re-apply pressure to the cylinder.

31

g. Repeat this process until the link is installed. Normally, the link is fully installed when the pressure raises significantly above the pressure used to install the link.

Inspection/Cleaning Inspect and clean all the parts of the multi-pitch track press tool before and after each use. Refer to the “Inspection Guide” in this manual for additional inspection information.

h. Verify that the track link is fully installed on the cartridge pins.

Clean and lubricate the threads of the threaded rods frequently with a lightweight oil.

Clean threads will extend the service life of the threaded rods and decrease the assembly time.

25. Remove the tooling and repeat the process to the other track link.

NOTE: Both links can be installed from the same setup. Reposition the contact plates to install the other track link.

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 to prevent personal injury due to possible parts breakage.

If parts are worn or damaged, they must be replaced. All hydraulic components repair/replacement work must be performed by a certified hydraulic technician. For repair service, contact Dealer Service Tools.

WARNING Hydraulic equipment must only be serviced by a qualified hydraulic technician. Due to high pressure of the hydraulic system, personal injury or death could occur if the hydraulic equipment is incorrectly repaired or serviced.

32

1. Stretch the top flexible guard (12b) over the clear plastic guard (12a). Install four bolts (12d), eight washers (12f), and four nuts (12g), as shown.

Assembling the Guard Group Assemble the guard group and add the decals to the top of the clear plastic guard by using the following steps.

2. Place the top half of the assembled guard into the bottom half of flexible guard (12c).

Make sure the retaining strap loops on flexible guards (12b and 12c) are both on the same end.

12b

NOTE: Make sure the holes in the lower flexible guard are on the same end as the holes in the clear plastic guard.

12a 12c

12i

12d 12f

12e

12h

12j

12g 0931-03B

Item Part No. 12

267-21081

Description Guard Group

12a —

Clear Plastic Guard

12b —

Flexible Guard (Upper Half)

12c —

Flexible Guard (Lower Half)

12d —

Bolt (holds 12b to clear plastic guard)

12e —

Bolt (holds items 12b, 12c, 12h, and 12i to clear plastic guard)

12f —

Flat Washer

12g —

Nut

12h —

Retaining Strap

12i —

Retaining Strap with Clip

12j —

Retaining Strap Buckle

1 This guard group must cover the tool and track link area

whenever installing or removing a track link.

33

3. Insert the two retaining straps with clips (12i) under the loops in the top guard, as shown.

4. Place the other retaining strap (12h) under the guard. Align the bolt holes of the two metal clips with the holes in the fabric and the clear plastic guard. Install using two bolts (12e), four washers (12f), and two nuts (12g).

NOTE: Make sure the rough edge of the retaining strap is facing the flexible guard material. This will prevent anything from getting caught on the rough edge.

5. Place the retaining straps through the loops in the flexible guard, as shown.

34

6. Place the retaining strap through the clasp, as shown.

7. Connect the clip into the buckle of both straps.

8. If not already installed, attach the decals, as shown.

35

Inspection Guide Inspection Guide Item

Visual Inspection

Possible Solution

Plates (Contact and Puller)

Check for cracks.

Replace the plate if cracks are found.

Threaded rods

Check threaded rods for damaged or galled threads.

Replace any damaged parts.

Hydraulic hose

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

Replace any damaged hose.

Hydraulic cylinder

Check the fitting for leakage.

Replace the fitting. If this does not correct the leakage, replace the cylinder.

Contact tooling

Inspect the tooling for excessive wear or cracks.

If any damage is found, replace the tooling.

Clear plastic guard

Check for cracks in the plastic.

Replace the guard if any cracks are found.

Flexible guard

Check for damage such as holes or tears. Make sure all snaps are in place and work properly.

Replace the flexible guard if any damage is found.

Retaining straps

Check for wear, abrasions, tears, or other types of damage.

Replace the retaining strap if any damage is found.

Troubleshooting Chart Troubleshooting Chart Problem

Possible Cause

Possible Solution

Hydraulic force not applied by cylinder.

Hydraulic power supply malfunctioning.

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

Quick disconnect fitting is not completely seated.

Completely connect or seat the fitting.

Damaged threads.

Replace threaded items.

Wrong parts.

Use correct parts.

Misaligned tooling.

Align tooling.

Damaged threads or threaded rods.

Replace threaded rods.

Parts of tool will not assemble.

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

Hydraulic leakage.

Worn contact tool.

Replace contact tooling.

Link is stuck.

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

Insufficient hydraulic force.

Use larger cylinder, but do not exceed maximum pressure rating for the tooling.

Leaky cylinder.

Replace cylinder.

Leaky hose.

Replace hose.

Leaky fitting.

Tighten or replace fitting.

36

Declaration of Conformity

37

Notes

38

Notes

39

For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 501 S.W. Jefferson Peoria, IL U.S.A. 61630-2184 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_Hotline@cat.com

©2005 Caterpillar All Rights Reserved

NEHS0931-01 Printed in U.S.A.