Caterpillar Small Multi-Pitch SystemOne Track Press Tool Operating Manual - PDF DOWNLOAD

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TOOL OPERATING MANUAL Operation and Parts for Small Multi-Pitch SystemOneTM Track Press Tool SMCS: 4150

NEHS0930 April 2005

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 Hoses . . . . . . . . . . . . . . . . . 9 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . 9 Additional Contact Information . . . . . . . . . . 10 References. . . . . . . . . . . . . . . . . . . . . . . . . . 10 Basic Multi-Pitch Track Press Tools . . . . . . . 11 Additional Multi-Pitch Track Press Tools . . . 13 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Track Separate Procedure . . . . . . . . . . . . 14 Required Parts . . . . . . . . . . . . . . . . . . . 14 Using Optional Shim Plates . . . . . . . . . 23 Track Connect Procedure . . . . . . . . . . . . 25 Required Parts . . . . . . . . . . . . . . . . . . . 25 Inspection/Cleaning . . . . . . . . . . . . . . . . . . . 33 Installing the Retaining Straps and Safety Decals Onto the Clear Plastic Guard . . . . 34 Inspection Guide . . . . . . . . . . . . . . . . . . . . . 35 Troubleshooting Chart . . . . . . . . . . . . . . . . . 35

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

1

1 49 1-7 26

2

2 49 1-7 26

261-7492

261-7491

0930-47

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

0930-54

0930-55

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

0930-57

WARNING

0930-56

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 Small Multi-Pitch Track Press Tools are sold as individual pieces. Using these tools, the following machine models can be serviced: D3G, D4G, D5G, D5M, and D5N Track-Type Tractors. Different combinations of tools can be ordered to make removal and installation of track links faster and work on several different machine models. For future releases of SystemOneTM track, individual parts can be ordered to expand the versatility of the tooling (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

NOTICE

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.

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.

WARNING

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

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 including the 1U-7519, 1U-7520, 2P-5550, 2P-5500, 1U-7545, 1U-7524, 1U-7554, or 1U-7522 Electric Power Supplies, the 1U-7545 Air-Over-Hydraulic Power Supply (shown below), or the 1U-5230 or 1U-7544 Hydraulic Hand Pumps.

Also required to operate the multi-pitch track press tool is a hydraulic cylinder. Two lowheight (flat) cylinders are available for use with this tooling. A 265-8034 50 ton Cylinder or a 6V-3170 55 ton Cylinder will work with the multi-pitch track press tool, depending on the amount of force required for your specific application. Other similar hydraulic cylinders will also work.

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

NOTE: Using the 6V-3170 Cylinder (double acting) will require two hoses and a hydraulic power supply with an inlet and outlet connection.

High-Pressure Hoses 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.

NOTICE Do not exceed 55 tons of force for the cylinder being used.

Refer to Caterpillar’s NENG2500 Tools and Shop Products Guide for possible hoses.

9

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

References NEHS0923

Master Link Tools for SystemOneTM Track

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

10

Basic Multi-Pitch Track Press Tools Refer to the Track Connect or Track Separate Procedure in this manual for quantities of each part.

Item Part No.

Description

1

266-8989

Contact Plate

2

266-8992

Puller Plate

3

—

Not Used

4

266-8997

Removal Contact Tool (D3G, D4G) or Removal Contact Tool (D5G, D5M, D5N)

268-1698 5

4L-7124

6

—

Socket Head Cap Screw Not Used

7

266-8994

Acme Threaded Rod

8

266-8999

Acme Half Nut

9

266-8998

Acme Nut

10

266-8996

Cylinder Centering Block

11

266-8993

Top Plate (D3G, D4G, D5M, D5N)

12

264-57761

Clear Plastic Guard

12a 2J-5245

Socket Head Cap Screw

12b 5M-2894

Flat Washer

12c 9S-8752

Nut

12d 264-5772

Retaining Strap

13

265-8034

50 ton Cylinder

14

6V-3170

55 ton Cylinder

1 This guard or a ballistic protective blanket must cover the tool

and track link area whenever installing or removing a track link.

11

Basic Multi-Pitch Track Press Tools 1 266-8989 (2)

4 266-8997 (2) 268-1698 (2)

5 4L-7124 (2)

2 266-8992 11 266-8993 (2) 7 266-8994 (4)

9 266-8998 (8) 10 266-8996 (2)

8 266-8999 (4)

12a 2J-5245 (2)

13 265-8034

12b 5M-2894 (4) 12c 9S-8752 (2) 12 264-5776 14 6V-3170

12d 264-5772 (2)

0930-04A

12

Additional Multi-Pitch Track Press Tools

Additional Multi-Pitch Track Press Tools Item Part No.

A4 A1

A5 A2

A6 A3

0930-58

13

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 368-7901

Shim, 76.2 mm (3.00 in) thick

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 round counterbore side of the contact plate is used for track links with a pitch distance of 175.4 mm (6.91 in).

The other side is used for pitches with distances of 190 mm (7.5 in) or 171.1 mm (6.75 in).

Required Parts Track Separate Parts List Item Part No.

Description

Qty.

1

266-89892

Contact Plate

2

2

266-8992

Puller Plate

1

4

266-8997

Removal Contact Tool (D3G, D4G) or Removal Contact Tool (D5G, D5M, D5N)

2

268-1698

2

5

4L-7124

Socket Head Cap Screw

2

7

266-8994

Acme Threaded Rod

4

8

266-8999

Acme Half Nut

4

9

266-8998

Acme Nut

8

10

266-8996

Cylinder Centering Block

2

11

266-8993

Top Plate (D3G, D4G)

2

12

264-57761

Clear Plastic Guard Assembly 1

1 This guard or a ballistic protective blanket must cover the tool

and track link area whenever installing or removing a track link.

2 The face of the contact plate with the single counterbore must

be facing the track link when working on D3G and D4G models. The face of the contact plate with the double counterbore must be facing the track link when working on D5G, D5M, and D5N models.

7 2 5

4

D5G, D5M, D5N

8

11

11

1

1

9

10 7 5 4 D3G, D4G

9 8

10 0930-48

14

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 The face of contact plate (1) with the single counterbore must be facing the track link when working on D3G and D4G models. The face of the contact plate with the double counterbore must be facing the track link when working on D5G, D5M, and D5N models.

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

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 and/or pitch, using socket head cap screws (5).

NOTE: The photos show a larger model machine, but the set-up of the tooling is the same for the small multi-pitch tooling.

2. Block the track assembly with the appropriate cribbing.

Model

Contact Tool Contact Plate Pitch mm (in)

D3G, D4G

266-8997

266-8989

175.4 (6.91)

D5G, D5M, D5N 268-1698

266-8989

171.1 (6.75)

171.1 mm (6.75 in)

268-1698

D5G, D5M, D5N

15

175.4 mm (6.91 in)

266-8989

266-8997

D3G, D4G

0930-09

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.

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

NOTE: The inside two holes (B) of the 266-8993 Top Plate are for D3G/D4G models, while the outer two holes (A) are used for the D5G, D5M, D5N models.

BA

A B

0930-52

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

Item Part No. Model

Part No.

Description

D3G, D4G

5P-8247

Flat Washer

D5G, D5M, D5N

5P-8247

Flat Washer

Description

A

266-8993

D5G, D5M, D5N

B

266-8993

D3G, D4G

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

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.

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

16

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 12 kg (28 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.

17

12. Install two cylinder centering blocks (10) onto the threaded rods. Install the blocks with the smaller offset of the block facing the center, if using the 265-8034 50 ton Cylinder.

NOTICE The face of contact plate (1) with the single counterbore must be facing the track link when working on D3G and D4G models. The face of the contact plate with the double counterbore must be facing the track link when working on D5G, D5M, and D5N models.

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

NOTE: If the 6V-7130 Cylinder is used, do not install the cylinder centering blocks.

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

10

265-8034

6V-3170

50 ton

55 ton 0930-53

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

18

15. Install a 1/4-20 bolt, customer supplied, 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 12 kg (28 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.

19

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 or 14) (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.

20

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

261-7492

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

24. Install either the clear plastic guard (12) or a protective blanket over the track press assembly. If using the clear plastic guard, make sure it is firmly held in place using the retaining belts.

21

g. Repeat this process until the link is removed.

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 pins. 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.

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

e. Fully retract the cylinder.

NOTE: Make sure the link is completely removed from both track pins before removing the tooling.

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

22

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

Install appropriate shim (A1-A6) on the upper threaded rods with the thick body of the shim facing away from the puller plate, as shown.

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 the outer top plate (11).

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

261-7492

1. Remove outer link using the standard procedure.

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

23

7. Install the cylinder, rod side inward.

5. Install appropriate shim (A1-A6) on the upper threaded rods with the thick body of the shim facing in. Make sure clearance (X) is greater than the thickness of the inner track link being removed.

8. Remove the bolts from the inner top plate.

NOTICE To prevent tooling damage, clearance (X) between the top plate and the hanger plate on the outer shim must be greater than the thickness of the inner track link being removed.

6. Install two centering blocks (10), contact plate (1), and four nuts (9).

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

9. Typical installation as viewed from machine side.

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

24

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

Qty.

1

266-89892

Contact Plate

2

2

266-8992

Puller Plate

1

7

266-8994

Acme Threaded Rod

4

8

266-8999

Acme Half Nut

4

9

266-8998

Acme Nut

8

10

266-8996

Cylinder Centering Block

2

11

266-8993

Top Plate

2

12

264-57761

Clear Plastic Guard Assembly 1

NOTE: The photos show a larger model machine, but the set-up of the tooling is the same for the small multi-pitch tooling.

1 This guard or a ballistic protective blanket must cover the tool

and track link area whenever installing or removing a link.

2 The face of the contact plate with the single counterbore must

be facing the track link when working on D3G and D4G models. The face of the contact plate with the double counterbore must be facing the track link when working on D5G, D5M, and D5N models.

1

9

D5G, D5M, D5N 7

11

D3G, D4G D5G, D5M, D5N

1

2 11 9

8

D3G, D4G

10

0930-49

25

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

3. Install the appropriate shim 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.

26

Model

Part No.

Description

D3G, D4G

5P-8247

Flat Washer

D5G, D5M, D5N

5P-8247

Flat Washer

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.

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.

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

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.

NOTE: The inside two holes (B) of the 266-8993 Top Plate are for D3G/D4G models, while the outer two holes (A) are used for the D5G, D5M, D5N models.

BA

A B

0930-52

Item Part No.

Description

A

266-8993

D5G, D5M, D5N

B

266-8993

D3G, D4G

27

Model

Starter Link

Yoke Plate

D3G, D4G

242-5362

242-5303

D5G, D5M, D5N

252-9942

252-9939

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

171.1 mm (6.75 in)

D5G, D5M, D5N

WARNING Contact plate (1) weighs approximately 12 kg (28 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).

D3G, D4G

175.4 mm (6.91 in)

0930-51

Model

Contact Tool Contact Plate Pitch mm (in)

D3G, D4G

266-8997

266-8989

175.4 (6.91)

D5G, D5M, D5N 268-1698

266-8989

171.1 (6.75)

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

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 single counterbore must be facing the track link when working on D3G and D4G models. The face of the contact plate with the double counterbore must be facing the track link when working on D5G, D5M, and D5N models.

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

28

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.

NOTICE The face of contact plate (1) with the single counterbore must be facing the track link when working on D3G and D4G models. The face of the contact plate with the double counterbore must be facing the track link when working on D5G, D5M, and D5N models.

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

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

WARNING Contact plate (1) weighs approximately 12 kg (28 lbs.) and will cause crushing injury to hands or feet if it slides off of the threaded rods. Hold the plate in place until half nuts (8) are installed (Step 9).

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.

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.

29

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

15. Install two cylinder centering blocks (10) onto the threaded rods. Install the blocks with the smaller offset of the block facing the center, if using the 265-8034 50 ton Cylinder.

NOTE: If the 6V-7130 Cylinder is used, do not install the cylinder centering blocks.

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.

10

265-8034

6V-3170

50 ton

55 ton 0930-53

WARNING Contact plate (1) weighs approximately 12 kg (28 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).

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

30

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

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 track pins.

31

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

261-7492

23. Install the clear plastic guard or protective blanket over the track press assembly. If using the clear plastic guard, make sure it is firmly held in place using the retaining belts.

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

32

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 light-weight 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.

33

2. Attach the following decals to the top of the clear plastic guard: 261-7491, Remove Pressure Warning Decal (4); 261-7492, Do Not Operate Without Guard Decal (3); 261-7493, Safety Glasses/Ear Protection Decal (1); 224-0554, Read Manual Decal (2).

Installing the Retaining Straps and Safety Decals Onto the Clear Plastic Guard It is necessary to install the 264-5772 Retaining Straps onto the 254-5776 Clear Plastic Guard.

1. Attach the two clip ends of the retaining strap to the clear plastic guard using a 2J-5245 Socket Head Cap Screw, two 5M-2894 Flat Washers, and a 9S-8752 Nut. Repeat this process on the other retaining strap.

2

1 4 93 -74 261

91 -74 261

92 -74 261

264-5772 9S-8752 3

0930-47a

5M-2894 2J-5245

264-5772

5M-2894

0930-03A

34

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.

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 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.

Possible Cause

Possible Solution

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.

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.

Use large multi-pitch tooling.

Leaky cylinder.

Replace cylinder.

Leaky hose.

Replace hose.

Leaky fitting.

Tighten or replace fitting.

35

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

NEHS0930 Printed in U.S.A.