Caterpillar Torque-Turn 7000 Hydraulic Track Wrench Tool Operating Manual - PDF DOWNLOAD

NEHS0703 February 1998

TOOL OPERATING MANUAL Torque-Turn 7000 Hydraulic Track Wrench SMCS Code 0729

Contents This manual contains the necessary information to install, operate, and maintain the track wrench.

Read and understand the Safety Section of this manual before operating the track wrench.

Bodily injury may result from the improper operation of the hydraulic track wrench.

Warranty Information For one year from date of purchase, Caterpillar Service Technology Group (CSTG) will replace for the original purchasers, free of charge, any part, or parts of equipment manufactured by CSTG found upon examination by the factory to be defective in material, workmanship, or both: this is the exclusive remedy. All transportation charges on parts submitted for replacement under this warranty must be born by the purchaser. THERE IS NO OTHER EXPRESS WARRANTY. IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM PURCHASE AND TO THE EXTENT PERMITTED BY LAW AND ALL IMPLIED WARRANTIES ARE EXCLUDED. LIABILITY FOR CONSEQUENTIAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW.

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Ordering Procedures The hydraulic track wrench and related tooling can be ordered through Caterpillar Class 3A emergency ordering procedure. Emergency order charges will not apply and shipment will be by surface carrier. Delivery within North America is F.O.B., Louisville, KY. Deliveries outside North America are for dealer account and are subject to C.I.F. plus EXP.

For your convenience...

Whenever you have questions or comments about our products or programs, we want you to use the phone numbers listed below to: • discuss tool applications or uses • answer questions about tool repair • resolve tool availability issues • register price complaints • clarify information in our publications • discuss benefits or our new products Caterpillar Service Technology Group is here to provide you the best service and products available.

If you’re needing faster service or have to get in touch with us here in the Caterpillar Service Technology Group, we want you to call us. Our toll free numbers are: 1-800-541-8665 ..... Illinois 1-800-542-8665 ..... USA 1-800-523-8665 ..... Canada 32 (2) 254.42.71 ... Grimbergen, Belgium or #404435 Telex ........ USA 1-309-675-6618 FAX ..... USA 32 (2) 252.56.06 FAX ... Grimbergen, Belgium Caterpillar Service Technology Group 600 W. Washington Street, Building AH East Peoria, Illinois 61630

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Safety Procedures

5. Keep hands and fingers clear of the area in the track link below the track bolts.

Read and understand all the safety procedures and operating instructions before operating the Torque-Turn 7000 Hydraulic Track Wrench

• The track wrench can apply high downward pressure on the bolt very quickly forcing the bolts down through the shoe and link. Anything under the bolt and nut is pushed down against the link.

Trapping the fingers in this situation could cause injury. Always use nut wrenches or pry bars to hold the track nuts while operating the track wrench.

1. Follow the Caterpillar guidelines for use and reuse of nuts and bolts.

6. Keep hands clear of the socket/arbor area to avoid possible injury.

• Use the recommended lubricants and only those bolts and nuts which have clean threads in good condition. The use of recommended lubricants reduces the torque required to properly tighten the bolts and reduces the loading imposed on the hydraulic track wrench and tooling.

• The operator should always keep hands, fingers, hair, and articles of clothing clear of rotating machinery. The track wrench delivers very high torque at high rotating speeds through the arbor.

Use the Start/Stop mushroom button anytime the arbor/socket has to be touched.

2. Keep hands out of area between the track and the sides of the conveyor.

7. Always hold the nut wrench (spoon) so that your hand cannot become trapped.

• The high torque generated by the track wrench in both FORWARD and REVERSE shifts the track to the side of the conveyor. This is particularly true for each end of the track. Tracks with dry joints and sealed track with internal wear move these joints to the side of the conveyor. A part of the track which has moved to the side during disassembly moves to the other side during assembly. Always be prepared for the track to slide to the side of the conveyor. Never place the hands between the sides of the conveyor and the track while operating the track wrench.

• Burrs or rust in the threads can suddenly increase the torque required to turn the bolt.

High torque not reacted by the seat in the track link can force the nut wrench (spoon) or pry bar to suddenly shift to the side during either the tightening or loosening process.

8. Do not torque-turn any bolt if there is a question that it may have been torque-turned previously.

• Pushing the Cycle Start button with the Forward/Reverse Switch in the FORWARD position, starts the track wrench in high gear for fast "run-down" of the bolt. Locating the socket on a bolt previously torque-turned, shifts the track wrench into low gear and tightens the bolt to pretorque, and then turns the bolt an additional 120 degrees. Each time the procedure is repeated, the bolt is turned another 120 degrees until the bolt is broken, damaged, or the drive torque exceeds the 9492 N⋅m (7000 lb ft) capacity of the track wrench. This unnecessarily loads the track wrench, sockets, and reducers and can break or damage the bolt. Loosen any bolt, if there is any question that it may have already been torqued, and torque-turn it again.

3. Always push IN the Pump Start/Stop mushroom button before installing or changing a socket.

• The track wrench has an automatic shutoff feature which minimizes the heat build-up in the oil reservoir. The pumps and motor shut off after 2 minutes of inactivity. Touching the Cycle Start button on the pistol grip instantly restarts the pump and motor and starts the arbor rotation.

Starting the arbor rotation while installing a socket could cause injury.

4. Start the track bolts by hand or with a small power tool before using the track wrench.

• Application of downward pressure and/or torque before the bolt and nut threads are properly engaged, can damage the bolt and nut. Position the shoes on the track chain and line up the bolt holes. Install the bolts and nuts at least four threads by hand or with a small power tool.

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Installation

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Special Tools and Materials Required . . . . . . . . . . 42 Installation on Caterpillar Conveyor. . . . . . . . . . . . 43 Installation of 4C-8614 Support Rail on Wolf Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Construction of Support Rail . . . . . . . . . . . . . . . . . 50 Options

Safety Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Introduction Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Controls

Frame Protection - LPG Track . . . . . . . . . . . . . . . . 53 Nut Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Pistol Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Parts Listing

Operation

152-2772 Wrench Assembly . . . . . . . . . . . . . . . . . 52 149-9950 Hydraulic Torque Turn Wrench Group (TT-7000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General Description. . . . . . . . . . . . . . . . . . . . . . . . 11 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Angle Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Maintenance Lubrication: Main Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Walk-Around Inspection . . . . . . . . . . . . . . . . . . . 16 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Instrumentation Hydraulic Schematic. . . . . . . . . 17 Instrumentation Electrical Schematic . . . . . . . . . 18 Electrical Sequence of Operation. . . . . . . . . . . . 21 Programmable Controller Fuses . . . . . . . . . . . . . 21 Replace Programmable Controller . . . . . . . . . . . 22 Strain Gage Link . . . . . . . . . . . . . . . . . . . . . . . . . 22 Spike Suppresser . . . . . . . . . . . . . . . . . . . . . . . . 23 Angle Optics Pickup . . . . . . . . . . . . . . . . . . . . . . 24 Directional Control Valves. . . . . . . . . . . . . . . . . . 24 Troubleshooting Guide for Experienced Electricians. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Controller Program . . . . . . . . . . . . . . . . . . . . . . . 28 Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . 40 Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . 41 Troubleshooting the Hydraulic System. . . . . . . . 42

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• All the primary operator controls are located in the swivel-mounted control handle. The pistol grip contains the control buttons for: Cycle Start, Head Raise, and Head Lower. The switch box mounted immediately above the pistol grip, contains switches for: Forward/Reverse and On/Off. It also contains a green cycle complete light.

Introduction The track wrench tightens track bolts using the torque-turn procedure recommended by Caterpillar. Torque-turn is the most dependable means of fastening track shoes and shoe loosening, due to inadequately tightened bolts, should be eliminated. The term "torque-turn" refers to a two step tightening procedure.

Dimensions

The first step is to tighten the bolt to a predetermined torque called a "pretorque". There is a pretorque recommended for each bolt size and track size. The second step is to "turn" the bolt an additional amount or angle. All standard track bolts require an additional 120 degrees of turn after the pretorque has been applied. The track wrench automatically applies the correct amount of torque to the bolt to complete the turn.

• The inside frame dimension is 44.0 inches (1118 mm). The track wrench handles the widest Caterpillar tracks using a pad lifter; avoids unnecessary handling; one-of-a-kind special shoes, wider than 44.0 inches can be worked with the track wrench, but the shoes must be removed from the conveyor.

• The vertical travel is 14.0 inches (356 mm).

Maximum raise locates D11N sockets 5 inches above shoes. It can also reach small tracks without extensions.

• The side-to-side pivot of the arbor is 11.5 inches from the center of the conveyor. This allows for 23.0 inches of side-to-side travel. The swing can be adjusted to 43.0 inches to accommodate quad track.

• The 1.5 inch square drive utilizes all current track sockets and reducers.

Some master bolts require 180 degrees of turn.

Master bolts, generally, are not assembled in the shop.

The FORWARD setting, used to install bolts, starts the track wrench at high speed to run down the bolt quickly. The track wrench automatically shifts to low speed to apply the correct turn. The REVERSE setting, used to remove bolts, starts the track wrench in "low-speed, high-torque" to break the bolt loose, and then automatically shifts to high-speed to quickly remove the bolt.

Mounting • The track wrench can be directly mounted to Caterpillar conveyor.

• The tram wheels, which support the track wrench, are adjustable (in and out) to fit a wide range of conveyor types. A rail conversion kit and/or rail assembly instructions, are available to mount the track wrench on other conveyors.

Features Breakaway Torque • The breakaway torque is 7000 lb ft (9492 N⋅m) which is the capacity for all current and future Caterpillar tracks.

Accurate Torque-Turn Quiet (all hydraulic) • Power is supplied by an on-board 10 hp electric motor and a two-section vane pump.

High speed • Automatic shifting capabilities between high speed run-in and low speed for the final turn.

Also shifts between "low-speed, high-torque" for breakaway, to high speed for run out.

Simple controls (easy to use) • Set the pretorque value, select the correct socket, push a button, and operate the wrench.

• Controls are designed for one person operation.

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Reduced Operation Cost • Salvaging bolts. The 2400 lb (10.7 kN) maximum down force on the sockets removes worn bolts that previously had to be cut off with a torch.

• Novice operator. A new operator is able to set the pretorque, select the correct socket for the track bolt, locate the socket on the bolt head, and squeeze the trigger. The track wrench does the rest. In contrast, the operator using an impact style wrench, must use the impact sound to set the bolt "tight enough" without breaking it.

• Socket life. The service life of sockets and reducers are increased. This is accomplished by the steady torque applied by the track wrench and the high down force on the socket, used to break loose worn bolts. The replacement cost of drivers and reducers are therefore reduced.

• Maintenance costs. The track wrench is a simple planetary gear design requiring only periodic oil and filter changes. In contrast, the impact wrench requires frequent disassembly and parts replacement.

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Illustration 1. Torque-Turn 7000 Hydraulic Track Wrench (Front View of Track Wrench) (1) Drive socket. (2) Drive arbor. (3) Pistol grip. (4) Gear case. (5) Head lift cylinder. (6) Pretorque light.

(7) Turns achieved light. (9) Control box. (10) Frame.

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Illustration 2. Torque-Turn 7000 Hydraulic Track Wrench (Rear View of Track Wrench) (8) Caterpillar torque-turn specifications chart. (11) Shift cylinder. (12) Hydraulic drive motor.

(13) Hydraulic oil fill port. (14) Directional control valve (Arbor rotation CW/CCW). (15) Directional control valve (Head RAISE/LOWER). (16) Directional control valve (Gear shift high/low). (17) Hydraulic oil filter.

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Control Box

Controls Pistol Grip

Illustration 5. Control Box Controls.

(24) Turns achieved light. (25) Pretorque light.

(26) Pretorque input number pad. (27) Function buttons: Set pretorque, Set calibration number, Check set values, Check transducer center, Cycle count.

Illustration 3. Pistol Grip Controls.

(18) Arbor direction switch - Forward (CW) and Reverse (CCW). (19) Turns achieved light. (20) Pump Start/Stop mushroom button. (21) Cycle Start button.

Illustration 4. Pistol Grip Controls (Side view) (22) Head lower button. (23) Head raise button.

Note: The motor and pumps shut down after 20 seconds of inactivity. Restart by touching either the Pump Start/Stop mushroom button (20) or the Cycle Start button (21) on the control handle .

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The track wrench is moved along the conveyor from shoe to shoe as the track is worked. The operator moves the track wrench using one of four hand wheels from either side of the conveyor. The track wrench rolls on tram wheels (30), mounted into the track wrench support rails (32) on each side of the conveyor. Split fastening rings (29) are used to adjust tram wheel (30) spacing to fit a variety of conveyors.

Operation Setup 1. Make sure the area around the arbor is clear.

2. Push in the Start/Stop mushroom button.

3. Turn on the power and leave it on for twenty minutes. This makes the setup procedure more precise.

The track wrench should be installed with a small gap (see the Installation Section of this manual) between the faces of the tram wheels (30) and the webs of the track wrench support rails (32) at the widest point in the conveyor. Periodically, check that split fastening rings (29) are tight and that the gap has not increased.

The weight of the drive motor and pump pulls the hydraulic track wrench to one side of the conveyor.

Nearly all of the initial gap occurs at the tram wheels (30), on the motor side of the track wrench. Operating forces on the track wrench force the track wrench to move relative to track wrench support rails (32). Guide wheels (31) should be extended about .06 inch closer to the web of the track wrench support rails (32) than the inside face of the tram wheels 30). Proper adjustment of the guide wheels (31) keeps the track wrench freely moving the length of the conveyor.

4. Make sure the arbor is not on a bolt and that nothing is exerting a side force on the gear case.

5. Read and understand the Operation Section of this manual before operating the track wrench.

General Description An on-board 10 hp electric motor drives a two-section vane pump to develop the hydraulic power. Hydraulic power is directed by solenoids and directional control valves mounted on the manifold located on back of the frame.

The hydraulic drive motor, mounted on top of the planetary gear case, delivers the power to a two-speed planetary gear system.

The track wrench can be mounted directly to the Caterpillar conveyor and track wrench rail. Other conveyor designs can be converted to accept the track wrench by adding a support rail (see the Installation Section of this manual).

Locate the socket above the bolt head by swinging the planetary gear case from side to side. Use the swivel mounted pistol grip controller to push or pull the planetary gear case side to side. The planetary gear case can swing a total of 107 cm (42.0 in) to locate the socket over any bolt on the shoe.

Use the Head Raise/Lower buttons on the pistol grip to move the head up or down and locate the socket on the bolt head. The head can be moved vertically a total of 35 cm (14.0 in) which eliminates the need for extensions to reach small track. Use the Head Lower button to move the socket down onto the head of the track bolt to be worked. Release the Head Lower button and depress the Cycle Start button to begin.

The socket drops into engagement with the bolt head.

Two flow control valves and a spring have been used to create an "indirect" connection between the gear head and the socket. The indirect connection allows the socket to be moved vertically a short distance before the socket comes up against the gear head. High down force is not required to break loose bolts with unworn heads.

Illustration 6. Wrench Travel Mechanism (28) Hand wheel. (29) Split fastening ring. (30) Tram wheel.

(31) Guide wheel. (32) Track wrench support rail.

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Apply high down force to bolt head only after the socket has dropped down into engagement with the bolt head. Applying high down force with the socket on top of the bolt and then rotating the socket into engagement creates unnecessarily high impact loads on the track wrench. Holding down the Head Lower button after the socket has been engaged with the bolt head produces a down force on the socket of 10.7 kN (2400 lbs). The high down force applied to a socket in good condition removes all but the most worn down bolts. A touch of the Head Lift button removes the down force from the bolt head.

The indirect connection, between the socket and gear head, provides that this can be done without lifting the socket off the bolt head.

NOTE: Remember the following guidelines: —Apply down force after the socket has been engaged with the bolt head.

—Apply high down force to break loose ONLY those bolts with badly worn heads.

The "indirect" connection also simplifies bolt installation. Two methods are used to hold the nut from spinning. Either the nut is held up against the nut seat or the nut is held in a nut wrench (spoon). The bolt head can be held above the surface of the shoe in either case. The bolt should have been started into the nut at least four threads before the track wrench is used. High down force applied on a bolt head with less than four threads engaged, may destroy both the bolt and the nut. Applying high down force pushes the nut down out of the nut seat. Use the Head Lower button to lower the socket onto the bolt head. Release the Head Lower button as soon as the socket touches the bolt head. Press the Cycle Start button to engage the socket with the bolt head and install the bolt. The gear head will automatically follow the bolt in or out of the shoe.

The track wrench function is determined by a programmable controller with routines for FORWARD and REVERSE. Use FORWARD to install bolts, and REVERSE to remove bolts. A button pad on the control box is used to set the pretorque required for the track being worked. An amber light is illuminated the instant pretorque is achieved. The wrench will then do an angle count.

A green light is illuminated when the correct turn is achieved. When the Cycle Start button is released, pretorque and turn lights are reset.

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Hold down the Cycle Start button to engage the bolt and socket and to run down the bolt at high speed.

The gear head will automatically follow the bolt as it moves down. Pulling the nut up against the seat in the track link increases the torque required. The track wrench shifts automatically into low speed to finish tightening the bolt. The track wrench pauses briefly when it shifts into low gear. DO NOT RELEASE THE CYCLE START BUTTON UNTIL THE TORQUE-TURN PROCESS IS COMPLETED.

Assembly Note: Read the important safety procedures before operating the track wrench.

There are three pieces or information needed to assemble track shoes. These are the pretorque, the socket part number, and the nut wrench part number required for the track. This information is provided on the Caterpillar Torque-Turn Specifications Chart attached to the control box on the track wrench.

Two conditions cause the track wrench to shift into low gear. These two conditions are either reaching the pretorque or the maximum drive torque for high speed operation. Maximum drive torque, for shifting purposes, is estimated using the hydraulic drive pressure. Large bolts reach maximum drive torque before pretorque is reached. The track wrench tightens large bolts by shifting into low gear and then increasing torque until the bolt reaches pretorque. Then the additional 120 degrees are turned.

Small bolts reach pretorque before the track wrench reaches the maximum drive torque. The track wrench starts recording the angle turned the instant the bolt reaches pretorque. The track wrench decelerates to a stop, shifts, then completes the 120 degree turn. The smallest bolts can be turned 20 to 30 degrees before the track wrench can stop to shift. The socket turns the additional 90 to 100 degrees after the shift has occurred. It may appear from watching the socket only that the bolt has not received the full turn. The turn can be checked by watching for the amber light on the torque display to illuminate. The instant the amber light comes on watch the socket to assure that the bolt is turned a portion of the 120 degrees required before the track wrench can shift. The remainder of the turn is completed after the track wrench shifts into low gear.

Illustration 7. Control Box Controls (24) Turns achieved light. (25) Pretorque light.

(26) Pretorque input number pad. (27) Function buttons: Set pretorque, Set calibration number, Check set values, Check transducer center, Cycle count.

Make sure that the area around the arbor is clear of foreign objects and debris. Push in the Pump Start/Stop mushroom button, to STOP the pump, before placing the socket on the arbor. Install the socket on the arbor using a large diameter pin such as a roll pin.

Turn the Forward/Reverse switch on the pistol grip control handle to FORWARD (CW). Start the pump by pulling out the Start/Stop mushroom button.

Position the socket over the track shoe using the hand wheel to move the track wrench along the conveyor. Use the pistol to swing the planetary gear case and locate the socket over the track bolt. Lower the socket onto the bolt head. Release the Head Lower button as soon as the socket comes in contact with the bolt head. The socket may not completely line up with the bolt head.

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Disassembly

Angle Check

Note: Read the important safety procedures before operating the track wrench.

Tighten a fastener to the proper pretorque with a standard torque wrench. Mark the position of one of the flats on the bolt head. Turn the Forward/Reverse switch on the pistol grip control handle to the FORWARD position (CW). Set the pretorque value into the controller. Position the socket over the bolt and finish installing the bolt. The track wrench should turn the bolt head two flats and the turns achieved light will illuminate.

Two items are needed to disassemble track shoes.

The nut wrench and the socket part numbers required for the track. These part numbers are provided on the Caterpillar Torque-Turn Specifications Chart found on the control box on the track wrench. Make sure the area around the arbor is clear of foreign objects and debris. Push in (stop) the Start/Stop mushroom button before placing the socket on the arbor. Install the socket using a large diameter pin such as a roll pin.

Maintenance

Turn the Forward/Reverse switch to REVERSE (CCW).

Start the pump by pulling out the Pump Start/Stop mushroom button. Position the socket over the track shoe using the hand wheel to move the track wrench along the conveyor. Use the pistol grip to swing the planetary gear case and locate the socket over the track bolt. Lower the socket onto the bolt head.

Release the Head Lower button as soon as the socket comes in contact with the bolt head. The socket may not completely line up with the bolt head. "Bump" the Cycle Start button to engage the bolt and the socket.

New bolts or bolts with little wear can be broken loose without maximum down pressure. Hold down the Head Lower button to apply down pressure on bolts with worn heads. Maximum down pressure is applied to the socket if the Head Lower button is held down until the tram wheels raise the support channel on each side of the conveyor.

Lubrication Main Reservoir

Press and hold the Cycle Start button to break loose the bolt. DO NOT RELEASE THE CYCLE START BUTTON UNTIL THE TORQUE-TURN PROCESS IS COMPLETED. The gear head will automatically follow the bolt as it moves up. the track wrench shifts automatically into high speed to finish loosening the bolt. The track wrench pauses briefly when it shifts to high gear. Every time the Cycle Start button is depressed and the wrench is set to REVERSE, the socket will start in low speed. There is a timer which will keep the socket in low speed for at least 4 seconds to ensure that the bolt has been broken loose.

Illustration 8. Main Reservoir Fill Point.

(12) Hydraulic motor. (13) Dip stick and filler port.

(14) Directional control valve (Arbor rotation CW/CCW).

The track wrench frame is also the main hydraulic reservoir. The reservoir is filled with approximately 159 L (42 gal) of 10W premium hydraulic oil, JIC. To control the operating temperature, the oil is constantly circulated throughout the entire frame.

The reservoir should be kept filled to within 75 mm (3.0 in) of the top of the frame. The fill location (13) is on the top of the track wrench frame on the motor side of the track wrench.

Change the oil in the main reservoir every two years.

The oils should contain anti-wear and anti-foaming additives. Use 8T-9581 Caterpillar Hydraulic Oil or 3E-5783 Caterpillar Biodegradable Hydraulic Oil. Both part numbers are 208 L (55 gal) quantities.

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Change the filter every year. The filter element, Parker #930119, is mounted high enough on the frame to minimize spillage.

Change the oil in the planetary gear case (11) twice a year. Fill the compartment with ATF oil.

Maintain the oil level to cover the planetary gear set. To fill the gear case, remove the hydraulic motor and fill the case to the top of the gears.

Approximately 3.8 L (1 gal).

Illustration 9. Main Reservoir Saddle Drain Plug.

(33) Electric Motor. (34) Access port. (35) Drain Plug.

Drain plug (35) is provided on each side of the track wrench frame to allow complete drainage of the hydraulic oil. Access port (34) is located on each side of the track wrench frame for the inspection and clean out of the bottom section of the reservoir.

Illustration 11. Planetary Gear Case Drain.

(4) Gear case. (38) Drain plug.

The drain plug for the planetary gear housing is located at the bottom of the gear case on the pistol mount side. The drain plug also holds the ball bearings for the drive.

Illustration 10. Oil Filter.

(17) Hydraulic oil filter.

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Walk-Around Inspection Each time the track wrench is prepared for use, perform a quick inspection. Inspect the wires leading from the optics pickup under the cover on the top of the planetary gear case and the strain gage link to ensure that they are located properly and cannot become damaged by the operation of the track wrench. Keep all hydraulic connections and bolts properly tightened. Bolts in critical areas should be monitored as follows: • hydraulic motor mount to the top of the gear case.

• strain gage link mount to the gear case and swing arm.

• split collars on each hand wheel shaft.

• guide wheel assemblies.

NOTE: Hydraulic motor and strain gage link are mounted with studs fastened into the gear case with 9S-3265 Retaining Compound. Make sure that the studs have not turned out of the gear case whenever tightening these nuts.

Instrumentation

Illustration 12. Inside Control Box (40) Keypad (Opti-mate Display #OP-1500) (41) Direct Logic 205 Programmable Logic Controller.

(42) Direct Logic DL230 CPU. (43) Sensotech In-Line Amp 060-6827-03 (44) Transformer (Cosel USA INC. #LCCA15s-24) (45) Fuses. (46) Inputs.

(47) Power supply. (48) Outputs. (71) Wiring block.

Note: Always disconnect the power before entering the control box. Electric wires inside the control box, which have blue insulation, are 24 volt DC, while those with red insulation are 110 volt AC.

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Instrumentation Hydraulic Schematic H79 RUN DOWN MOTOR

H62

GEAR SHIFT CYL H77 3/4" BORE 1.00" STROKE SPRING RETURN

H65

H55

H76 SPINDLE LIFT CYL 2.00" BORE 5.00" STROKE

3/8 HOSE

H64

CW

T

B

P

A CCW

1/2 HOSE

.065

T

B

T

A

P

A

P

B

3/8 HOSE

.065

3000 PSI

950 PSI H61 H85

1.0 TUBE

1/2 TUBE

5/8 TUBE

H68 H48

H53

5/8 TUBE

H21 10 HP 1725 RPM 20A/220/440

1.0 TUBE H52

OPTION

H58, H57

H51

H59

0703-01

Illustration 13. Hydraulic schematic. (TT-7000 Hydraulic Track Wrench)

17

Instrumentation Electrical Schematic 4 ANALOG INPUT CARD CAT.#F2-04AD-L 2 17 2 18 2 19 2 20 2 21 2 22 2 23 2 24 2 25 2 26 2 27 2 28 2 29 2 30 2 31

3

PS106 MODULE + SUPPLY 24 VDC

0 VDC RED

+24 VDC

WHT

CH 1 +

BLK

CH 1 -

221 CR323

222

1 PWR 4 +OUT 3 COM

AMP219 SENSOTECH IN-LINE AMP 060-6827-03 DIP SWITCH #1 ON ALL OTHERS OFF

5 SHUNT CAL. EX SEL JUMPER=3 6 ENABLE

+EXC A +SIG C -SIG D -EXC B

CH 2 +

RED R1

R2

WHT SG220

GRN BLK

R3

R4 TORQUE TRANSDUCER

CH 2 -

CH 3 + CH 3 -

CH 4 + CH 4 -

2 32 SLOT 1

0682-02

Illustration 14. Electrical schematic. 1 of 4. (TT-7000 Hydraulic Track Wrench)

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120VAC 1 RELAY OUTPUT CAT.#D2-12TR

317 3 18 3 19 3 20 3 21 3 22 3 23 3 24 3 25 3 26 3 27 3 28

OUT A0 OUT A1

100

25A

110

CA OUT A3 OUT A4

OUT B0 OUT B1 OUT B2

SP317

101

FU317 25A 111 SOL318 BLK

102 103 104

OUT B3

25A

113

BLK

OUT B5

3 30 3 31

SLOT 3

RUNDOWN MOTOR REVERSE

WHT

2 21 2 22

SPINDLE DOWN

105 106

ENABLE SHUNT CAL. AMP. 219

OR 323

LDE 222 M10L

107

M 1 LT325

108

Y

109

G

G

3 29

WHT

SPINDLE UP

RED FU320 SOL321 25A 114

LT327

OUT B4

(SPIKE SUPRESSOR)

SOL320

LT326

CB

2 17 2 18 2 19 2 20

SOL328

1100

25A

1110

RED FU321 SOL329 25A 116

115

FU321

BLK

HYDRAULIC PUMP ON/OFF LDE 101

PRETORQUE ACHIEVED TORQUE TURN ACHIEVED (LOCATED ON CONTROL BOX)

TORQUE TURN ACHIEVED (LOCATED ON HANDLE BOX)

SHIFT UP

$S302 PB303

12 BLK

START IN A0 CYCLE

13 BLU

IN A1 FWD./REV.

14 RD/BLK PB304 15 WHT PB305 16 GRN 17

2 23 2 24

18

2 25 2 26

210

2 27 2 28

212

2 29

214

2 30 2 31

215

2 32

217

19

211

213

(THUMB PB)

IN A2 START/STOP HYD. PUMP IN A3 SPINDLE UP (TOP INDEX PB) IN A4 SPINDLE DOWN (BOTTOM INDEX PB) IN A5 SPARE IN A6

SPARE

IN A7

SPARE

IN B0

DEGREES TURNED

IN B1

SPARE

IN B2

SPARE

IN B3

SPARE

IN B4

SPARE

IN B5

SPARE

IN B6

SPARE

IN B7

SPARE

SHIFT DOWN

216

RED

RED

BLK

BLK

DEGREES TURNED ANGLE SENSOR PR316

316 BLK

COM B

PHYSICAL VALVE LAYOUT RED

COM A

WHT

3 32

BLK

PS106 24V COM 4

20-28VDC INPUT CAT.#D2-16ND3-2

PB301

RUNDOWN MOTOR FORWARD

SPARE

FU321

OUT A5

SOL317

RED

FU318

OUT A2

PS106 +24VDC 3

120VDC 2

BLU 4

BRN

3

WIRE COLOR

SHIFT

UP/DWN RUNDOWN

SLOT 2

WHT. WIRE=COMMON(NEUTRAL)

0703-03

0703-04

Illustration 16. Electrical schematic. 3 of 4. (TT-7000 Hydraulic Track Wrench)

Illustration 15. Electrical schematic. 2 of 4. (TT-7000 Hydraulic Track Wrench)

19

USER SUPPLIED DISCONNECT

1 01 1 02

480 VAC 3 PHASE 60 HZ

L1

FU1

L2

1 04

MTR 1 T3

T2

1L3

FU3

1 03

480 VAC H3

H1 6.3A 1

1 17 T1

1L2

FU2

L3

LINE 324 M1

1L1

LPS-20

H2

H4

10 HP 13.3 FLA 1750 RPM 215TC FRAME

1 19

T1 .5KVA

X1

1 20

2

FU103

120 VAC

1 21

1 05 1 06 1 07

1 18

PS106 DIRECT LOGIC 205 24VDC .2A 2 1 L1 #D2-O6B L2 POWER SUPPLY +

1 08

24VDC

1 22

POWER TO CPU AND INPUT DEVICES

1 23

-

1 24

POWER TO INPUT DEVICES SLOTS 1,2,3

1 09

1 25 PS110

1 10 1 11

1

COSEL USA INC. 24VDC .7A 2 #LCA15S-24 POWER SUPPLY +

24VDC 5

1 12 1 13

POWER TO OPERATOR TERMINAL/DISPLAY

-

1 26 1 27

6

1 2 OPTI-MATE OPERATOR TERMINAL/ DISPLAY #OP-1500 SERIAL COMM

1 28

OPERATOR TERMINAL/DISPLAY

1 29

RS232 CABLE

1 14 1 15

1 30

PORT1 DIRECT LOGIC 205 DL230 CPU #D2-230 CPU

CPU COMMUNICATION PORT 1

1 31 1 32

1 16

0703-05

Illustration 17. Electrical schematic. 4 of 4. (TT-7000 Hydraulic Track Wrench)

20

Reverse-Disassemble-CCW

Electrical Sequence of Operation

Initial Conditions • Power ON • Pump motor OFF. • Hydraulic reservoir full of clean 10W premium hydraulic oil and gear case half full of 90W gear lube.

• Programmable controller conditions met (Power ON, run ON, and Input 3 OFF - Not in FORWARD).

Note: Indicator lights on Programmable Controller (11) are identified as follows. Output/Input XX.

Forward-Assemble-CW Initial Conditions • Power ON - (proper voltage per label).

• Pump motor starter timed out - (motor starter OFF).

• Hydraulic reservoir full of clean 10W premium hydraulic oil and gear case half full of 90W gear lube.

• Programmable controller shows power - (ON).

Operation 1. Pull the Pump Start/Stop mushroom button.

Output B1 comes ON and pump starts.

2. Press the Cycle Start button - Input A0 ON. Shift to slow - Output B5 was accomplished, Rotation REVERSE - Output A1.

Operation

3. Output conditions:

1. Pull the Pump Start/Stop mushroom button.

The 10 hp pump motor should start - Output B1, if not, press the Cycle Start button on the pistol grip - Input A0.

a. Output A1 OFF, REVERSE. b. Output B5 OFF, slow. c. Output B4 OFF, fast.

4. Elapse, shift complete. Output A1, REVERSE. 5. Release the Cycle Start button, Input A0 OFF. Output A4 pulses to put the track wrench back in slow.

To avoid injury, stay clear of the arbor when the track press is started. The arbor begins to rotate at 450 rpm.

Programmable Controller Fuses Fuse: Remove fuse holder (70) from the fuse sockets as shown below. Using a standard, straight blade screwdriver, remove the defective fuses and insert the new ones.

2. Press the Head Raise/Lower buttons - Input A3 and A4. The head should raise and lower Outputs A3 and A4. In forward, Output B4 must energize to close the path back to the reservoir to produce pressure for this action.

3. Press the Cycle Start button - Input A0. a. Output A0 goes on FORWARD. c. Output B4 goes on giving high speed and the hydraulic pump.

4. Torque builds as the bolt is tightened and the analog input card senses the increase in torque and shifts the gear box into a lower speed.

5. When the pretorque is reached, the yellow Pretorque light illuminates. (Output B2)

Illustration 18. Fuse Replacement (70) Fuse holder. (71) Wiring terminal.

6. The green Turns Achieved light illuminates and output A0 goes OFF - track wrench stops.

(Output B3)

21

Replace Programmable Controller

Strain Gage Link

1. Turn OFF the power to the programmable controller (11). If the power is OFF to begin with, turn ON the power and wait 10 seconds, then turn it OFF. Pull Fuse # 1 from the main terminal strip (7).

The following diagram shows how to find the top of the strain gage link.

2. Remove the programmable controller mounting screws (69) from the corners of the mounting rack. Then remove the mounting rack.

BD

3

2

A 1

C

EXC +

+ B

A S-

S+ C

D EXC -

-0703-08

Illustration 20. Strain Gage Link Diagram Method Of Finding Top Of Strain Gage Link.

(1) Push here. (2) Top of strain gage: reading is positive. (3) Hold this end fixed.

Illustration 19. PLC Panel Mounting Screws.

(69) Mounting screw.

3. Install new programmable controller (11) by locating the controller in the old position and replacing the mounting screws (69).

Procedure to Replace Strain Gage Link

4. Rewire the controller in the same manner as the old controller.

1. Turn OFF power to the track wrench.

2. Open the control box.

3. Disconnect the four leads and the braided wire shield from the right hand side (the strain gage side) of the special terminal strip.

4. Loosen the wire fitting in the wall of the control box and remove the wire from the control box all the way to the strain gage link (49). Observe the routing of the original wire so that the new wire can be routed the same.

22

Note: The top of the strain gage link (49) is marked so that the strain gage link can be installed properly. The wire from the strain gage link (49) is routed out of the top of strain gage link (49).

12. Restring the cable. Be careful to locate slack in the cable similar to the original routing to avoid tight spots. Move the gear case side to side to ensure that the routing is correct.

13. Rewire the cable to the terminal strip.

Carefully check wire for a complete and flawless connection.

Illustration 21. Strain Gage Block.

Spike Suppressor

Illustration 23. Lower Right Hand Corner Of Control Box Or Above Wiring Terminal Strip.

(51) Spike suppresser.

Illustration 22. location Of Strain Gage Link.

(49) Strain gage link. (50) Optics pickup.

The track wrench generates a quick torque peak in order to accelerate the track wrench to high speed required to run bolts in and out. This quick torque peak is produced by a quick pressure spike at the hydraulic motor. The pressure switch prevents this startup pressure spike from shifting the track wrench down into the lowest speed prematurely.

5. Block up gear case to support it because strain gage link (49) ordinarily supports the planetary gear case.

6. Remove the six nuts from the mounting bolts in the side of the gear case mounting brackets.

7. Carefully pull the planetary gear case away from strain gage link (49).

Spike suppresser (51) is mounted in the top of the terminals (or below) in the right hand corner of the control box. The solid lead from the spike suppresser (51) is wired into the # 2 wire on the fuse block.

8. Remove the six bolts from the rear of the strain gage link (50), which connect the strain gage link to the parallel arms.

9. Mount the new strain gage link (49) to the track wrench arms.

10. Install the gear case back onto the new strain gage link (49) and tighten the nuts to a torque of 102 N⋅m (75 lb ft). Tighten in an even pattern.

23

Angle Optics Pickup

Directional Control Valves

Illustration 24. Angle optics pickup, located in the top of the planetary gear case (53) senses the timing mark on the rotating disk (52) attached to the hydraulic motor shaft. Angle optics pickup must not touch the rotating disk (52).

Illustration 25. Directional Control Valves.

(14) Arbor Forward/Reverse control valve. (15) Head Raise/Lower control valve. (16) Shift High/Low control valve.

Arbor FORWARD/REVERSE Directional Control Valve

Checking Optics Pickup Operation

Arbor Forward/Reverse directional control valve (14) is actuated by Output A0 and A1, shown on the indicator light panel on the programmable controller. Each time Output A0 or A1 flashes on the programmable controller, arbor Forward/Reverse directional control valve (14) should be heard clicking or felt actuating with the hand. Changing the Forward/Reverse arbor rotation switch on the swivel control handle, with the ON/OFF mushroom button pushed IN, causes the wrench to shift from high speed FORWARD to low speed REVERSE. If the output lights are flashing and directional control valve is not functioning, check Fuses # 317 and 318.

1. Push IN the mushroom ON/OFF button located on the swivel control handle.

2. Rotate the arbor with a hand held wrench.

3. Adjust the mounting for the angle optics pickup (16) to provide a clearance of 2.03 mm (.080 in) on all sides of the counter disk (52).

4. Check the installation by turning the arbor one full turn by hand.

5. Open the control box. Input B0, an indicator light on the programmable controller, pulses each time an optic plate passes through the angle optics pickup. The indicator light pulses 2 times for each revolution of the arbor.

To reduce the possibility of electrical shock, turn OFF the power to the track wrench before touching item in the control box.

24

Inspect the fuses by pulling on the fuse holder on the right hand end to rotate it outward. See the position of the disconnect fuse holder in the previous topics, showing the location of the spike suppresser. If the fuses are good and the indicator lights are flashing properly, replace the directional control valve.

To reduce the possibility of electrical shock, turn OFF the power to the track wrench before touching items in the control box.

Head Raise/Lower Directional Control Valve Inspect the fuses by pulling on the fuse holder on the right hand end to rotate it outward. See the position of the disconnect fuse holder in the previous section, showing the location of the spike suppresser. If the fuses are good and the indicator lights are flashing properly, replace the directional control valve.

Head Raise/Lower directional control valve (15) is actuated by Output A3 (Raise) and A4 (Lower) shown on the indicator light panel on the programmable controller. Each time Output A3 or A4 flashes on the programmable controller, Head Raise/Lower directional valve (15) should be heard clicking or felt actuating with the hand. Actuating the Head Raise/Lower on the swivel control handle, with the ON/OFF mushroom button pushed IN, causes the track wrench to actuate the Raise/Lower circuit. If the output lights are flashing, and the directional control valve is not functioning, check Fuses # 320 and 321.

To reduce the possibility of electrical shock, turn OFF the power to the track wrench before touching items in the control box.

Inspect the fuses by pulling on the fuse holder on the right hand end to rotate it outward. See the position of the disconnect fuse holder in the previous topics, showing the location of the spike suppresser. If the fuses are good and the indicator lights are flashing properly, replace the directional control valve.

Shift High/Low Directional Control Valve Shift High/Low directional control valve (16) is actuated by Output B5 (Low) and Output B4 (High) shown on the indicator light panel on the programmable controller. Each time Output B5 flashes on the programmable controller panel, shift High/Low directional valve (16) should be heard clicking of felt actuating with the hand. Changing the Forward/Reverse switch on the swivel control handle, with the ON/OFF mushroom button pushed IN, causes the track wrench to shift from high speed FORWARD to LOW speed REVERSE. If the output lights are flashing and the directional control valve is not functioning, check Fuses # 328 and 329.

25

Troubleshooting Guide for Experienced Electricians 1. Programmable control does not have lights ON. • No power from source. Check incoming lines or transformer, if supplied.

• Check incoming fuse control box (Wire X1 to 1).

• The voltage between Wire 1 and Wire 2 should be 120 volts AC. a. If the voltage is correct to the programmable controller and the lights are not ON, replace the programmable controller. b. If the voltage is not correct, check for loose wires, blown transformer, or power source disconnected.

1 L1

3 L2

5 L3

2 T1

4 T2

6 T3

54

55

0703-09

Illustration 26. Starter.

(54) Heater reset button. (55) Variable dial.

2. Programmable controller has lights ON. NOTE: Pushing the Cycle Start button on the pistol grip control handle should illuminate Input A0 on the indicator light panel on the programmable controller.

• If Input A0 does not illuminate, check the wires to and from the Cycle Start button on the pistol grip control handle and inspect the Cycle Start button.

• If Input A0 goes ON and OFF when the Cycle Start button is pressed and released, but the track wrench does not start, check that Input A2 is ON. • If Input A0 and A2 are ON when the Cycle Start button is pressed, then Output B1 should come ON. If not, replace the programmable controller.

• If Output B1 is ON and the electric motor start does not pull in, check the heaters. Reset by pushing in the heater reset button (54). Heater reset button (54) is the little white rectangular button next to the variable dial (55).

To prevent electrical shock, high voltage should be serviced by experienced electricians ONLY.

• If Output B1 is ON and the heater is correct, then check the voltage between Wire # 107 and Wire # 2 in the control box. If the voltage is 120 volts AC, have the starter replaced by an experienced electrician.

3. Pump runs, but the head does not Raise or Lower.

NOTE: When the Head Raise/Lower buttons on the pistol grip control handle are pushed, Input A3 and Output A3 (Raise), or Input A4 and Output A4 (Lower), should flash.

• If Input A3 does not flash, repair or replace the wire to the Head Raise button, or replace the button.

• If Input A4 does not flash, repair or replace the wire to the Head Lower button, or replace the button.

• If Input A3 flashes and Output 3 does not flash, replace the programmable controller.

• If Input A4 flashes and Output 4 does not flash, replace the programmable controller.

• If the directional control valves are clicking and the lines to the head cylinder are flexing, check the hydraulic connections.

26

4. Pump runs and head goes up and down slowly (normal cycle time is one second to travel from fully raised to fully lowered).

7. The track wrench runs fast, but does not shift down to low in Forward (track wrench does not have enough torque to complete the turn on the large track). If Output B4 is ON and the track wrench does not speed up, check Fuse # 329.

Note: Prior to checking out the electrical circuits, check the hydraulic pressure set in the accessories circuit. See Hydraulics System, in the Maintenance Section of this manual.

If Fuse # 329 is good, check the voltage between Wires # 1110 and # 2. The voltage should be 100 - 120 volts AC.

The Head Raise/Lower direction control valve, Output A3 or A4, must fire at the same time as the shift High/Low directional control valve, Output B4, to give fast head movement.

If the voltage is correct , replace the shift High/Low directional control valve.

8. The track wrench shifts to low, but does not shut OFF. The track wrench starts to count the angle only after reaching pretorque.

After the track wrench reaches pretorque, then it counts approximately 20 flashes of Input B0.

• If Outputs A3 and A4, or Outputs B4 and B5 go ON, then check Fuses # 320 & 321 &328 & 329.

• If the fuses are good, check the voltage between Wires # 103 and # 2 and Wires # 104 and # 2.

The voltage should be 100 - 120 volts AC. • If voltage is correct, replace the Head Raise/Lower directional control valve.

• Output A0 (Forward), goes OFF, but the track wrench continues to run. Replace the Arbor Forward/Reverse directional control valve.

5. Track wrench operates in the Reverse direction only. Input A1 Should be ON when the Arbor Rotation Direction switch, located on the swivel control handle, is switched to the Forward direction.

9. The track wrench does not run in REVERSE. Starting off in Reverse without load on the arbor, the track wrench should have Inputs A1 and B1 ON, and Input A1 OFF.

• If Input A1 does not come ON, replace the Arbor Rotation switch, located on the swivel control handle, or repair or replace the wire to the switch.

• If the voltage between Wire # 3 and Wire # 4 is 24 volts DC, then replace the programmable controller. (Check all COM connections)

• The track wrench shifts to the second speed by turning ON Output B5. If Output B5 comes ON and the track wrench does not slow down, check the voltage between Wire # 1110 and Wire # 2. If the voltage is not 120 volts AC while Output B5 is ON, replace the programmable controller.

• If there is 120 volts AC at Output B5, check fuse.

• If 120 volts AC between Wire # 1110 and Wire # 12, then replace the shift High/Low directional control valve.

• To shift the arbor Forward/Reverse directional control valve, Output A1 turns OFF. The shift-up solenoid comes ON (Output B4), then Reverse comes back ON (Output A1). If Output B4 comes ON, but the track wrench fails to up-shift, check the fuses.

6. Track wrench runs Forward, but not fast (200 + rpm).

• High speed is produced when Output A0 (FORWARD), and Output B4 (Shift High) are ON. If Output B4 is ON and the track wrench does not speed up, check Fuse # 328.

• If Fuse # 328 is good, check the voltage between Wires # 1100 and # 2. The voltage should be 100 - 120 volts AC. • If the voltage is correct , replace the shift High/Low directional control valve.

• The track wrench is shifted by a small hydraulic cylinder mounted on the top of the gear case.

See the Maintenance Section of this manual to check the mechanical connections between the shift cylinder and the shifter mechanism.

• When the unit shifts to low then the visible spring on top of the hydraulic motor will compress.

• Check the spike suppresser to be sure that the Wires # 2 and # 110 are properly connected.

27

Controller Program _FirstScan SPO

LD

1

K100 OUT UPSHIFT TORQUE V2030 Pretorque has been achieved, start counter for angle Pretorq_achieved C50

CNT

ANGLE COUNTER X30

Turn counter done

2

CT0 Pretorque has been achieved, start counter for angle Pretorq_achieved C50

K24

X16 LD

3

ANDD

VX0 Kfff

BCD

Read analog card and convert to BCD

X16

X14

X15 OUT

4

Analog input V2013

Store analog card channel 1 value in word V2013

_On SP1

CAL. ENABLE C70

CAL. TIMER 4 T16

Start one shot C60

OUT

5 MUL CAL. TIMER 1 T13

CAL. TIMER 5 T17 DIV SUB OUT

CAL FACTOR V2020 6

K8000

Analog input V2013 CAL FACTOR V2020 K1000 V2023 Torque V2010

LD

>

K8000 OUT

CAL FACTOR V2020 0703-15

Illustration 27. Controller Program For TT-7000 Hydraulic Track Wrench.

28

CAL FACTOR V2020 7

K1500

LD

>

K1500 OUT

CAL FACTOR V2020

Store analog card channel 1 value in word V2013

_On SP1

CAL. ENABLE C70

CAL. TIMER1 T13

OUT

8

MUL

Start one shot C60

DIV OUT

Analog input V2013 CAL FACTOR V2020 K1000 V2023

C71 OUT

Scale analog value to FT.LB. of torque and store in word V2010

START CYCLE X20

Start one shot C60 PD

9

Start one shot C60

LD

10

SUB

OUT

Start one shot C60

Torque V2010

UPSHIFT TORQUE V2030 UPSHIFT POINT V2031

LD

11

K65

ADD

OUT

START CYCLE X20

LD

12

Torque V2010

Down shift torq V2012

Down shift torq V2012 Down shift torqued achieved C61 RST

0703-16

Illustration 28. Controller Program For TT-7000 Hydraulic Track Wrench.

29

Start one shot C60

FWD/REV. X21 LD

13

K1

OUT Top line message selection number for display V2000 LD

K0

OUT Top line data value for display V2002 LD

K2

OUT Bottom line message selection number for display V2001 LD OUT

K0

Data from bottom line of display V2004 Pretorque has been achieved, start counter for angle Pretorq_achieved C50 RST

Start one shot C60

FWD/REV. X21 LD

14

K1

OUT Top line message selection number for display V2000 LD

K0

OUT Top line data value for display V2002 LD

K15

OUT Bottom line message selection number for display V2001 LD

K9999

OUT REVERSE TORQUE V2033

0703-17

Illustration 29. Controller Program For TT-7000 Hydraulic Track Wrench.

30

_On SP1

LD

15

Display status register V2006

OUT

VC0

LD

VC20

OUT Display control register V2007 Remap status and control registers to internal relays

F1 button on display F1 C0

LD

16

K3 OUT Top line message selection number for display V2000 LD

K4

OUT Bottom line message selection number for display V2001 F1 key has been pressed to set pretorque C42 SET

F1 key has been pressed to set pretorque C42

The enter key has been pressed, read data value from display DA C5

Read pretorque C40 PD

17

F1 key has been pressed to set pretorque C42 RST

Read Pretorque C40

LD

18

Data from bottom line of display V2004

OUT

Pretorque from display V2015 0703-18

Illustration 30. Controller Program For TT-7000 Hydraulic Track Wrench.

31

F2 button on display F2 C1

LD

19

K8 OUT

Top line message selection number for V2000

LD

K11

OUT

Bottom line message selection number for display V2001 F2 key has been pressed ENTER PASSWORD C43 SET

F2 key has been pressed ENTER PASSWORD C43

The enter key has been pressed, read data value from display DA C5

Read new value for password C44 PD

20

F2 key had been pressed ENTER PASSWORD C43 RST Read new value for password C44

Data from bottom line of display V2004

K2811

LD

=

21

K12 OUT

LD

Top line message selection number for display V2000 K11

OUT

Bottom line message selection number for display V2001

CORRECT PASSWORD ENTERED C46 SET

CORRECT PASSWORD ENTERED C46

TMR CAL NUMBER INPUT TIME LIMIT T20

22

K50 0682-19

Illustration 31. Controller Program For TT-7000 Hydraulic Track Wrench.

32

The enter key has been pressed, read data value from display DA C5

CAL NUMBER INPUT TIME LIMIT T20

NEW CAL NUMBER ENTERED C47 PD

23

CORRECT PASSWORD ENTERED C46 RST NEW CAL NUMBER ENTERED C47

LD Data from bottom line of display V2004

24

OUT CAL NUMBER V2016

CAL NUMBER V2016

K5000

LD

>

25

K4999 OUT

CAL NUMBER V2016

K3000

LD

>

26

CAL NUMBER V2016

K3000 OUT

CAL NUMBER V2016

NEW CAL NUMBER ENTERED C47

CAL TIMER 5 T17

CAL ENABLE C70 OUT

27

CAL ENABLE C70

28

CAL ENABLE C70

TMR CAL TIMER 1 T13 K10

29

CAL ENABLE C70

CAL TIMER 1 T13

TMR CAL TIMER 2 T14 K10

30

CAL TIMER 2 T14

TMR CAL TIMER 3 T15 K20

0703-20

Illustration 32. Controller Program For TT-7000 Hydraulic Track Wrench.

33

CAL TIMER 3 T15

TMR CAL. TIMER 4 T16

31

K10

CAL TIMER 3 T15

CAL. ONE SHOT C72 PD

32

CAL ONE SHOT C72

LD

33

CAL NUMBER V2016

MUL K100

DIV

MUL

DIV OUT

CAL TIMER 4 T16

Torque V2010 CAL FACTOR V2020 K100

CAL FACTOR V2020

TMR CAL. TIMER 5 T17

34

K10 The enter key has been pressed, read data value from display DA C5

F1 key has been pressed to set pretorque

F2 key has been pressed ENTER PASSWORD

CAL NUMBER INPUT TIME LIMIT

C42

C43

T20

Data acknowledge bit from display DAK C26 OUT

35

_On SP1

LD

36

Pretorque from display V2015

OUT Pretorque with zero offset compensation Pretorque V2014 FWD/REV. X21

START CYCLE X20

TMR Delay to auto zero torque reading T4

37

K3 Delay to auto zero torque reading T4 38

Torque V2010

>

Down shift torq V2012

Torque V2010

TMR

>

K7000

Torque spike filter timer for downshift T1 K2

0703-21

Illustration 33. Controller Program For TT-7000 Hydraulic Track Wrench.

34

Down shift torqued achieved C61 SET

Torque spike filter timer for downshift T1 39

Delay to auto zero torque reading T4 40

Torque V2010

Pretorque with zero offset compensation Pretorque 2014

>

Pretorque has been achieved, start counter for angle Pretorq_achieved Torque V2010

>

C50

K7000

SET

Turn complete, store values and send to display C51 PD

Turn counter done CT0 41 Turn complete, store values and send to display 42

LD

C51 Torque V2010 OUT Top line data value for display V2002 LD

K120

OUT Pretorque has been achieved, start counter for angle Pretorq_achieved C50

Data from bottom line of display V2004 Delay to auto zero torque reading T4

START CYCLE X20

Shift to low

FWD/REV. X21

C62 OUT

43

Down shift torqued achieved C61

Shift to low C62

Shift to low C62

TMR Shift Down T7

44

K1 Spindle down and in low gear

Shift to low C62

START CYCLE X20

C63 OUT

45 Spindle down and in low gear C63

TMR Shift to low delay T5

46

K10 0703-22

Illustration 34. Controller Program For TT-7000 Hydraulic Track Wrench.

35

TMR

Turn counter done CT0

Reverse time at end of cycle to release torque on socket T3

47

K2

FWD/REV. X21

START CYCLE X20

Torque V2010

TMR

UPSHIFT POINT V2031

Low speed in reverse timer T11

>

48

K15 Torque V2010

>

Torque V2010

K0

>

K200

Low speed in reverse timer T11

FWD/REV. X21

START CYCLE X20

Torque V2010

K200

Torque V2010

>

49

REVERSE TORQUE V2033

>

LD

Torque V2010

OUT REVERSE TORQUE V2033

FWD/REV. X21

START CYCLE X20

REV TORQUE DIS. C75 PD

50

REV TORQUE DIS. C75

LD K9999

51 SUB

REVERSE TORQUE V2033 OUT Top line data value for display V2002 Low speed in reverse timer T11

TMR

52

Low speed release T12 K2

Low speed in reverse timer T11

High speed in reverse

START CYCLE X20

C64 OUT

53

High speed in reverse C64

0703-23

Illustration 35. Controller Program For TT-7000 Hydraulic Track Wrench.

36

Turn complete, store values and send to display C51

CNT

54

High speed in reverse C64

Cycle counter CT1 K9999

Cycle counter CT1

Cycle counter CT1

CNT

55 10000 cycle counter CT2 K9999

10000 cycle counter CT2

F3 button on display F3 C2

LD K13

56 OUT

Top line message selection number for display V2000 LD Pretorque from display V2015 OUT Top line data value for display V2002 LD K7 OUT Bottom line message selection number for display V2001 LD CAL NUMBER V2016 OUT Data from bottom line of display V2004

0703-24

Illustration 36. Controller Program For TT-7000 Hydraulic Track Wrench.

37

F4 button on display F4 C3

LD K14

57 OUT

Top line message selection number for display V2000 LD

Analog input V2013

OUT Top line data value for display V2002 LD

K15

OUT Bottom line message selection number for display V2001

F5 button on display F5 C4

LD K5

58 OUT

Top line message selection number for display V2000

LD CTA1 OUT Top line data value for display V2002 LD K6 OUT Bottom line message selection number for display V2001 LD CTA2 OUT

Data from bottom line of display V2004

TMR START CYCLE X20

FWD/REV. X21

JOG SPINDLE UP TIME DELAY T22

59

K20

JOG SPINDLE UP TIME DELAY T22

TMR JOG SPINDLE UP TIME T23

60 K2

0703-25

Illustration 37. Controller Program For TT-7000 Hydraulic Track Wrench.

38

Delay to auto zero torque reading

Shift to low

Turn counter done

FWD/REV. X21

C62

CT0

Low speed in reverse timer

Low speed release

FWD/REV. X21

T11

T12

FWD/REV. X21

START CYCLE X20

Low speed in reverse timer T11

Shift to low C62

Shift Down T7

Turn counter done CT0

Reverse time at end of cycle to release torque on socket T3

T4

RUNDOWN FORWARD Y0 OUT

61 Shift to low delay T5

RUNDOWN REVERSE Y1 OUT

62

Low speed release

FWD/REV. X21

T12

SPINDLE UP X23

SPINDLE UP SOL. Y3 OUT

63

JOG SPINDLE UP TIME JOG SPINDLE UP TIME DELAY T23 T22

SPINDLE DOWN X24

SPINDLE DOWN SOL. Y4 OUT

64 F4 button on display F4 C3

ENABLE SHUNT CAL Y10 OUT

65

CAL. TIMER 2 T14

CAL. TIMER 4 T16

START/STOP HYD. X22

Hydraulic pump HYDRAULIC PUMP Y11 OUT

Pump shutoff timer T21

66

START/STOP HYD. X22

START CYCLE X20

SPINDLE UP X23

SPINDLE DOWN X24

TMR Pump shutoff timer T21

67 0703-26

Illustration 38. Controller Program For TT-7000 Hydraulic Track Wrench.

39

K450

Two vane pumps are used to supply the hydraulic power to operate the track wrench. Low pressure pump (67) [6546 kPa (950 psi)] supplies power for the lift cylinder and the shift cylinder (accessory circuit), and is added to the high pressure pump (66) [20670 kPa (3000 psi)] to produce high speed arbor rotation.

High pressure pump (66) is used to drive the arbor.

Both pumps send the hydraulic power to the hydraulic manifold (59) mounted on top of the track wrench frame. Pressure gages are mounted on the hydraulic manifold (59) for the proper setup and diagnosis of the hydraulic system. The relief valves and check valve are mounted on the hydraulic manifold (59).

Hydraulic System

Illustration 39. Solenoids And Manifold (Front View).

(56) Pressure gage for accessory circuit.

(57) Pressure gage for main hydraulic circuit.

(58) Supply line for main hydraulic circuit.

(59) Hydraulic manifold. (60) Supply line for accessory circuit. (16) Shift High/Low Directional control valves.

Illustration 41. Solenoid And Manifold (Bottom View).

(62) Relief valve for main circuit (arbor drive).

(63) Relief valve for accessory circuit. (64) Locknut.

(65) Pressure adjust screw.

Illustration 40. Solenoid And Manifold (Top View).

(59) Hydraulic manifold. (61) Check valve.

40

9. The pressure can be adjusted by loosening locknut (64) on relief valve (62) and turning pressure adjusting screw (65) while the track wrench is held with the arbor stalled against the track bolt. Turning the adjusting screw (65) IN (CW), increases the relief valve (62) setting and increases the maximum pressure generated in the main hydraulic circuit. Tighten the locknut after the pressure has been set.

10. Release the Cycle Start button.

11. Turn OFF the power to the track wrench.

12. Reinstall Fuse # 106.

13. Close the control box.

Accessory Circuit (Head Raise/Lower and Shifter) Illustration 42. Pumps And Motor.

(33) Electric motor. (66) High pressure pump.

(67) Low pressure pump. (68) Coupler.

1. Turn ON the track wrench.

2. Raise the head fully and HOLD the Head Raise button, located on the swivel mounted control handle.

Check Valve (61) prevents the high pressure flow from entering the accessory circuit. Check valve (61) allows the low pressure flow to be added to the motor drive circuit, when required.

3. The reading on the pressure gage for the accessory circuit (56) should be 6546 kPa (950 psi).

3. Flip out Fuse # 329.

4. The pressure can be adjusted by loosening locknut (65) on relief valve (63) and turning pressure adjusting screw (65) while the track wrench Head Raise button is held. Turning the adjusting screw (65) IN (CW), increases the relief valve (63) setting and increases the maximum pressure generated in the accessory hydraulic circuit. Tighten the locknut after the pressure has been set.

4. Turn ON the power to the track wrench.

5. Release the Head Raise button.

Relief Valve Setting Main circuit (Arbor Drive) 1. Turn OFF the power to the track wrench.

2. Open the control box.

5. Select FORWARD on the swivel mounted control handle.

6. Locate a socket on a track bolt 19 mm (3/4 inch) or larger.

7. Press the Cycle Start button on the swivel mounted control handle.

NOTE: Removing Fuse # 106 prevents the track wrench from shifting to low speed. The track wrench generates the maximum pressure at stall.

8. The reading on pressure gage for main hydraulic circuit (58) should be 3000 psi (20670 kPa).

41

Troubleshooting the Hydraulic System

Installation Introduction

Main Hydraulic Circuit

Use this procedure to set up the Caterpillar Torque-Turn 7000 Track Wrench. The track wrench has been designed to fit the Caterpillar conveyor without any modifications. The 9U-5752 installation group contains the materials needed to supply electricity to the track wrench. The wrench rail is made from structural channel, 152.4 mm x 50.8 mm; 59.2 kg/M (6.00 in x 2.00 in; 8.2 lbs/ft), supported by legs made from the same channel spaced 10.0 ft (3 m) apart along the conveyor.

These legs are securely bolted to the floor and are braced to resist the side loads generated by the track wrench.

Before replacing any component, make sure it is clean (free from dirt or debris) and properly adjusted.

1. If the pressure cannot be adjusted to 20670 kPa (3000 psi), remove and replace relief valve (62). Relief valve (62) is threaded directly into hydraulic manifold . Repeat the procedure to set relief valve (62).

2. If the relief pressure cannot be set, plug the hoses connected to the hydraulic motor, mounted on the top of the gear case. Repeat the procedure to set relief valve (62). If the relief pressure can be set replace the hydraulic motor.

Wolff conveyors, OTC conveyors, and most dealer designed and built conveyors must have a rail added to support the track wrench. A 4C-8614 Kit can be obtained for support rail to modify the Wolff 12 m (40 ft) conveyor. A sketch for this support rail is also provided for those who wish to build their own rail. The tram wheels, which support the track wrench, can be spaced apart a maximum width of 698.5 mm (27.5 in) to accommodate the various width conveyors. This feature also allows the track wrench to be fitted to most conveyors with dealer-designed and installed support legs.

Contact Caterpillar Service Technology Group with any questions about modifying conveyors or supports to accept the Caterpillar Torque-Turn 7000 Hydraulic Track Wrench.

3. If relief valve (62) cannot be set, replace high pressure pump (66).

Accessory Hydraulic Circuit Before replacing any component, make sure it is clean (free from dirt or debris) and properly adjusted.

1. If the pressure cannot be adjusted to 6546 kPa (950 psi), remove and replace relief valve (63).

Relief valve (63) is threaded directly into hydraulic manifold (59). Repeat the procedure to set relief valve (63).

2. If the relief pressure cannot be set, plug the hoses connected to the head raise cylinder and then the shift cylinder. Repeat the procedure to set relief valve (63) after each component has been isolated to determine the cause. If the relief pressure can be set with one of the components plugged off, replace that component.

Note: Read and understand the installation and setup instructions before performing the procedures in this publication.

3. If relief valve (63) cannot be set, replace low pressure pump (67).

Special Tools and Materials Required 1. Electric drill - suitable for drilling in concrete.

2. Masonry drill bit - 12.7 mm (1/2 in) diameter.

3. Steel shims - thickness such as 1.5 mm (.06 in), 3.0 mm (.12 in), 6 mm (.25 in) minimum plus thickness dictated by the condition of the shop floor. Shims should have 12.7 mm (.50 in) diameter holes to fit over the concrete anchors.

4. The track wrench stops (design optional) - The track wrench stops are used to stop track wrench from rolling off the end of the conveyor and from rolling into the track indexer.

42

8. Attach lift straps capable of holding 2992 kg (1360 lbs) to the track wrench in the shown locations. Be sure not to damage any wiring or hoses during the installation process. Add leveling chains as needed. Make sure the gear case is securely fastening to the track wrench frame. Total weight is 2992 kg (1260 lbs).

Note: Level, straighten, and align the conveyor prior to the installation of the track wrench.

Installation on Caterpillar Conveyor 1. Inspect for shipping damage before removing the track wrench from the skid.

2. Remove all protective materials. Do not remove the straps which hold the gear case to the side of the track wrench. The straps prevent the gear case from swinging freely during installation.

Illustration 44.

10. Using any one of the following procedures, install the track wrench into the support rails (32) with the operating side of the track wrench away from the track press end of the conveyor .

Illustration 43. Wrench Travel Mechanism.

(28) Hand wheel. (29) Split fastening ring.

(30) Tram wheel. (31) Guide wheel.

(32) Track wrench support rail.

Install the track wrench from the end of the conveyor over the standard ramp. The ramp can be removed to facilitate installation.

3. Loosen all eight split rings (29) on all four tram wheel axles (30) and remove four inner split rings (29).

Lower the wrench down over the conveyor from above. Be careful not to damage the plumbing under the electric motor side of the track wrench.

Tram wheels (30) open to 698.5 mm (27.5 in) maximum width to fit over support rails (32) which are 673.1 mm (26.5 in) apart (inside dimension).

4. Pull all tram wheel axles (1 ) out from the sides of the frame to full extension.

5. Remove four guide wheel assemblies (4) from track wrench frame (2).

Remove one section of the support rail (32) from one or both sides of a Caterpillar conveyor (if it has been modified) and lower the track wrench down from above. Install the track wrench into support rail (32) by moving the track wrench along the conveyor and replace the support rails.

6. Make sure that the gear case is tied securely to the side of the track wrench before the track wrench is removed from the skid.

7. Remove the fasteners from the skid.

43

13. Adjust tram wheels (30) on the side of the track wrench without the electric motor, so that the inside faces of the tram wheels (30) are against the web of the support rail (32).

14. Adjust tram wheels (30) on the electric motor side of the track wrench, so that the inside faces of the tram wheels (30) are approximately 6.0 to 9 mm (.25 to .38 in) from the web of the support rail (32).

15. Clean the clamping area and split rings (29) to remove any oil or grease. Install one split ring (29) against the side of each axle support (74) to hold the four tram wheels (30) inside the support rails. Install on split ring (29 on the outside end of the tram wheel axle. Split rings must be kept tight to maintain proper track wrench support.

16. Remove the chain supports.

Illustration 45. Wrench Travel Mechanism (30) Tram wheels. (32) Support rails.

17. Move the track wrench along the conveyor to find the widest point in the support rails (32).

The track wrench tends to pull away from the electric motor side. Tram wheels (30), on the side opposite the electric motor, tend to scrub along the web of the support rail (32).

11. Install tram wheels (30) into support rail (32).

12. Adjust the gap (76) between pry fence (75) and support rail (32), so that it is the same on both sides of the conveyor and the track wrench is parallel to the conveyor.

18. Loosen split rings (29), if necessary, to provide gap (76) between the inside faces of the tram wheels (30) and the web of the support rails.

Gap (76), approximately .25 to .38 in (6 mm to 9 mm), tends to stay on the electric motor side of the track wrench .

19. Reinstall and adjust guide wheels (31) to extend 1.5 mm (.06 in) inside the faces of the tram wheels (30) closer to the web of the support rails. Guide wheels (31 contact the webs of the support rails before the inside faces of the tram wheels (30). To adjust the clearance, pry between the web of the support rail and the inside faces of the tram wheels (30).

20. Install track wrench travel stops at each end of the support rail.

Note: The dealer must provide these stops.

21. Remove the straps holding the gear case (4).

Illustration 46. Travel Mechanism.

(29) Split fastening ring. (30) Tram wheels.

(31) Guide wheels. (32) Support rail. (74) Axle support.

(75) Pry fence. (76) Gap.

44

Illustration 47. Support Trolley.

(24) Support trolley for wire rope. (25) Electric starter box.

(26) Electric motor side of the track wrench.

Illustration 49. Press Support Bracket.

(31) Track press wall. (32) Threaded coupling.

(33) Eye from turnbuckle.

22. Measure both horizontally and vertically from the support rail to the point on the support trolley (24) for wire rope through which wire rope (38) is threaded.

24. Assemble eye from turnbuckle (33) into threaded coupling (32).

25. Weld threaded coupling (32) to track press wall (31) so that it approximately lines up with the support trolley (24) on the track wrench.

26. Move the track wrench as close to the track press as possible. Measure the distance from the support trolley to the power supply point on the track press. This is the straight distance on the one end of the power cable.

27. Arrange 21 m (70 ft) of electric cable (36) with the straight length (35) on one end equal to the length measured in Step 26. Provide straight length (35) 3 ft (1 m) on the other end of the electric cable (36). Arrange the rest of the cable in 13 equal coils (37). Be careful to arrange the coils without any twists in the electric cable (36).

Illustration 48. Turnbuckle.

(20) Track wrench support rails. (27) Turnbuckle.

(28) Bolt. (29) Conveyor leg. (30 Plate.

23. Assemble the end bracket for wire rope (38).

The bracket consists of plate (30), turnbuckle (27), and bolt (28). Bolt (28) is substituted for one end of the turnbuckle (27) and is installed in plate (30). Locate plate (30) so that the hole in the plate approximately lines up with the support trolley (24) on the track wrench.

Position plate (30) so that the track wrench can be rolled onto the end of the conveyor without contacting the plate (30). This provides that the track wrench can be removed from the conveyor by removing the support trolley (24) from the track wrench.

Illustration 50. Electric Wires And Trolleys.

(34) Trolleys. (35) Straight length. (36) Electric cables.

(37) Coils.

45

28. Lay the electric cable (26) on top of the bench and spread the coils (37) about 6.0 in (150 mm) apart. Attach one trolley (34) to the top of each coil (37) in the electric cable (36). Do not twist the cable to attach the trolleys (34).

Be sure the trolley supports the cable without twisting the coils (37). Extra care mounting the trolleys (34) to the cable ensures correct coiling of the wire.

32. Attach the end of the wire rope (38) to the turnbuckle (27) at the end of the conveyor.

Use two wire rope fasteners (39) provided.

Cut off the excess wire rope.

33. Tighten the turnbuckle (27) to pull the wire rope (38) tight.

Illustration 53. Cable And Starter.

(14) Track wrench. (25) Starter box. (36 Electric cables.

Illustration 51. Cable, Trolleys And Wire Rope.

(34) Trolleys. (35) Electric cable. (38) Wire rope.

34. Hook up the electric cable (36) to the starter box (25) on the track wrench (14) and the supply point on the track press. Use the electric cable strain relieves provided.

29. Thread wire rope (28) through the trolleys (34), keeping the coils in order.

35. Move the track wrench the full length of the conveyor to identify and correct any problems.

30. Attach one end of the wire rope (38) to the eye from the turnbuckle (33) mounted on the track press. Use two wire rope fasteners (39) supplied.

31. Thread wire rope (28) through the support trolley on the track wrench. Keep the track wrench close to the track press end of the conveyor (16).

Illustration 54. Plastic Cover On Motor.

(40) Pump. (41) Housing for drive coupling.

(42) Plastic cover. (43) Electric motor.

36. Remove the orange plastic cover (42) from the drive coupling housing (41) between the electric motor (43) and pump (40). Also make sure the brass ball valve is open. This will allow oil to flow to the pump.

Illustration 52. Pulling Rope Tight.

(27) Turnbuckle. (38) Wire rope. (39) Wire rope fastener.

46

2. The 4C-8614 Support Rail consists of the following:

1

Illustration 55. Drive Coupling.

(33) Electric motor.

(67) Low pressure pump. (68) Drive coupling.

2 3 4

Qty.

Length

Description

8

2438 mm (96 in)

Structural Channel1

2

3048 mm (120 in)

Structural Channel1

12

749 mm (29.5 in)

Structural Channel1

6

597 mm (23.5 in)

Angle Iron2

24

—

Concrete Anchors3

48

—

Bolts4

152 mm x 51 mm; 58.9 kg/m (6.0 in x 2.0 in; 8.2 lbs/in) 51 mm x 51 mm (2.0 in x 2.0 in) .12.5 mm dia. x 127 mm (50 in dia. x 5.0 in) .12.5 mm (50 in)

37. Make sure the On/Off mushroom button is pushed IN. Turn ON the power supply.

38. Jog the On/Off mushroom button to start the electric motor (43) rotating. Make sure drive coupling (68) is turning with the side nearest the widow moving upward.

39. Replace the plastic cover (42) over the drive coupling housing (41). Remove the straps holding the gear case (11) to the side of the track wrench and operate the track wrench.

Installation of 4C-8614 Support Rail for Wolff Conveyor

Illustration 57. Rails And Legs.

(2) Support rails for track wrench.

(3) Wolff gravity conveyor. (4) Leg for support rail.

3. Lay the rails end to end, along the Wolf gravity conveyor (3). Place the rails either on the floor adjacent to the stands, or on top of the gravity conveyor. Place the 3 m (10 ft) rail section at the ramp end of the conveyor. Place the first 2.4 m (8 ft) section on the press end of the conveyor extending 61 cm (2 ft) onto the indexer.

Illustration 56. Assembled Rail.

(2) Gravity conveyor. (2) Support rail for track wrench.

1. Straighten and align the current conveyor.

Straighten and align the plates on each end of the top of the stands for the gravity conveyor.

The distance across the plates should be about 597 mm (23.5 in). Do not remove the current track rails. The 4C-8614 Support Rail mounts outside the gravity conveyor stands.

47

Illustration 58. Bolt Leg To Rail.

(2) Rail. (4) Leg. (5) Mounting bolts.

Illustration 60. Concrete Anchors.

(4) Leg. (6) Concrete anchors. (7) Shims - dealer supplied.

4. Leg (4) extends straight down to the floor from each joint in rails (2). Adjust the position of the rails (2) along the length of the Wolff gravity conveyor (3), to fit between the stand spacing.

If necessary, reposition some of the stands to make room for the new legs.

7. Install shims (7) supplied by the dealer, to level rail (2) on the first side and install concrete anchors (6). Position the top of the rail (2) 25.4 mm (1.0 in) above the rollers in the Wolff gravity conveyor (3).

8. Assemble Side # 2 and level it with respect to Side # 1 with shims and install the concrete anchors for this side.

5. Install legs (4) to rails (2) along one side of the Wolff gravity conveyor (3), using mounting bolts (5). Stand up this assembly along the side of the conveyor and use safety chains to hold assembly to the side of the conveyor.

9. Tighten all bolts.

Illustration 61. Ends Of Welded Rail (2) Rails. (8) Weld on top of flange.

Illustration 59. Leg Bolted To Rail.

(2) Rail. (4) Leg. (5) Mounting bolts.

10. Use a C-clamp to align the ends of the rail (2) and weld the top flanges together

6. Plumb legs (4), straighten rails (2), and drill 12 mm (.5 in) holes into the floor for the concrete anchors (6).

Note: Make provisions to install the track wrench from the ramp end of the conveyor. If the ramp cannot be reworked for the track wrench to pass over it, one section of the rail (2) should be left without welding into the supports so that its section can be removed to install the track wrench.

48

Illustration 62. Cross Brace.

(2) Rail. (4) Leg. (5) Mounting bolts.

(9) Angle iron brace.

11. Weld angle iron braces (9) between each leg (4).

12. Weld the plates on the ends of the supports for the Wolff gravity conveyor (3) to the back surfaces of the support channels. This gives the new support rail added rigidity.

13. Remove the safety chains.

14. Install the track wrench using the procedure outlined in the previous topic, Installation on Caterpillar Conveyor.

49

Construction of Support Rail The tram wheels which support the track wrench are designed to fit exactly into a structural channel which is 152 mm x 51 mm; 58.9 kg/m (6.0 in x 2.0 in; 8.2 lbs/ft). This structural channel forms the support rail for the track wrench. The rail can be purchased in 3 m (10 ft) sections or 2.4 m (8 ft) sections as needed, to fit with the leg spacing on the present gravity conveyor. These support rails can be mounted a maximum of 673 mm (26.5 in) apart. See the sketch provided. Position the top of the support rail 25.4 mm (1.0 in) above the top of the rollers in the gravity conveyor. This locates the track wrench in the correct position to avoid the use of the extensions to reach the track being worked. The sketch shows legs made of the same structural channel. Any leg design of similar strength can be used. Space the legs a maximum of 3 m (10 ft) apart. Secure the legs to the floor using concrete anchors. Brace the legs to resist the side loads generated by the operation of the track wrench. The rail section can be mounted directly to the support legs for the present gravity conveyor, if the support legs have equal or greater strength and rigidity than those shown in the sketch.

1

A

A 2 3 4 A

5

6

3

3

7 5

Note: Install the track wrench using the procedure outlined in the Installation on Caterpillar Conveyor above.

VIEW A - A

0703-52

Illustration 63. Rail Sketch.

(1) Width. (2) Roller. (3) Rail. (4) Angle iron. (5) Leg. (6) Concrete anchor. (7) Threaded plate. (A) 25.4 mm (1.0 in).

50

Nut Wrenches

Options Frame Protector for LGP Track Shoes

Illustration 65. Nut Wrenches.

Four double-ended nut wrenches have been designed to work with the square track nuts designed for the Track-Type Tractors, Track-Type Loaders and Excavators. The decals, mounted on the Torque-Turn Wrench, identify which wrench is required for each nut.

Decal NEEG2481 contains specifications for the Track-Type Tractors, Track-Type Loaders and 200 Series Excavators. Decal NEEG2514 contains specifications for all Excavators. Nut wrenches have not been provided for the "L" and "N" Series, mail box, track nuts. Four wrenches are available as follows:

Illustration 64. Roller Frame Protector.

(1) Roller. (2) Bracket. (3) U-Bolt.

The torque-turn wrench shifts the track chain against the side of the conveyor. Normally, the track links contact the sides of the conveyor before the ends of the shoes contact the sides of the wrench. Low ground pressure shoes on small track size contact the sides of the wrench before the link touches the side of the conveyor. Use of the Torque-Turn wrench on wide conveyors can bring the ends of the shoes against the sides of the wrench before the links touch the side of the conveyor. Contact by the ends of the shoes make it difficult to move the wrench along the conveyor.

The frame Protector prevents the shoes from contacting the sides of the wrench. The roller contacts the ends of the shoes, making it easy to move the wrench along the conveyor. One frame protector is mounted on each side of the wrench.

The surface of the roller is held about 6 mm (.25 in) inside the uprights in the frame.

4C-8207 . . . . . . . . . . . . . . . . . . . . (1.51 and 1.32 in) 4C-8202 . . . . . . . . . . . . . . . . . . . . (1.27 and 1.19 in) 4C-8209 . . . . . . . . . . . . . . . . . . . . (1.15 and 1.03 in) 4C-8210 . . . . . . . . . . . . . . . . . . . . (1.00 and 0.89 in)

51

Illustration 66. 152-2772 Wrench Assembly

52

152-2772 Wrench Assembly Item

Qty

Part No.

1

1

3098A-1

Hydraulic Fitting

Description

2

1

3098A-2

Hydraulic Adapter

3

1

151-2789

Polypack

4

1

3098A-4

Shifting Cylinder Rod

5

1

3098A-5

Shifting Cylinder Housing

6

1

3098A-6

Shifting Cylinder Mounting Bracket

7

1

3098A-7

Snap Ring

8

2

3098A-8

Shifting Cylinder Mount Stand Offset

9

1

3098A-9

Custom Washer

10

1

3098A-10

Return Spring

11

1

3098A-11

Rod Spring

12

1

3098A-12

Shifter Pin

13

1

3098A-13

Ball Bearing

14

1

3098A-14

Shifting Rod

15

1

151-2793

Motor

16

1

151-2794

Counter

17

1

151-2795

Coupling

18

1

151-2796

Shaft

19

1

3098A-19

Snap Ring

20

1

3098A-20

Hydraulic Motor Adapter (Motor to Gearbox)

21

1

3098A-21

Gearbox

22

1

151-2797

Driver

23

1

3098A-23

Ball Bearing

24

1

151-2798

Cross

25

1

151-2799

Shift Gear

26

1

3098A-26

Lower Spring

27

1

151-2801

Output

28

21

3098A-28

Ball Bearing

29

1

151-2802

Seal

30

1

3098A-30

Output Driver

31

1

3098A-31

Ball Bearing

32

2

151-2803

Optic Pickup

53

Illustration 67. 149-9950 Hydraulic Torque Turn Wrench Group (TT-7000).

54

149-9950 Hydraulic Torque Turn Wrench Group (TT-7000).

Item

Qty

Part No.

1

1

152-2772

Description

2

1

M52

Parallel Arm Pivot Mount

3

4

M53

Parallel Arms

4

1

M54

Transducer Mounting Bracket

5

1

M55

Planetary Gearbox Mount

6

6

M56

Socket Head Cap Screw

7

6

M57

Socket Head Cap Screw

8

16

M58

Bushing

9

4

M59

End Cap

10

1

M60

Handle Mount

11

1

M61

Handle Assembly

12

1

151-2788

13

1

M63

Cylinder

14

1

M64

Cylinder Rod Adapter

Wrench Assembly

Transducer

55

For information on service tools or shop supplies contact Caterpillar Service Technology Group on: Caterpillar Service Technology 100 N.E. Adams Street Peoria, Illinois 61629-9110 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6618 (Fax) or Caterpillar Service Technology Caterpillar Overseas S. A. P.O. Box 6000 1211 Geneva 6 Switzerland 41 (22) 849 40 36 (Geneva Phone) 41 (22) 849 45 44 (Geneva Fax) 413323 (Geneva Telex) CATOVERSEA (Geneva Cable) 36CSTG (COSA E-Mail Address)

©1998 Caterpillar All Rights Reserved

NEHS0703 Printed in U.S.A.