Caterpillar Track Torque Wrench Tool Operating Manual - PDF DOWNLOAD

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TOOL OPERATING MANUAL Track Torque Wrench Operation SMCS: 0729, 4170

NEHS0807-01 July 2001

Contents

Introduction

Introduction . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 References . . . . . . . . . . . . . . . . . . . . . . . . . 5 Features . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Nomenclature . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . 10 General Description . . . . . . . . . . . . . . . . . 11 Travel Mechanism . . . . . . . . . . . . . . . . . 11 Electric Motor. . . . . . . . . . . . . . . . . . . . . 12 Hydraulic Power. . . . . . . . . . . . . . . . . . . 12 Hydraulic Drive Motor . . . . . . . . . . . . . . 12 Planetary Gear Case . . . . . . . . . . . . . . . 13 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Transformer Control Box. . . . . . . . . . . . . . 13 Swivel-Mounted Control Handle . . . . . . . 14 Operator Control Box . . . . . . . . . . . . . . . . 17 Pre-Operation Inspection . . . . . . . . . . . . . 19 Operation. . . . . . . . . . . . . . . . . . . . . . . . . 19 General Information . . . . . . . . . . . . . . . . . 19 Track Assembly . . . . . . . . . . . . . . . . . . . 20 Angle Check . . . . . . . . . . . . . . . . . . . . . 25 Track Disassembly . . . . . . . . . . . . . . . . . 25 Planetary Gear Case . . . . . . . . . . . . . . . . . 28 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Frame Protector for LGP Track Shoes. . . . 30 Nut Wrenches . . . . . . . . . . . . . . . . . . . . . 30 Warranty Information . . . . . . . . . . . . . . . . 31 Customer Satisfaction . . . . . . . . . . . . . . . 31

This manual contains information necessary for operating the track torque wrench. The track torque wrench tightens track bolts using a torque-turn procedure recommended by Caterpillar or the final torque method used by other manufacturers.

The torque-turn procedure yields the most dependable means of fastening track shoes and prevents them from loosening due to inadequately tightened bolts. It is a two-step tightening procedure that starts by tightening bolts to a predetermined torque (pretorque).

After the pretorque is achieved each standard track bolt will receive an additional 120 degree turn. The track torque wrench automatically applies the right amount of torque to complete the turn.

NOTE: Each bolt and track size has a recommended pretorque.

NOTE: Some master bolts may require an additional 180 degree turn. Master bolts are not generally assembled in the shop.

The track torque wrench includes a forward/reverse, two-speed gear box for installing and removing bolts.

The FORWARD setting installs bolts by starting the track torque wrench at high speed to quickly “run-down” the bolt and then automatically shift to low speed to complete the torque turn.

The REVERSE setting removes bolts by starting the track torque wrench at low-speed, high-torque to break the bolt loose and then automatically shifts to high speed to quickly remove the bolt.

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Safety To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment. DO NOT operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals.

Contact CSTG for replacement manuals.

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

Always wear protective clothing while operating any machinery.

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

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

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

The track shoe support structure passes between the outer rails of the conveyor.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not specifically mentioned by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. Make sure the product or machine will not be damaged or be made unsafe by any operation, lubrication, maintenance, or repair procedures that you choose.

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

Check hydraulic oil lines, tubes, and hoses carefully.

DO NOT use your bare hand to check for potential leaks.

Always use a board or cardboard when checking for a leak. Escaping hydraulic fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

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

3

Personal injury can result from hydraulic oil pressure or hot oil. DO NOT remove a hydraulic tank filler cap unless it is cool enough to touch with bare hands.

Remove the hydraulic tank filler cap slowly to relieve pressure. Relieve all pressure in a hydraulic system before any caps, lines, fittings, or related items are disconnected or removed.

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

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

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

D O NOT allow any hot oil or components to contact the skin.

Personal injury or death can result from a fire.

Flammable fluid leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled flammable fluid immediately. Sparks or open flames can cause flammable fluid to ignite. DO NOT smoke while working on or near any flammable fluids.

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

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

DO NOT use a winch cable that is k i nk e d o r f r ay ed.

Wear protective gloves while handling the winch cable.

Make sure all limit switches are in proper working order.

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

The operator should always keep hands, fingers, hair, and articles of clothing clear of rotating machinery. The track torque wrench delivers very high torque at high rotating speeds through the arbor. Make sure an Emergency Stop button is pressed in anytime the arbor/socket has to be handled.

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

Even when a track torque wrench is powered down, press an Emergency Stop button before installing or changing a socket to prevent arbor rotation which could cause personal injury. The track torque wrench has an automatic shutoff feature which causes the pumps and motor to shut off after two (2) minutes of inactivity to minimize heat build-u up in the oil reservoir. A slight touch to a START CYCLE button can instantly engage the pump and motor to initiate arbor rotation.

4

NOTICE

Keep fingers away from any moving parts or pinch points to prevent

Follow Caterpillar guidelines for use and reuse of nuts and bolts. Only reuse bolts and nuts with clean threads and in good condition. Use a recommended lubricant which can reduce the required torque needed to properly tighten the bolts and the torque load imposed on the hydraulic track torque wrench and tooling.

pinching and crushing.

Always be prepared for the track to slide to the side of the conveyor. To prevent personal injury keep hands out of the space between the sides of the conveyor and the track while operating the track torque wrench. The high torque generated by the track torque wrench in FORWARD and REVERSE shifts the track to the side of the conveyor. In addition, tracks with dry joints and sealed track with internal wear can move these joints to the side of the conveyor. The parts of the track which have moved to one side during disassembly will move to the other side during assembly. This is particularly true for each end of the track.

Applying downward pressure and/or torque on the bolt before it is properly engaged can cause damage to the bolt and nut. To prevent damage, position the shoes on the track chain and line up the bolt holes; thread the bolts and nuts together at least four threads by hand or with a small power tool before using the track torque wrench.

DO NOT apply torque to a bolt if there is any doubt it has already been tightened. Loosen the bolt before applying additional torque to avoid damaging the track torque wrench, sockets, reducers, or the bolt. Pressing the CYCLE START button with the FORWARD/REVERSE switch in the “FORWARD” position and the 120° TURN/FINAL TORQUE switch in the “120° TURN” position starts the track torque wrench in high gear for a fast “run-down” of the bolt. It then shifts into low gear to tighten the bolt to the pretorque setting, finally turning the bolt an additional 120 degrees.

Each time this procedure is repeated on a bolt that is already tightened causes the track torque wrench to tighten the bolt until it is damaged, broken, or the torque exceeds the track torque wrench capacity of 9492 N·m (7000 lb ft).

Always use nut wrenches or pry bars to hold the track nuts while operating the track torque wrench. Keep hands and fingers clear of the area in the track link below the track bolts, because the track torque 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 and fingers can be trapped in this area causing serious injury or severed fingers.

Always hold a nut wrench (spoon) or pry bar so your hands cannot become trapped. Burrs or rust in threads can suddenly increase the amount of torque required to turn a bolt. This higher torque can suddenly force the nut wrench (spoon) or pry bar to shift to the side during the tightening or loosening process causing personal injury.

References Track Torque Wrench Reference Listing

5

Reference

Title

NEHS0806

Caterpillar 375T Track Press Installation

NEHS0810

Track Torque Wrench Maintenance

NEHS0814

Track Torque Wrench Parts and Schematics (Model TW001)

NEHS0815

Track Torque Wrench Parts and Schematics (Model TW002 and TW003)

NEHS0816

Track Torque Wrench Parts and Schematics (Model TW004)

NEHS0817

Track Torque Wrench Parts and Schematics (Model TW005)

Features

Mounting

Accuracy

The track torque wrench can be directly mounted to the Caterpillar conveyor and the tram wheels that support the track torque wrench are adjustable (in and out) to fit a variety of conveyors. A conversion kit and assembly instructions are available for mounting the track torque wrench on other conveyor systems.

Torque values are automatically measured by a strain gauge (transducer) built into the mounting fixtures of the track torque wrench.

Breakaway Torque The track torque wrench uses a high down force with a breakaway torque of 9492 N·m (7000 lb ft) on the socket to break loose worn bolts. This capacity works on all current and future Caterpillar tracks.

Options An oil cooler is an available option for standard versions of the track torque wrench.

Controls (Usability)

Reduced Operating Cost

The controls are designed for one person operation with all the primary operator controls located in the swivel-mounted control handle.

Bolts. The track torque wrench applies a maximum downward force of 8010N (1800 lbs) to remove worn bolts that previously had to be cut off with a cutting torch.

The joystick includes CYCLE START, HEAD RAISE, and HEAD LOWER buttons.

Maintenance. The track torque wrench is a simple planetary gear design, requiring only periodic oil and filter changes. In contrast, the standard impact wrench used in most shops require frequent disassembly and parts replacement.

The switch box above the joystick includes a green CYCLE COMPLETE light, plus a FORWARD/REVERSE and an ON/OFF switch.

Dimensions

Noise. The track torque wrench noise level is significantly lower than that of an impact wrench.

The inside frame of the track torque wrench is 1118 mm (44.0 in), but it can handle the widest Caterpillar tracks using a pad lifter.

One-of-a-kind special shoes wider than 1118 mm (44.0 in) can be reworked with the track torque wrench, by removing each track shoe from the conveyor to advance the track torque wrench to the next track shoe.

Sockets. The replacement cost of drivers and reducers are lessened and the service life is increased due to a steady application of force from the track torque wrench.

Training. A novice operator can set the proper pretorque, select the correct socket for the track bolt, place the socket on the bolt head, and squeeze the trigger while the track torque wrench does the rest. In contrast, an operator using an impact-style wrench must gain experience using the impact sound to set the bolt tight enough without breaking it.

The track torque wrench uses a 1-1/2 inch square drive for all track sockets and reducers. It can reach smaller tracks without extensions and it has a maximum rise which provides D11N sockets with 127 mm (5.0 in) clearance above the track shoes.

The track torque wrench has a vertical travel of 356 mm (14.0 in) with a side-to-side pivot of the arbor of 292 mm (11.5 in) from the center of the conveyor, allowing 584 mm (23.0 in) of side-to-side travel. The pivot can adjust to 1092 mm (43.0 in) for handling quad track.

Speed The track torque wrench uses an analog card for automatic shifting between “high-speed run-down” and “low-speed final-turn” or from “low-speed, high-torque” for breakaway, to “high-speed, low-torque” for run out.

Quiet (All Hydraulic) Power is supplied by a 15 horsepower electric motor and a Caterpillar piston pump.

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Nomenclature 27 24

15

11

17 18 19

8

21

14

16

12

5

5

5

20

1

14 13

6

7

0807-01

Illustration 1. Typical Track Torque Wrench (Side View).

(1) Track Torque Wrench Support Rails. (5) Hand Wheels. (6) Electric Motor. (7) Piston Pump. (8) Spindle Rotation Valve.

(11) Hydraulic Drive Motor. (12) Planetary Gear Case. (13) Transformer Control Box. (14) Emergency Stop Button.

(15) Swivel-Mounted Control Box. (16) Joystick. (17) ON/OFF Switch. (18) Cycle Complete Light. (19) Forward/Reverse Switch. (20) Head Raise/Lower Button. (21) Cycle Start Button. (24) Operator Control Box. (27) OptiMate Control Panel.

7

15

24

11

10

9

8

17 18

25

19 26

14

12

5

5 3

321

1 2 3

4

3

4 14

13

0807-02

Illustration 2. Typical Track Torque Wrench (Front View).

(1) Track Torque Wrench Support Rails. (2) Tram Wheels. (3) Split Fastening Rings. (4) Guide Wheels. (5) Hand Wheels.

(8) Spindle Rotation Valve. (9) Gear Shift Valve. (10) Head Up/Down Valve. (11) Hydraulic Drive Motor.

(12) Planetary Gear Case. (13) Transformer Control Box. (14) Emergency Stop Button. (15) Swivel-Mounted Control Box. (17) ON/OFF Switch. (18) Cycle Complete Light. (19) Forward/Reverse Switch. (24) Operator Control Box. (25) 120° Turn/Final Torque Switch. (26) Run/Shunt Switch.

8

3

5

5

5

3

3

3

5

3

5

A 1

2

Detail A

3

4 0807-03

Illustration 3. Typical Track Torque Wrench (Top View).

(1) Track Torque Wrench Support Rails. (2) Tram Wheels. (3) Split Fastening Rings. (4) Guide Wheels. (5) Hand Wheels.

9

Installation

a. The track torque wrench rolls along the conveyor system on tram wheels (2).

Mount the track torque wrench directly on a Caterpillar conveyor system with track torque wrench support rails (1).

b. Tram wheels (2) help control side-to-side movement of the track torque wrench.

NOTE: The weight of electric motor (6) and piston pump (7) (Illustration 10) pulls the track torque wrench to one side of the conveyor.

2. Make sure the track torque wrench has a small gap between the faces of tram wheels (2) and the webs of track torque wrench support rails (1) at the widest point in the conveyor.

Illustration 1. Track Torque Wrench On Rail System.

(1) Track Torque Wrench Support Rails.

Illustration 3. Gap Between Tram Wheel And Track Torque Wrench Support Rail Indicated By. Arrow.

(1) Track Torque Wrench Support Rails. (2) Tram Wheels.

NOTE: Conversion kits and instructions are available for mounting track torque wrench support rails and a Caterpillar track torque wrench on other conveyor system designs.

3. Use split fastening rings (3) to adjust the spacing of tram wheels (2).

1. Mount tram wheels (2) within track torque wrench support rails (1) on each side of the conveyor system.

Illustration 4. Split Fastening Ring (3).

Illustration 2. Tram Wheel (Close-Up View).

(1) Track Torque Wrench Support Rails. (2) Tram Wheels.

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General Description

a. Making adjustments to split fastening rings (3) allows tram wheels (2) to be arranged to fit a variety of conveyor systems.

Travel Mechanism 1. The track torque wrench travel mechanism includes track torque wrench support rails (1), tram wheels (2), split fastening rings (3), guide wheels (4), and hand wheels (5).

b. Make sure split fastening rings (3) are tight to prevent the gap (Illustration 6) between tram wheels (2) and track torque wrench support rails (1) from becoming wider. c. Check for large gaps which usually occur with tram wheels (2) on the motor side of the track torque wrench.

4. Make sure guide wheels (4) are properly adjusted.

Illustration 1. Track Torque Wrench Travel System.

(1) Track Torque Wrench Support Rails. (2) Tram Wheels.

(3) Split Fastening Rings. (4) Guide Wheels. (5) Hand Wheels.

2. Use the travel mechanism to move the track torque wrench to each shoe being repaired or replaced.

Illustration 5. Guide Wheels (4).

3. Turn hand wheel (5) to move the track torque wrench along track torque wrench support rails (1). Four hand wheels (5) are available to the operator.

a. Proper adjustment of guide wheels (4) provide greater freedom of movement along the length of the conveyor system.

NOTE: Operating pressure on the track torque wrench can force it to move relative to the track torque wrench support rails (1).

b. Extend guide wheels (4) approximately 1.5 mm (.06 in) closer to the web of track torque wrench support rails (1) than the inside face of tram wheels (2).

NOTE: Refer to NEHS0810 Track Torque Wrench, Maintenance Manual for installation information.

11

Electric Motor An on-board 15 horsepower electric motor (6) drives a load sensing 100-3259 Piston Pump (7) to develop hydraulic power.

Illustration 4. Solenoids And Directional Control Valves (Back View).

Hydraulic Drive Motor

Illustration 2. Electric Motor.

(6) Electric Motor. (7) 100-3259 Piston Pump.

Hydraulic drive motor (11) delivers power to a two-speed planetary gear system (12).

Hydraulic Power Hydraulic power is directed by solenoids and directional control valves mounted on the manifold located on the frame.

Illustration 5. Hydraulic Drive Motor (11).

(12) Planetary Gear System.

Illustration 3. Solenoids And Directional Control Valves (Front View).

(8) Spindle Rotation. (9) Gear Shift. (10) Head Up/Down.

12

Planetary Gear Case The track torque wrench is a simple planetary gear (12) requiring periodic oil and filter changes.

Illustration 1. Transformer Control Box (13).

(14) Emergency Stop Button.

Emergency Stop Illustration 6. Planetary Gear Case (12).

EMERGENCY STOP button (14), located on transformer control box (13) access door, is used to shut down power to the track torque wrench in an emergency situation.

Planetary gear case (12) can pivot within a horizontal range of 107 cm (42.0 in) and be raised or lowered within a vertical range of 35 cm (14.0 in). This allows the torque head and socket to be positioned over any bolt on the shoe and eliminates the need for extensions to reach small track.

Controls The track torque wrench has three separate electrical control boxes. These include a transformer control box (13), swivel-mounted control box (15) with joystick (16), and operator control box (24). (Electrical control boxes are briefly explained in this publication.

Additional information resources are located in the “References” section).

EMERGENCY STOP

0807-16

Illustration 2. Emergency Stop Button (14).

NOTE: The track torque wrench has an EMERGENCY STOP button (14) on transformer control box (13) and operator control box (24).

Transformer Control Box Transformer control box (13) is located on the track torque wrench frame. It contains the 24VDC power supply, circuit breakers, motor starter, thermal overload, and EMERGENCY STOP button (14).

1. Push EMERGENCY STOP button (14) to shut down power to electric motor (6).

2. Before starting the track torque wrench again, turn EMERGENCY STOP button (14) in the direction of the arrow to reset it.

13

Swivel-Mounted Control Handle

Swivel-Mounted Control Box

The primary track torque wrench controls are part of the swivel-mounted control handle.

These controls are designed for one-person operation.

Swivel-mounted control box (15) contains ON/OFF switch (17), CYCLE COMPLETE light (18), and FORWARD/REVERSE switch (19).

Use the swivel-mounted control handle to: • Position the planetary gear over the bolt head.

• Raise and lower the socket head.

• Engage the track torque wrench.

Illustration 4. Swivel-Mounted Control Box (15).

(17) On/Off Switch. (18) Cycle Complete Light.

(19) Forward/Reverse Switch.

ON/OFF Switch ON/OFF switch (17) is used to turn power ON and OFF for electric motor (6).

OFF

ON

Illustration 3. Swivel-Mounted Control Handle.

(15) Swivel-Mounted Control Box. (16) Joystick.

0807-24

Illustration 5. On/Off Switch (17).

14

Cycle Complete Light

2. Setting FORWARD/REVERSE switch (19) to “REVERSE” rotates the torque head in a counterclockwise direction for track shoe disassembly.

CYCLE COMPLETE light (18) will illuminate after the track torque wrench turns the bolt to the pretorque setting and an additional 120° turn.

REVERSE

FORWARD

CYCLE COMPLETE

0807-27 0807-25

Illustration 8. Forward/Reverse Switch (19) Set To “Reverse”.

Illustration 6. Cycle Complete Light (18).

Joystick

NOTE: 120° TURN/FINAL TORQUE switch must be set to “120° TURN” when used on tracks manufactured by Caterpillar.

1. Loosen the bolt of joystick (16) to secure it in one of three positions. The bolt will be on the bottom of the joystick when it is in the vertical position.

Forward/Reverse Switch FORWARD/REVERSE switch (19) is used to select the rotation direction of the torque head.

1. Setting FORWARD/REVERSE switch (19) to “FORWARD” rotates the torque head in a clockwise direction for track shoe assembly.

REVERSE

FORWARD 0807-18

Illustration 9. Positioning Of Joystick (16).

0807-26

Illustration 7. Forward/Reverse Switch (19) Set To “Forward”.

15

2. Use joystick (16) to position the socket above a bolt head.

Illustration 12. Joystick (16) Top View.

(20) Head Raise/Lower Button. (21) Cycle Start Button.

(22) Press to Raise. (23) Press to Lower.

Illustration 10. Joystick (16) (Side View).

c. Press one of the CYCLE START buttons (21) to start the pre-torque cycle.

NOTE: Planetary gear case (12 - Illustration 14) can pivot within a horizontal range of 107 cm (42.0 in).

3. Joystick (16) has four buttons, Head Raise/Lower button (20) and three Cycle Start buttons (21).

Illustration 13. Press One Cycle Start Button (21) To Start Torque Cycle.

NOTE: The joystick (16) is equipped with three CYCLE START buttons (21) because of the amount of wear these buttons receive.

A CYCLE START button (21) does not need to be replaced each time a single button wears out, simply use the remaining two buttons.

Illustration 11. Joystick (16) Buttons.

(20) Head Raise/Lower Button. (21) Cycle Start Buttons.

a. Press HEAD RAISE/LOWER button (20) to raise or lower the torque head. b. Press HEAD RAISE/LOWER button in location (22) to raise the torque head and HEAD RAISE/LOWER button in location (23) to lower the torque head.

(Refer to Illustration 26).

16

Operator Control Box

NOTE: The track torque wrench includes EMERGENCY STOP button (14) on transformer control box (13) and operator control box (24).

Operator control box (24), located on the track torque wrench frame, includes EMERGENCY STOP button (14) on the access door, 120° TURN/FINAL TORQUE (25) and RUN/SHUNT switches (26) on the left side, and OptiMate control panel (27) on the back.

1. Push EMERGENCY STOP button (14) to shut down power to electric motor (6).

2. Before starting the track torque wrench again, turn emergency stop button (14) in the direction of the arrow to reset it.

120° TURN/FINAL TORQUE Switch 120° TURN/FINAL TORQUE switch (25), located on the left side of operator control box (24), is used to select the bolt tightening method.

120˚ TURN

FINAL TORQUE

0807-29

Illustration 14. Operator Control Box (24).

(14) Emergency Stop Button. (25) 120° Turn/Final Torque Switch. (26) Run/Shunt Switch. (27) OptiMate Control Panel.

Illustration 16. 120° Turn/Final Torque Switch (25).

Run/Shunt Switch RUN/SHUNT switch (26), located on the left side operator control box (24), is set to “RUN” for normal operations and “SHUNT” for calibrating the strain gauge.

Emergency Stop EMERGENCY STOP button (14), located on operator control box (24) access door, is used to shut down power to the track torque wrench in an emergency situation.

RUN

SHUNT

0807-30

EMERGENCY STOP

Illustration 17. Run/Shunt Switch (26).

0807-16

Illustration 15. Emergency Stop Button.

NOTE: For TT5000 to TT7000 Torque Turn Wrench Conversion Kits, the machine is operated in the shunt mode for normal operations.

17

OptiMate Control Panel

Set Pretorque Key

OptiMate control panel (27), located on the back of operator control box (24), interfaces between the programmable logic controller (PLC) and the operator. The PLC will prompt an operator for the information needed to perform operations.

Use SET PRETORQUE key (31) to enter the value of the pretorque setting.

1. OptiMate control panel (27) includes function keys (28), numerical keypad (29), and indicator lights (30).

3. Press Enter key to store the value into the torque program.

1. Press SET PRETORQUE key (31).

2. Use numeric keypad (28) to enter the required pretorque value.

NOTE: When the Enter key is pressed the display will change to zero and the value can be checked using Check Set Values key (33).

Set Calibration Number Key Only use SET CALIBRATION NUMBER key (32) if the track torque wrench has been serviced.

NOTE: To reset the calibration, a password must be obtained by calling CSTG. Check Set Values Key Press CHECK SET VALUES key (33) to display the pretorque and calibration values stored in the program.

Illustration 18. OptiMate Control Terminal (27).

(28) Function Keys. (29) Numeric Keypad.

(30) Indicator Lights.

Check Transducer Center Key Press CHECK TRANSDUCER CENTER key (34) to display the reading from the strain gauge.

2. The five function keys (28) include: SET PRETORQUE (31), SET CALIBRATION NUMBER (32), CHECK SET VALUES (33), CHECK TRANSDUCER CENTER (34), and CYCLE COUNT (35).

1. The display should read: a. If RUN/SHUNT switch (26) is set to RUN, the value on the display should read 2000 ± 50. b. If RUN/SHUNT switch (26) is set to SHUNT, the value on the display should read 3750 ± 50.

2. Press CHECK TRANSDUCER CENTER key (34) a second time to clear the display and resume operation.

Cycle Count Key Press CYCLE COUNT key (35) to display the number of times a CYCLE START button (21) on joystick (16) has been pressed.

Illustration 19. Function Keys (28).

(31) Set Pretorque. (32) Set Calibration Number.

(33) Check Set Values. (34) Check Transducer Center.

(35) Cycle Count.

18

Pre-Operation Inspection

Operation

Perform a pre-operation inspection just prior to each use of the track torque wrench.

When the track torque wrench meets enough resistance during high speed operation an analog input card senses the torque value causing the track torque wrench to briefly pause as it automatically shifts into low gear to finish tightening the bolt.

1. Inspect the wires from the proximity sensor under the cover on the top of the planetary gear case and the strain gauge link to make sure they are properly located and cannot be damaged by the operation of the track torque wrench.

Two conditions will cause the track torque wrench to shift into low gear.

2. Keep all hydraulic connections and bolts tight.

• When it has achieved the pretorque setting.

3. Bolts in these critical areas should be constantly monitored:

• When it has reached the maximum drive torque for high-speed operations.

• Hydraulic motor mount to the top of the gear case.

Maximum drive torque is estimated using input from the strain gauge.

• Strain gauge link mount to the gear case and swing arm.

• Large bolts can create a maximum drive torque prior to reaching the pretorque setting.

• Split collars on each hand wheel shaft.

• The track torque wrench will shift from “high-speed, low-torque” to “low-speed, high-torque” with torque increasing until the bolt is tightened to the pretorque setting.

• Guide wheel assemblies.

4. Make sure the studs mounting the strain gauge links and hydraulic motor to the gear case have not unthreaded from the gear case.

General Information

NOTE: To prevent studs from loosening, use 9S-3265 Retaining Compound.

Even when a track torque wrench is powered down, press an Emergency Stop button before installing or changing a socket to prevent arbor rotation which could cause personal injury. The track torque wrench has an automatic shutoff feature which causes the pumps and motor to shut off after two (2) minutes of inactivity to minimize heat build-u up in the oil reservoir. A slight touch to a START CYCLE button can instantly engage the pump and motor to initiate arbor rotation, possibly causing personal injury.

19

Track Assembly

1. Press EMERGENCY STOP button (14).

Track Assembly Sequence Chart The Track Assembly Sequence Chart is a quick reference guide for track assembly procedures.

Track Assembly Sequence Chart Initial Conditions Power ON - (proper Voltage per label).

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

EMERGENCY STOP

Hydraulic reservoir full of clean 10W premium hydraulic oil.

0807-16

Gear case half full of 90W gear lube.

Illustration 1. Emergency Stop Button (14).

Programmable logic controller shows Power ON. Operation 1. Turn the ON/OFF selector switch.

2. Use a large diameter pin, such as a roll pin to install a socket on the arbor.

• The 15 hp pump motor should start.

• Output B0, Y0.

3. Make sure the arbor is clear, the socket is not on a bolt, and that nothing is exerting a side force on the gear case.

2. Press the Head Raise/Lower buttons.

• Input A3 and A4.

• The head should raise and lower.

4. Turn EMERGENCY STOP button (14) in the direction of the arrow to release it.

• Output A3 and A4.

3. Press the Cycle Start button.

5. Turn the power ON and allow the hydraulic oil to warm for twenty minutes to make the setup procedure more precise.

• Input A0.

• Output Y1 goes on.

• Rotation FORWARD. 4. Torque pressure builds as a bolt is tightened and the analog input card senses the increase in torque to shift the gear box into a lower speed.

5. When the pretorque setting is reached, the yellow Pretorque light illuminates.

• Output B2.

6. The green Turns Achieved light illuminates.

• Output A0 goes OFF • Track torque wrench stops.

• Output B3.

20

Track Assembly Procedures

• A socket with a 1-1/2 inch drive, in good condition.

NOTE: This section describes an operation with 120° TURN/FINAL TORQUE switch (25) set to “120° TURN”. (For additional information on operations with this switch set to “FINAL TORQUE”, refer to the “Final Torque” section in this manual).

• A nut wrench.

3. Set RUN/SHUNT switch (26) to RUN.

1. Obtain the correct tools and information needed to assemble the track shoes.

• The correct pretorque value.

This information is available on the Caterpillar Torque-Turn Specifications chart.

RUN

SHUNT

2. Set 120° TURN/FINAL TORQUE switch (25). a. Set 120° TURN/FINAL TORQUE switch (25) to “120° TURN” for track made by Caterpillar.

0807-30

120˚ TURN

Illustration 4. Run/Shunt Switch (26) Set To “Run”.

FINAL TORQUE

4. Set FORWARD/REVERSE switch (19) to FORWARD.

0807-29

REVERSE

FORWARD

Illustration 2. 120° Turn/Final Torque Switch (25) Set To “120° Turn”.

b. Set 120° TURN/FINAL TORQUE switch (25) to “FINAL TORQUE” for track made by another manufacturer.

0807-26

Illustration 5. Forward/Reverse Switch (19) Set To “Forward”.

120˚ TURN

FINAL TORQUE

0807-33

Illustration 3. 120° Turn/Final Torque Switch (25) Set To “Final Torque”.

21

c. Press ENTER key (36) to enter the pretorque value in the torque program.

5. Enter the pretorque value into OptiMate control panel (27). a. Press SET PRETORQUE key (31).

Illustration 8. Press Enter Key (36).

Illustration 6. Press Set Pretorque Key (31).

NOTICE b. Use number keys (29) to enter the pretorque specifications.

Applying downward pressure and/or torque on a bolt before it is properly engaged can damage the bolt and nut. Start track bolts by hand or with a small power tool before using a track torque wrench.

6. Attach the track shoes to the track chain. a. Position the shoes on the track chain and line up the bolt holes. b. Install the bolts and nuts by hand or with a small power tool. c. Make sure the bolt threads engage the nut a minimum of four threads.

Illustration 7. Use Number Keys (29) To Enter The Pretorque Specifications.

NOTE: Refer to the Caterpillar Torque-Turn Specifications chart for the pretorque value.

22

7. Move the socket above the bolt head.

NOTE: The torque head can be moved in a vertical range of 35 cm (14.0 in), which eliminates the need for extensions to reach small track.

a. Use hand wheels (5) to move the track torque wrench horizontally along the conveyor system.

NOTE: If the socket does not completely align with the bolt head briefly press Cycle Start (21) button enough to engage the bolt and socket.

NOTICE DO NOT apply torque to a bolt if there is any doubt it has already been tightened. Loosen the bolt before applying additional torque to avoid damaging the track torque wrench, sockets, reducers, or the bolt. Pressing the CYCLE START button with the FORWARD/REVERSE switch in the “FORWARD” position and the 120°TURN/FINAL TORQUE switch in the “120° TURN” position starts the track torque wrench in high gear for a fast “run-down” of the bolt, shifting into low gear to tighten the bolt to the pretorque setting, and then turning the bolt an additional 120 degrees.

Each time this procedure is repeated on a bolt that is already tightened will cause the track torque wrench to tighten the bolt until it is damaged, broken, or the torque exceeds the track torque wrench capacity of 9492 N·m (7000 lb ft).

Illustration 9. Use Hand Wheels (5) To Move The Track Torque Wrench.

b. Use joystick (16) to position the socket over a bolt.

8. Press HEAD RAISE/LOWER button (20) on joystick (16) to lower the torque head onto the bolt.

9. Press and hold one CYCLE START button (21) to start the tightening process.

Illustration 10. Head Raise/Lower Button (20).

(20) Head Raise/Lower Button. (21) Cycle Start Buttons.

(22) Head Raise. (23) Head Lower.

Illustration 11. Joystick (21) Cycle Start Buttons.

23

NOTE: DO NOT release CYCLE START button (21) until the torque-turn process is finished.

NOTE: CYCLE COMPLETE light (18) on swivel-mounted control box (15) will also illuminate when the torque-turn process is complete.

10. Follow either with the Torque-Turn process Step 11, or the Final Torque process, Step 12.

11. Torque-Turn process. a. The yellow light (37) on the OptiMate control panel will illuminate when the pretorque setting is reached.

CYCLE COMPLETE

0807-25

Illustration 14. Cycle Complete Light (18) Will Illuminate When The Torque-Turn Cycle Is Complete.

d. Release CYCLE START button (21).

12. Final Torque process.

Illustration 12. Yellow Light (37) Will Illuminate When The Pretorque Setting Is Reached.

a. The OptiMate control panel yellow light (37) and green light (38) will illuminate at the same time when the final torque setting is reached.

b. The track torque wrench will then turn the bolt an additional 120°. c. The green light (38) on the OptiMate control panel will illuminate when the torque-turn cycle is complete.

Illustration 16. Yellow Light (37) and Green Light (38) Will Illuminate When The Final Torque Setting Is Reached.

NOTE: The red light is not used on the 375T Track Press OptiMate control panel.

Illustration 13. Green Light (38) Will Illuminate When The Torque-Turn Cycle Is Complete.

24

Angle Check

Track Disassembly

1. Tighten a bolt to the pretorque specification with a standard track torque wrench.

Track Disassembly Sequence Chart The Track Disassembly Sequence Chart is a quick reference guide for track disassembly procedures.

2. Mark the location of one bolt head flat.

3. Set FORWARD/REVERSE switch (19) to “FORWARD”.

Reverse-Disassemble (Counterclockwise) Sequence Chart Initial Conditions Power ON Pump motor OFF.

REVERSE

FORWARD

Hydraulic reservoir full of clean 10W premium hydraulic oil.

Gear case half full of 90W gear lube.

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

Operation 1. Turn ON the ON/OFF selector switch.

• Output B1 comes ON.

0807-26

• Pump starts.

2. Press the cycle start button.

Illustration 17. Forward/Reverse Switch (19) Set To “Forward”.

• Input A0 ON. • Shift to slow.

• Output B5 was accomplished.

4. Enter the pretorque value into OptiMate control panel (27) using Set Pretorque key (31).

• Rotation REVERSE. • Output A1.

3. Output conditions: • Output A1 OFF, reverse.

• Output B5 OFF, slow.

• 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 torque wrench back in slow.

Illustration 18. Enter The Pretorque Value Using Set Pretorque Key (31).

5. Position the socket over the bolt and tighten the bolt.

NOTE: The track torque wrench should turn the bolt head two flats and illuminate the CYCLE COMPLETE light (18) on swivel-mounted control box (16).

25

Track Disassembly Procedures

4. Locate the socket above the bolt head. a. Use hand wheel (5) to move the track torque wrench horizontally along the conveyor.

1. Obtain the correct tools needed to remove the track shoes from a particular track. a. Make sure the correct socket for the track being repaired is in good condition.

NOTE: The track torque wrench uses a 1-1/2 inch square drive. b. Make sure the correct nut wrench required for the track is on hand.

2. Make sure RUN/SHUNT switch (26) on operator control box (24) is set to RUN. NOTE: For TT5000 to TT7000 Torque Turn Wrench Conversion Kits, the machine is run in the shunt mode for normal operations.

RUN

Illustration 21. Use Hand Wheels (5) To Move The Track Torque Wrench.

b. Use joystick (16) to position the socket over a bolt.

SHUNT

5. Press HEAD RAISE/LOWER button (20) on joystick (16) to lower the torque head onto the bolt.

0807-30

Illustration 19. Run/Shunt Switch (26) Set To “Run”.

3. Set FORWARD/REVERSE switch (19) to REVERSE.

REVERSE

FORWARD

Illustration 22. Head Raise/Lower Button (20).

(20) Head Raise/Lower Button. (21) Cycle Start Buttons.

(22) Head Raise. (23) Head Lower.

0807-27

Illustration 20. Forward/Reverse Switch (19) Set To “Reverse”.

26

NOTE: The torque head can be moved in a vertical range of 35 cm (14.0 in), which eliminates the need for extensions to reach small track.

c. Maximum down-force is applied to the socket until the tram wheels raise off of the support channel on each side of the conveyor.

NOTE: If the socket does not completely align with the bolt head briefly press CYCLE START button (21) enough to engage the bolt and socket.

NOTICE Applying a 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 torque wrench. Use this procedure only in cases where the bolts will not loosen with normal torque.

6. Press and hold one CYCLE START button (21) to loosen the bolt.

8. Hold the nut in the seat force to prevent it from spinning while applying high downforce.

9. When the nut breaks loose, briefly touch HEAD RAISE button (23) to remove the down-force from the bolt head.

Illustration 23. Joystick Cycle Start Buttons (21).

7. Press HEAD LOWER (22) to create the high down-force needed to break loose bolts with badly worn bolt heads.

Illustration 25. Head Raise Button (23).

NOTE: When the FORWARD/REVERSE switch (19) is set to “REVERSE”, the socket moves a short distance vertically without lifting the socket off the bolt head.

Illustration 24. Head Lower Button (22).

a. ONLY press HEAD LOWER (22) after the socket has engaged the bolt to produce a high down-force of up to 8010N (1800 lb ft). b. DO NOT use high down-force on new bolts or bolts with little wear.

27

Planetary Gear Case 51

33

50 36

49 35

1 2 28

22

3 4 26

42 31

61 7

34

32

8 23

39

58

62 10

57

11 54 53

52

12

64

13

48 55 56 46

14 15

45

59 60

16

44 21

17 18

47

27

43

41

19 63 20 LOWER DRIVE UNIT

0807-43

Illustration 1. Planetary Gear Case.

28

Parts List Track Torque Wrench Item Qty

Part No.

Description

Parts List Track Torque Wrench Item Qty

Part No.

36

1

3B-6552

Description

1

1

SS-1

Aurora, stroke - 38 mm (1.5 in)

2

1

—

Cylinder Mount Plate

3

1

—

Adapter

37

—

—

—

4

2

—

Threaded Bushing

38

—

—

—

1

—

Shaft

Male NPTF/Female NPTF with 90° Elbow (1/8-27)

5

—

—

—

39

6

—

—

—

40

—

—

—

7

1

—

Split Cylinder

41

1

—

Special O-ring

8

1

—

Motor Mount Plate

42

1

—

43

1

—

Motor (Spline Shaft)2

44

1

F40HG2

Conversion Adapter Male BSPPFemale 1/4 to 1/4

45

1

558K11

Nose Nipple1, (Stainless Steel)

46

1

5553K13

Tygon Tubing1, 6.4 mm (.25 in) ID,

9

—

—

10

1

111A-088-AS-1

11

1

—

Mounting Plate, Torque Body

12

1

—

Pickup/Drive Gear (1-6 thread)

13

1

—

Coupling

14

1

—

Drive Shaft

15

1

5100-98 S-PP

16

1

5100-196

17

1

18

5203SBKZZ-H502 Bearing

Metal Locknut, 5/16-24

9.53 mm (.375 in) OD, 127 mm (5.0 in) long

Retaining Ring

47

2

—

Lockwasher

Waldes Snap Ring

48

2

—

Spacer

16010

Bearing Fag

49

1

—

1

—

Drive Coupling

Pipe Nipple, 1/4 NPT x 52 mm (2.0 in) long

19

1

—

Sliding Shift Gear

50

1

1/4DD45-5

Elbow2

20

1

—

Stub Axle

51

1

1229K23

Oil Hole Cover1

VGF-092

Gear Box4

52

1

Proximity Sensor XSIN08NA3400 with XS2CD121Y

53

1

161

O-ring2

54

1

152

O-ring2

55

1

8876T22

Nylon Loop Clamp1, [for hose with 9.53 mm (.375 in) OD]

56

1

—

Button Head Screw, 10-32 x 12.7 mm (.50 in) long

21

1

22

1

Mounting Weldment

23

1

—

Shifting Rod

24

—

—

—

25

—

—

—

26

4

—

Socket Head Cap Screw, 5/16-18 x 150 mm (6.0 in) long

57

1

5372K212

Barbed Tube Fitting Female Nipple1, 1/4 NPT

27

1

—

Dowel Pin, 6.4 mm (.25 in) diameter 57.15 mm (2.250 in) long

58

1

4450K2

Exhaust Muffler/Filter1

59

1

1/4 DD

Female Pipe Elbow2

60

1

44615K412

61

2

—

62

6

M18

Lock Washer

63

6

—

Dowel, 12.7 mm (.50 in) diameter x 38 mm (1.5 in) long

64

4

—

Spring Pin, 7.93 mm (.312 in) diameter x 38 mm (1.5 in) long

28

4

—

Button Head Screw, 1/4-20 x 19.1 mm (.75 in) long

29

—

—

—

30

—

—

—

31

2

—

Hex Head Screw, 1/2-13 x 31.8 mm (1.25 in) long

32

2

31905

Hard Washer3, SAE

33

2

1079K18

Flow Sight1, 1/4 NPT

34

2

—

35

1

—

1 McMaster-Carr

Socket Head Cap Screw, 1/2-13 x 51 mm (2.0 in) long

2 Parker 3 Jergens 4 Reggiana

Socket Head Set Screw, 10-24 x 19.1 mm (.75 in) long

29

Pipe Nipple1 Hex Head Screw, 1/2-13 x 38 mm (1.5 in) long

Options

Nut Wrenches

Frame Protector for LGP Track Shoes The frame protector prevents the track shoes from contacting the sides of the track torque wrench. The roller of the frame protector contacts the ends of the track 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 6.0 mm (.25 in) inside the uprights in the frame.

0807-44

Illustration 2. Nut Wrenches.

Four double-ended nut wrenches are available for the square track nuts used on track-type tractors, track-type loaders, and excavators.

• 4C-8207 38.4 and 33.5 mm (1.51 and 1.32 in) • 4C-8208 32.3 and 30.0 mm (1.27 and 1.19 in) • 4C-8209 29.2 and 26.1 mm (1.15 and 1.03 in) • 4C-8210 25.4 and 22.6 mm (1.00 and .89 in) The decals on the track torque wrench identify which wrench to use for each nut.

• Decal NEEG2481 includes specifications for track-type tractors, track-type loaders and 200 series excavators.

• Decal NEEG2514 includes specifications for all excavators.

NOTE: Nut wrenches have not been provided for the “L” and “N” Series, mail box, track nuts.

30

Warranty Information

Customer Satisfaction

For up to one year from the 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 and 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.

Whenever you have questions or comments, such as: • discussing tool applications or uses, • discussing benefits or our new products, • resolving tool availability issues, • answering questions about tool repair, or • clarifying information in our publications, please call us about our products or programs. Caterpillar Service Technology Group is here to provide you with the best service and products available.

If you need fast service or a general question answered, call us at one of our toll free numbers. For specific product information or questions on the track torque wrench or track press, contact the Caterpillar Service Technology Group Diagnostic Lab. Phone: (309) 636-1761 (CSTG Diagnostic Lab) Fax:

31

(309) 636-1663 or (309) 636-1664 (CSTG Diagnostic Lab fax)

For information on service tools or shop supplies, contact Caterpillar Service Technology Group on: Caterpillar Service Technology 501 S.W. Jefferson Ave. Peoria, Illinois 61630-2184 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6650 (Fax) Hotline Email “CSTG” or Caterpillar Service Technology Caterpillar Overseas S.A. P. O. Box 6000 1211 Geneva 6 Switzerland +41 (22) 849 40 56 (Geneva Phone) +41 (22) 849 49 29 (Geneva Fax) 36CSTG (COSA E-Mail Address)

©2001 Caterpillar Inc. All Rights Reserved

NEHS0807-01 Printed in U.S.A.