150T Track Repair Group Field Follow Tools, Operation, and Parts {0374, 0700, 0729, 4169, 4170, 4171} Caterpillar

Excavator

All

Track-Type Tractor

All

Introduction

This manual contains safety information, operation instructions, and maintenance information and should be stored with the tool group.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

Some photographs or illustrations in this publication may show details that can be different from your service tool due to updates. Guards and covers might have been removed for illustrative purposes.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator is responsible for ensuring that the procedures used are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

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Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understand the operation lubrication, maintenance, and repair information.

When replacement parts are required for this product, Caterpillarrecommends using Catreplacement parts or parts with equivalent specifications including, but not limited to physical dimensions, type, strength, and material.

Whenever a question arises regarding your service tool or this publication, contact the Global Dealer Solutions Networkhot line at:

USA: 1-877-228-2420

International: 1-309-578-7372

Safety Information

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. The operator should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons

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Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Safety Signal Words

The following safety signal words can be found throughout this publication. Review the image below to understand the severity of bodily harm that can occur during certain operational steps. Refer to "ANSI Z535.1-2002 - American National Standard For Safety Color Code" and "ANSI Z535.6-2011- American National Standard - Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials"for more information.

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Tool Image

There are specific safety messages on this tool. The exact location of the hazards and the description of the hazards are reviewed in this section. Become familiarized with all safety messages.

Make sure that all the safety messages are legible. Clean the safety messages or replace the safety messages if you cannot read the words. Replace the illustrations if the illustrations are not visible. When you clean the safety messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to fall.

Replace any safety message that is damaged, or missing. If a safety message is attached to a part that is replaced, install a safety message on the replacement part. Any Catdealer can provide new safety messages.

Do Not Operate

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Do not operate or work on this machine unless you have read and understand the instruction and warning in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact and Cat dealer for replacement manuals. Proper care is your responsibility.

Crush -Hand

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Warning - Crush Point/Stay Clear

High Pressure - Hydraulic

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure.

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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

Flying Debris - Secure Guard

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Warns against operating the tool without the guard in place.The decal above is located on top of the guard and the bolster. Wear Proper Ear and Eye Protection

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The decal above warns against hearing and eye damage and is located on top of the tool case.

Mandatory Action and Personal Protection Identification

The personal protective equipment symbols shown in this section are all not used with this tool. Read and understand the manual fully to know which personal protective equipment should be used during tool operation. Always use the appropriate personal protective equipment when operating the tool.

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During the operation of this tool, wear proper personal protective gear, such as gloves, when operating hydraulic equipment or working around the track link assembly. Wear protective shoes when handling, installing, or removing this track links, track repair group, or tooling. The portable track press weighs enough to cause personal injury if dropped onto your hand or foot. Always wear protective shoes and use care when handling the unit. Wear gloves for protection when handling sharp objects. Sharp corners or burrs on track links, or sharp threads on track bolts, can cause cuts.

Know how to safely shut-off the hydraulic power supply (energy source). If an emergency situation occurs, immediately shut down and lock out the equipment.

Product Safety Information

General Safety Hazards

• Read and understand this and all other manuals before installing, operating, repairing, maintaining, or working near the machine.

• Only trained operators should install, adjust, or use this tool. Do not allow unauthorized personnel to operate tool.

• It is your responsibility to make this information available to others that will operate this product.

• The warnings given in this manual are for identified hazards that are foreseeable in the general use of this tool.

• Never use a tool that has been damaged or is malfunctioning.

• Do not modify the tool, safety devices, and accessories. Doing so will increase hazards to the operator and others.

• Perform preventative maintenance on the tool regularly. Keep tool clean of fluids, grease, dust, and debris found around the workspace.

• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment.

• Have a clean workspace to perform tool operation in. Do not leave tools or machine components laying around the workspace. Clean up all spilled liquids on the floor, maintain a dry work area.

• The track repair group is heavy and can cause back injury if not handled properly. Use a crane or other lifting device to move the track repair group as needed.

• Only use tool for the intended design purpose.

• No smoking in vicinity of the tool.

Crushing and Cutting Hazard

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

• Support the equipment properly before you perform any work or maintenance beneath that equipment.

• Moving parts are found on this tool, keep hands, fingers, and loose clothing away when tool parts are in motion.

• Use of the tool can expose the operator’s hands and feet to hazards, including crushing, impacts, cuts, abrasions, and heat. Wear suitable gloves to protect your hands, and suitable footwear to protect your feet.

• Avoid pinch points when assembling the tool and/or when positioning the tool onto the track.

• Personal injury or death can result from improper use of this tool and from improperly supporting and bracing of the load.

High-Pressure Hazard

• The hydraulic system can be pressurized to 700 bar (10,000 psi). Make sure that all hydraulic pressure has been relieved before disconnecting hoses or servicing the unit. Failure to relieve pressure can cause personal injury.

• Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved. Personal injury can result from removing hoses or quick disconnect fittings in a pressure system.

• This unit is designed for a maximum pressure of 700 bar (10,000 psi). Use care when this unit is connected to a portable hydraulic supply. Do not exceed the maximum pressure ratings. Overloading causes equipment failure and possible personal injury. Do not connect this unit to a pump or power supply with a higher pressure rating.

• Check high-pressure hydraulic 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.

Flying Debris Hazard

• To prevent personal injury or even death from ejected parts or flying objects, never remove guards during operation of the track repair group.

• Never remove guards when the tool is under pressure.

• Always wear eye protection when operating, performing maintenance, or washing this tool.

• Make sure that other personnel are a safe distance away when working on a component that could cause flying debris. Safe distance for unprotected people is approximately 40 m (130 ft.).

• Always verify that the tool is set up correctly, and guards are in place.

General Description

The 458-2111 Track Repair Group and related tooling allows qualified service personnel to remove or install track pins into track link assemblies on track chain. This group can be used in the shop or in the field. Each track size and type requires specific track tooling.

This guideline provides the procedure for removal and installation of track pins to repair or replace dry joints.

This Track Repair Group is compliant to the European Union 2006/42/EC Directive and EN982 requirements. The required Declaration of Conformity document is included in this manual.

Parts List

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Table 1

Item	Part No.	Description
1	458-2114	Back Plate Assembly-Bolster
2	458-2115	Rod
3	458-2116	Front Plate
4	458-2117	Nut Guard
5	458-2118	Catch Basket
6	458-2119	Handle
7	458-2120	1-3/8 Acme Nut
8	458-2124	Lexan Guard Assembly
9	457-0812	Hydraulic Cylinder (150T)
10	395-1100	Lifting Eyebolt Assembly
11	450-6676	Threaded Adapter
12	-------	Shaft Collar
13	-------	Spring

Additional Tooling

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Do not try to repair track without the proper tooling. Damage to the track or tooling could result. Each size and type of track requires specific track tooling. Refer to Undercarriage Reconditioning Guides for the proper tooling to be used. Do not strike the tooling or any components with a hammer or other similar hand tool when it is pressurized. Failure to follow this recommendation could result in tool failure causing ejected parts, which will result in personal injury or death. Never operate the unit if the guards are cracked or damaged. Immediately replace damaged parts with a newCaterpillar parts.

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Shown above, is a general guide to help identify the different contact tooling that may be required.

Inspection

Unpack and Inspect

Remove the lid from the top of the shipping crates by removing the screws in the top panel. Remove the flexible guard lying on the top tool tray. Remove blocking from the crate. s. Remove any protective film from the guard to create an unobstructed view.

1. Inspect for missing or damaged part

2. Inspect flexible guard.

3. Inspect all components prior to each use for nicks, burrs, dents, cracks, bends, or worn parts. If damage is found, discontinue use until inspected and released for use by an approved inspector at dealership.

4. Inspect all welds and check for damaged, cracked, or bent components.

5. Inspect all hardware for damaged threads and cracked or bent components.

6. Do not use if bolt holes are elongated.

7. Have tools inspected annually by an approved dealership inspector. Maintain a written record of all inspections

Complete a visual inspection of the individual components before using the tool.

Table 2

Inspection Guide
Item	Visual Inspection	Possible Solution
Plates	Check for cracks	Replace plate if cracks are found
Tie Rods	Check threads for damage or galling	Replace any damaged bolts
ACME Threaded Nuts	Check nut for damage or galling, cracks, or other damage	Replace any damaged nuts
Hydraulic Hoses	Inspect all hoses for damage, cracks, or abrasions to the outer covering, and/or leaks	Replace any damaged hoses
	Fittings are not damaged, displaced, or leaking Wire shields are exposed Outer coverings are ballooning Flexible parts of the hoses are kinked	Replace any damaged hoses
Hydraulic cylinders	Check for leakage	Replace fittings Repair Cylinder Seals Replace the cylinder
Contact tooling	Inspect the tooling for excessive wear or cracks	If damage is found, replace the tooling
Safety Guard	Guard is securely held in place. Check for cracks or discoloration of plastic	Replace the window if any of these conditions are found
Lifting Eyes	Ensure tightness	Tighten
	Ensure correct bolt (threaded stud) size, quality, and length	Replace Lifting Eyes
	The plane area of the eyebolt must properly flat down on the work piece.	Replace Lifting Eyes
	The lifting point should be complete	Replace Lifting Eyes
	The working load limit and manufacturers stamp should be clearly visible	Replace Lifting Eyes
	Deformation of the component parts such as body, load ring, and threaded stud	Replace Lifting Eyes
	Mechanical damage, such as notches, particularly in high stress areas.	Replace Lifting Eyes
	Wear should be no more than 10% of cross sectional diameter	Replace Lifting Eyes
	Evidence of corrosion or cracks	Replace Lifting Eyes
	Damage to the bolt and/or thread	Replace Lifting Eyes

Hydraulic Power Supply (Energy Source)

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

This unit is designed to work with a hydraulic power supply (energy source) equipped with a 700 bar (10,000 psi) maximum pressure relief valve and hoses rated for that working pressure. The hydraulic power supply should be compliant to the European Union 98/37/EC Directive and EN 982 requirements. Refer to Cat NENG2500 Tools and Shop Products Guide for possible power supply units.

Pressure can be trapped in a hydraulic system. Trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings. High-pressure oil that is released can cause a hose to whip while oil is spraying. Relieve all pressure before any lines, any fittings, or any related items are disconnected or removed.

High-pressure hoses [700 bar (10,000 psi) maximum pressure], are required to be used with this Track Repair Group. Connect the Track Repair Group to a recommended hydraulic power supply.

457-0818 Hydraulic Power Supply (115V - 5 Gal Tank) 457-0819 Hydraulic Power Supply (230V - 5 Gal Tank)

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Table 3

Type of Oil	Cat HYDOTM 10W Oil
Maximum hydraulic pressure	700 bar (10,000 psi)
Maximum pump flow:
First stage	350 in3/min@ 100 psi
Second stage	60 in3/min @10,000 psi
Recommended operating oil temp	104° to 300° C (40° to 150° F)

Oils

Always place dust caps onto quick-disconnect fittings when the unit is not in use to helps prevent contamination of the hydraulic power supply and related components.

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At operating temperature, the hydraulic power supply is hot. Hot oil and components can cause personal injury. Do not allow hot oil to contact the skin.

Hoses

Avoid damaging hydraulic hoses. Avoid sharp bends and kinks when routing hydraulic hoses. Using a bent or kinked hose will cause severe back-pressure. Sharp bends and kinks will internally damage the hose, leading to premature hose failure resulting in personal injury.

Do not drop heavy objects on hoses. Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install bent hoses. Do not install damaged hoses. Do not handle pressurized hoses.

Keep this unit and high-pressure hoses away from flames and excessive heat. Excessive heat will soften packings and seals, resulting in fluid leaks. Heat also weakens hose materials and packings. For optimum performance, do not expose equipment to temperatures of 65°C [150°F] or higher. Protect hoses and cylinders from weld spatter.

Check hoses carefully. Tighten all connections to the recommended torque. When you check for a leak, use a board or cardboard. Leaking fluid that is under pressure can penetrate body tissue. Pin hole leaks can cause severe injury. Never operate equipment with a known malfunction or leak.

Containing Fluid Spillage

Care must be taken to ensure that hydraulic oil is contained during installation and removal of hoses. Be ready to collect the oil before removing any hoses. Obey all local regulations for the disposal of liquids.

Tool Assembly

Connect the hydraulic power supply to the cylinders using the hose group. Make sure Hose A is connected to Cylinder Port A, and Hose B is connected to Cylinder Port B. Remove all trapped air from the high-pressure hoses and cylinders by fully extending and retracting the cylinders several times. Connect the two high-pressure hydraulic hoses the cylinders. Power Supply ports are labeled with an "A" and "B". Make sure that the correct hose is connected to the corresponding port.

Note: Make sure that all connections are clean and tight. Connect hose assembly to the hydraulic power supply (energy source).

Operation

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To avoid personal injury or death, carefully read and understand all instructions in this and all other applicable manuals before attempting to operate this tool. This tooling should never be used for any other application other than the intended use of removing and installing track pins. Using this tooling for any other purpose can result in serious injury or even death. There is potential for a crush/pinch hazard to the technician’s hands during the tool assembly. Watch hand placement when assembling the different group assemblies.

The procedure in this manual repairs the damaged track joint on the ground not on the machine.

Note: The sound level of this tool without hydraulic supply does not exceed 70 dB(A). However, the actual sound levels, when in use, can be much higher depending on the hydraulic power supply and track-generated noise during pressing.

Removal of Track Pin

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See Reference Documents section for additional process documentation regarding reuse and salvage of components. Extreme care should be taken to prevent the bushing from contacting the seal lips as the joint is brought into alignment. Sharp corners on the edge of the bushing can cut the seal lips resulting in a leak and a dry joint.

1. Use a CE Compliant Load Positioner Group to suspend the track repair group. Load Positioners make it easier to handle the track repair group.
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2. Use wooden blocks to provide clearance for the Track Repair Group. Place the blocking perpendicular to and below the bottom of the track link assembly. Blocking height should be so that the center line of the pin is at or slightly below the center of the hydraulic cylinder rod. Center line of the Track Repair Group is 181.0 mm (7.13") above the bottom of the Track Repair Group. See Illustration 23.
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3. Remove the Acme threaded nuts (7) and Back Plate (1) from the track repair group. See Illustration 24.

4. Install correct forcing pin (A) by threading it completely onto the threaded adapter (11). Failure to thread the forcing pin completely onto the adapter may cause deformation of the threads and make it difficult to remove. The forcing pin must be slightly smaller in diameter than the track pin to pass through the pin boss of the link to fully disassemble the track pin.

5. Use a Load Positioner to locate the Track Repair Group so that the tie rods are above and below the link assembly that is to be serviced.
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6. Connect the hydraulic lines to the Track Repair Group. The hose from valve port "A" (Extend) must be attached to the piston end of the hydraulic cylinder. The hose from valve port "B" (Retract) must be attached to the quick coupler that is on the rod end of the cylinder. Connect the hydraulic lines to the Track Repair Group. The hose from valve port "A" (Extend) must be attached to the piston end of the hydraulic cylinder. The hose from valve port "B" (Retract) must be attached to the quick coupler that is on the rod end of the cylinder. Connect the hydraulic lines to the Track Repair Group. See Illustration 25 and 26.

7. Set proper pressures on the hydraulic power supply. Only use minimum pressure required to perform the disassembly process. Excessive pressure could lead to damage to contact tooling or the link assembly.
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8. Install the correctly sized Pin Receiver (C) into the Back Plate (1). Magnets are permanently installed into the Back Plate to help retain the Pin Receiver. Inside diameter of the Pin Receiver (C) must be larger than the track pin being removed. See Illustration 27.

9. Install Back Plate (1) onto the ends of the all the Tie Rods (2) and secure with ACME Nuts (7) that are hand tightened only. See Illustration 27.
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10. Carefully align Tooling (A) and Tooling (C) on the track link assembly. Carefully align the center line of the track pin with the tooling. See Illustration 28.
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11. Install the Top Guard Assembly (8), Nut Guard (4), and Pin Basket (5) onto the Back Plate (1). Extend the ram and assembled tooling slowly until the track pin is trapped between the Forcing Pin and the Removal Adapter. Slowly extend the cylinder rod to push the track pin completely through the opposite side link and into the pin basket. Once track pin has been removed, remove the pin basket. Basket cannot be removed unless pin has been pressed through the pin boss of the opposite side link. See Illustration 29.
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12. As the cylinder is retracted, insert Alignment / Pilot Pins (B) through the pin bosses of both the Right-Hand and Left-Hand links. See Illustration 30.

13. Repeat the process to remove additional track pins as needed to perform service.

Track Pin Installation

1. Use the 6V-3160 Double Acting Cylinder between the raised links to spread the links apart. Rotate the mating links to the full extent of the upward arc. Carefully align the bushing with the seals and lower the hoist to position the link airs together, at the same time. Allow the joint to fold together.

2. After the two link pairs are in alignment, install a guide pin. Release the hydraulic pressure and remove the 6V-3160 Double Acting Cylinder.

3. Lubricate the new stopper with lightweight oil and install the stopper in the pin end.

4. Use a CE Compliant Load Positioner Group to suspend the track repair group. A Load Positioner will make it easier to handle the track repair group.
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5. Use wooden blocks to provide clearance for the Track Repair Group. Place the blocking perpendicular to and below the bottom of the track link assembly. Blocking height should be so that the center line of the pin is at or slightly below the center of the hydraulic cylinder rod. Center line of the Track Repair Group is 181.0 mm [7.13"] above the bottom of the Track Repair Group.
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6. Remove the Acme threaded nuts (7) and Back Plate (1) from the track repair group. See Illustration 32.

7. Install the new track pin with the cross hole towards the wear surface of the links, and position the pin with the oil hole facing the same side of the track as the other pins.
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   Illustration 33	g03741705

8. Align Track Pin, the tooling with the links as close as possible. Press the pin into the link pin bores.
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9. Do not remove the guide pin from the link bore until the guide pin is pushed out completely. Once the pin is installed completely, increase the hydraulic pressure to the proper assembly force. This pressure ensures that the joint is properly assembled to "ZERO" end play.

10. Pin projection is set by the counter bore in the Piston Rod Cap. Remove all foreign material such as burrs and cold-flowed material from the counter bore and the pin boss of the links.

11. Move the tooling to the second joint and install the track pin, following the same procedure.

12. Remove the track repair group.

Maintenance and Repair

Inspect all component of this tool before each use. Check for damage or wear on any part. Replace all damaged or worn parts immediately. Do not reuse bent or deformed threaded components. Failure of these parts may produce flying objects, which could result in serious injury or even death.

Refer to the "Inspection Guide" in the Inspection Section for additional inspection information.

Service Parts

When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material. Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.

Note: Current tools are found in the Dealer Service Tool Catalog NENG2500.

Troubleshooting Chart

Table 4

Troubleshooting Chart
Problem	Possible Cause	Possible Solution
Hydraulic force not applied by cylinders	Hydraulic power source malfunctioning	Check oil level. If oil level is correct, fix or repair hydraulic power source.
	Hydraulic leak	Repair leak
	Quick disconnect fitting if not seated	Completely connect or seat the fitting
Parts of tool will not assemble	Damaged threads	Replace threaded items
	Check part numbers	Use correct part numbers
Tool is operated at full operating pressure but link does not disassemble	Misaligned tooling	Align tooling
	Check condition of link	Replace link
	Damaged threads	Replace link
	Worn contact tool	Replace threads
Hydraulic leakage	Leaky cylinders	Replace cylinder
	Leaky hoses	Replace hose
	Leaky fittings	Tighten or replace
Viewing window is not clear	Age or chemical damage	Replace viewing window

References

Refer to the Operation and Maintenance Manual for equipment. Additional information may be found in the following literature below.

1. ANSI Z535.1-2002 - American National Standard For Safety Color Code

2. ANSI Z535.6-2011- American National Standard - Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials

3. NENG2500 - Dealer Service Tools Catalog

4. PECP3003 - Undercarriage Parts Sales Kit

5. PEPK9400 - Custom Track Service

6. REHS2586 - Field Service for Positive Pin Retention 2 (PPR 2)

7. SEBF8566 - Track Data Charts

8. SEBF8599 - Undercarriage Reconditioning Guide

9. SEBF8612 - Field Service for Positive Pin Retention Track

10. SEBF8613 - Field Service for Sleeve Bearing Track

11. SEHS8881 - Repair Procedure For Quad Track

12. SEHS8957 - Field Servicing Procedure for Non-Positive Pin Retention Sealed and Lubricated Track

Declaration of Conformity

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