Shop Repair Procedure for Non-PPR Sealed and Lubricated Track {4170} Caterpillar

Caterpillar Products

Machines with non-PPR Sealed and Lubricated Track

Introduction

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Undercarriage Reconditioning Bulletin contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Undercarriage Reconditioning Bulletin must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) Interface.

Summary

The information in this guideline covers the servicing procedures in the shop for the sealed and lubricated track. Machines with the elevated sprocket and the oval track are covered. A procedure for Disassembly and Assembly of the track link assembly is included with specifications, service tips, and the required tooling. A list of important reference and training materials is listed in this guideline. The operator of the track press should become familiar with this material prior to servicing the track.

Each track pin has an oil reservoir in the center of the track pin. A rubber stopper and a plastic plug are used to close the oil cavity. The track pin contains a crosshole to allow the oil to flow to the outside of the track pin. The oil lubricates the track pin, the bushing, and the seal face. If the seal face is wet with oil, the seal prevents dirt from entering the track joint. The seal and the end of the bushing will wear if there is no oil film. The seal will no longer retain oil in the track joint. A good press fit between the track pin and the pin bore of the track link also prevents loss of lubrication.

Illustration 1	g03749978

References

Reference: Undercarriage Reconditioning Guide, SEBF8599

Reference: Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts"

Reference: Undercarriage Reconditioning Bulletin, SEBF8553, "Reusability Guidelines and Installation Procedures for Split Master Links"

Reference: Undercarriage Reconditioning Bulletin, SEBF8562, "Procedure and Guidelines for Cleaning Phosphate Coated Track Pins"

Reference: Undercarriage Reconditioning Bulletin, SEBF8554, "Track Press Assembly Specifications Decals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8594, "Nitrogen Pressure Test Unit FT2724"

Reference: Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts"

Reference: Undercarriage Reconditioning Bulletin, SEBF8577, "Oil Volumes for Track Link Assemblies"

Reference: Shop Repair Procedures for Non-PPR Track, PEVN4322

Reference: Tool Operating Manual, NEHS0804, "Caterpillar Track Press Contact Tooling"

Reference: Tool Operating Manual, NEHS0826, "Caterpillar 300T Track Press Manual"

Reference: Tool Operating Manual, NEHS0803, "Caterpillar 375T Track Press Manual"

Reference: Tool Operating Manual, NEHS0895, "Caterpillar 375T Track Press Operation Manual"

Reference: Tool Operating Manual, NEHS0830, "Caterpillar Track Torque Wrench"

Reference: Tool Operating Manual, NEHS0785, "Test and Fill Manual"

Reference: Service Handbook, PEKP9400, "Caterpillar Track Service Handbook"

Reference: Parts Sales Kit, PECP3003, "Undercarriage Parts Sales Kit"

Reference: Catalog, NENG2500, "Dealer Service Tools Catalog"

Safety

Illustration 2	g02139237

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

This bulletin may contain hazardous steps. A safety alert symbol like the ones below is used to identify a hazard.

Warning messages identify a specific, imminent, latent, hazard that has a reasonable probability of resulting in personal injury or death if the warning is ignored.

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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

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Inspect all threaded components before use. Damaged threads may fail under hydraulic pressure. Broken threads may release flying objects that are propelled with great force. Personal injury or death can occur if struck by flying objects.

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Do not stand near the hydraulic press while the press is in operation. A component that slips or breaks under pressure may fly into the air with great force. Personal injury or death can occur if struck by flying objects.

Canceled Part Numbers and Replaced Part Numbers

This document does not include all canceled part number and replaced part number information. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Required Tooling

Preparation for Disassembly

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Illustration 3	g03745699

1. Use a high-pressure washer to remove mud and debris from the track assembly before the track is brought into the shop.

   Note: Cleaning the track helps reduce the possibility of scoring of the pin bore. If the pin bore is scored across the entire length of the pin bore, the track link cannot be reused.

2. Inspect each opening to the oil reservoir of the track pins for metal smearing and peening of the track pin.
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   Illustration 4	g03750937

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   Illustration 5	g01212271

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   NOTICE
   When using Tooling (B) deburring tool, do not plunge tooling directly into the center of the oil reservoir of the track pin. The tool can shatter, seize up, and break. Use a high-speed grinder and orbit the deburring bit around the side of the oil reservoir of the track pin.

3. Remove any burrs from the track pin with Tooling (A) die grinder and Tooling (B) deburring tool . Make a new chamfer at the opening of the oil reservoir.
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   Illustration 6	g03745709

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   Illustration 7	g03745715

4. Remove the stoppers from the track pins with a slow drill and a 12.5 mm (0.50 in.) drill bit. The stopper can also be removed by pushing the plug into the oil cavity and removing the stopper with a small punch.Do not push the stopper into the oil reservoir of the track pin.
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   Illustration 8	g03745018

5. Use Tooling (C) vacuum tank to remove the oil from the oil reservoirs of the track pins. It may be necessary to wash the oil from the track pins after the oil has been removed.

6. Measure the track shoes, track links, and bushings and record the measurements.

   Note: Refer to Service Handbook, PEKP9400, "Caterpillar Custom Track Service Handbook" for the correct measurements needed to calculate the percentage of wear.

Disassembly of the Track

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Illustration 9	g03745717

1. Use the Caterpillar Track Torque Wrench to remove the bolts from the track shoes. Remove the track shoes.
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   Illustration 10	g03745722

2. Use a permanent pen to mark the track pins and bushings for proper installation.
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   Illustration 11	g03745727

3. Examine the track press and the components of the track press before disassembling the track.

   Note: If the contact surfaces of the tooling are not flat or if the surfaces are peened, grind the contact surfaces so the surfaces are flat. Replace any tooling that is beyond repair.

4. Reference Illustration 45 and Table 5 for track link offset dimensions.
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   Illustration 12	g03780110

5. Measure the height of the track pin disassembly tooling use tooling (D) calipers.
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   Illustration 13	g03780119

6. Measure the height of the bushing disassembly tooling use tooling (D) calipers.

7. Determine track link offset by using this calculation (height of bushing tooling - height of pin tooling = track link offset.)

   Note: If the dimensions for the track link offset of the tooling are incorrect, spacers / shims can be used to the correct tooling dimensions.

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   Illustration 14	g03751401
   Certain Track-Type Tractors Series L, Series N, Series R, and Series T may have snap rings on the master track links.

8. Remove the snap rings from the master track links with Tooling (D) pliers and Tooling (E) snap ring pliers.
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   Illustration 15	g03751456

9. Align the tooling with the track pin and the bushing.

10. Follow Steps 10a through 10e before the track pin or the bushing is pressed out of the track link.

    1. Make sure that the bushings are fully seated in the saddle of the track press.
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       Illustration 16	g03748436

    2. Lower the hold down shoe, allow a small amount of clearance between the hold down shoe and bushing.

       During disassembly, the bushing will slide to the left and right in the saddle.

       Reference Illustration 16.

       Due to the wear step, the bushing will need to float within the saddle and hold down shoe.

       A small amount of clearance between the hold down shoe and bushing must be maintained during disassembly.

       The amount of clearance depends on the amount of wear on the bushing.

    3. Ensure that the correct tooling is being used.

    4. Make sure that the face and the chamfer of the pin / bushing tooling are clean and smooth.

    5. Confirm that the tooling is centered on the end of the track pin and the bushing.

       Note: Gouging on the bores of the track link will occur if the tooling is not centered.

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    Illustration 17	g03745743

11. Press the track pins and bushings out of the track links.

12. Remove the thrust rings as each track pin is pressed out of the bore of the track link.

13. Examine the thrust ring for reusability. Gently strike the thrust ring against a metal object to check for cracks. Refer to Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts".

    Note: A thrust ring will make a clear ringing sound if not cracked. Thrust rings that are cracked will not have the clear ringing sound, but will make a dull thumping sound.

14. Examine the track links for cracks, scoring in the pin bore, and damaged seals. Refer to Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts".

Preparation for Assembly

Caterpillar recommends cleaning the track pins, bushings, and thrust rings. Cleaning the track components removes any foreign material and contaminated oil. Inspection of the track components is easier when the components are clean. A cross section of the track joint is shown in Illustration 1 to help the serviceman identify the track components.

Note: Whenever any track joint is disassembled, always replace the seal with a new seal.

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Illustration 18	g03751637

1. Inspect each track pin for cracks, plugged crossholes, or other signs of damage such as spalling or galling.

   Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts".

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   Illustration 19	g03751680

2. Restore the chamfer on the track pins by use of a grinder to grind a 4.8 mm (0.20 in.) chamfer at 10° on the ends of the track pins.
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   Illustration 20	g03745754

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   Illustration 21	g03745044

3. Lubricate the stopper with a lightweight oil and install the stopper in the end of the track pin with Tooling (G) installation tool.

   Note: The stopper must be installed 7.0 - 15.0 mm (0.28 ± 0.59 in.) below the surface of the track pin.

   Note: Absorption of the oil by the stopper causes the rubber to swell. Swelling of the stopper locks the stopper in place. Installing all stoppers before inspecting the remaining track components will allow time for the stoppers to swell. The plastic plugs will be installed later.

4. Remove any burrs, material, and any paint from the spot face of track link that will interfere with the tooling on the track press.
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   Illustration 22	g03745758

5. Thoroughly clean the counterbores of the track links for the seals with Tooling (A) die grinder and Tooling (F) end brush.

   Note: Tooling (F) end brush should be rated at the maximum rpm of Tooling (A) die grinder.

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   Illustration 23	g03745759

6. Wipe the counterbore of the track link with a lint free cloth.
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   Illustration 24	g03745782

7. Hold each bushing up to a bright light to examine the bushings for cracks.

8. Weld an identification number on the master track link.
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   Illustration 25	g03745840

9. Use Tooling (T) end groove gauge to check the end grooving of the bushing. Replace the seal with a Post Turn Seal if the bushing is reused. Replace the seal with a standard seal if a new bushing is used.

   Post Turn Seals are now available for all D10T/R/N and D10 track link assemblies.

   These new seals have a smaller diameter than the original seals. If a bushing has a maximum of 50 percent end grooving and the bushing is being reused, the Post Turn Seal should be used. The Post Turn Seal will contact a new, unworn surface of the bushing which will provide better reliability of the seal after service.

   Reference Information Release Memo, PELJ0443, "D10R/N and D10 Post Turn Seals" for more information.

   Use the 262-9822 Seal Installer with the D10T/R/N and D10 Post Turn Seal.

   Post Turn Seals are available as an option and these seals are adaptable to all former D10T/R/N and D10 track link assemblies.

   The standard seal is still available for use when the bushings are replaced. If the end grooving is visible inside Tooling (T), the bushing should be replaced. Ignore the shiny band of contact area.

   Reference Undercarriage Reconditioning Bulletin, SEBF8558, "Guideline for Reusable Track Parts"

   Refer to Table 4 or Parts Sales Kit, PECP3003 for the seal part numbers.

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   Table 4

   D10T/R/N D10
   	Original Seal	Post Turn Seal
   Seal Assembly	222-7001	252-6327
   Seal Set	239-5272	252-6329

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   Illustration 26	g03745843
   Original Seal (1) Seal (2) Link (3) Bushing (4) Thrust Ring (5) Pin

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   Illustration 27	g03745846
   Post Turn Seal (1) Seal (2) Link (3) Bushing (4) Thrust Ring (5) Pin

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   Illustration 28	g03757277

10. Place the seal into Tooling (P) seal installer.
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    Illustration 29	g03757317

11. Use Tooling (P) to install the seals. Make sure that the seal is seated properly in the counterbore of the track link. Use firm even pressure to properly seat the seal.

    Note: For ease of seal installation, the outer load ring may be lubricated with a lightweight oil.

    Note: Do not lubricate the track pin, the bore for the track pin, or the bore for the bushing.

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    Illustration 30	g03757372
    (1) Facing group (P) Seal installer

12. Install the optional facing group (1) on Tooling (P) seal installer with the adhesive side facing upward.

    Note: The facing group is optional to help achieve proper articulation of the track joint after installation on the tractor. Some models of machines have oil impregnated thrust rings available. If oil impregnated thrust rings are used, the facing group will not be necessary.

    Note: Thrust rings can be ordered with the applied ring. Refer to Parts Sales Kit, PECP3003 for the correct part numbers for the thrust rings.

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    Illustration 31	g03757385

13. Slide the thrust ring onto Tooling (P). Press firmly on the thrust ring until the ring adheres to the thrust ring.

14. Remove the thrust ring from Tooling (P).

15. Repeat Steps 12 through 14 for the reverse side of the thrust ring.

First and Second Assembly Side Concept

The Caterpillar assembly contact tooling requires that only one link is pressed onto the assembly at a time. For example, to service a track joint, the tooling on the left side is used to hold the track assembly while the right link is pressed completely onto the pin and bushing. The right side tooling then remains in the extended position while the left side link is pressed onto the pin.

Note: During the assembly process, it is important that the links never hit the saddle.

The pin assembly plunger on the first assembly side or nominal side is longer than the pin assembly plunger on the second assembly side or the non-nominal side. The nominal side longer plunger initially establishes the correct pin projection, and the non-nominal shorter plunger allows the joint to be pressed to zero end-play. The shorter second side pin assembly plunger never “bottoms-out” against the base, therefore the joint cannot be released from the zero end-play condition. The use of Molykote or thin plastic coatings establishes the slight end-play. According to Caterpillar track assembly specifications, pin projection is established and controlled on one side only. Due to the “stack-up” of tolerances throughout the track joint, it is necessary to assemble the joint one side at a time.

In contrast, bushing projection is controlled on both sides of the track joint. Thus, the two bushing assembly plungers are both the same length resulting in the same projection. The establishment of proper bushing projection is critical to ensure that adjacent links do not scrub against one another.

Setup of the Track Press

Illustration 32	g03757401

The operator of the track press must use great care in the adjustment and operation of the track press and selecting the correct tooling. The cleanliness and condition of the tooling must be checked frequently. Buildup of dirt and metal shavings in the counterbores of the tooling for the track pins will cause the track pins to bottom out before the track links have been pressed far enough to remove all the end play. Bushing projection will also be affected by any foreign material. Refer to Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts" or Table 5 for the dimensions for the track link assemblies.

1. Clean any foreign material off the tooling for the track press with a lint free cloth.

2. Remove the springs from the pin and bushing tooling and reinstall the plunger and the base.

3. Verify the correct track link offset of the tooling dimensions by measuring the pin and bushing tooling on both sides of the track press. Refer to Table 5 for the correct dimensions.
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   Illustration 33	g03780149

4. Use Tooling (D) calipers to measure the height of the tooling for the track pin.
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   Illustration 34	g03780141

5. Use Tooling (D) calipers to measure the height of the tooling for the bushing.

6. Determine track link offset by using this calculation (height of bushing tooling - height of pin tooling = track link offset.)

   Note: If the dimensions for the track link offset of the tooling are incorrect, shims / spacers can be added to the tooling.

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   Illustration 35	g03745892
   Use Tooling (R) dial indicator to measure the correct bushing projection.

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   Illustration 36	g02133241

7. Use Tooling (R) dial indicator to measure the correct bushing projection for the bushing tooling on both sides of the track press. Refer to Table 5 for the correct dimensions. Correct bushing projection must be maintained for both sides of the track press.

   Note: For incorrect bushing projection, shims can be added to the tooling. Tooling can also be machined to obtain the correct projection. Make sure that the correct track link offset is maintained. Refer to Step 3.

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   Illustration 37	g03745923

8. Consider inserting shims or machining the tooling if needed. Assemble the bushing tooling including the spring, plunger, and base.
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   Illustration 38	g03745931
   Use Tooling (R) dial indicator to measure the tooling for the track pin.

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   Illustration 39	g02133244

9. Use Tooling (R) dial indicator to measure the tooling for the track pin on both sides of the track press.

10. Verify the correct pin projection on the nominal side of track press. Refer to Table 5 for the correct dimensions.

11. Verify the non-nominal side pin assembly plunger never “bottoms-out” against the base during pin assembly.

    Note: For incorrect pin projection, shims can be added to the tooling or the tooling should be machined to obtain the correct pin projection. Make sure that the correct track link offset is maintained.

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    Illustration 40	g03745943

12. Consider inserting shims or machining the tooling if needed. Assemble the pin tooling including the spring, plunger, and base.

13. Perform the final check to verify that the tooling is set up properly. Refer to Step 13a through Step 16.
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    Illustration 41	g03745960

    1. Place a track pin and a bushing in the front and rear pockets of the saddle.

    2. Install the tooling on the left and right-hand side of track press.
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       Illustration 42	g03777137

    3. Lower the hold down shoe, ensure light contact with the bushings.

    4. Move the cylinders toward the track pins and bushings.

    5. Alignment of the tooling / pin and bushing is critical adjust as needed.

    6. Continue moving the cylinders toward the track pins and bushings until the bushing tooling firmly presses onto each of the bushing ends.
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    Illustration 43	g03747618

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    Illustration 44	g03747619

14. Adjust the setting on the relief valve to achieve the recommended assembly force. Reference Table 6 for correct assembly force.

    Other Reference's

    Undercarriage Reconditioning Bulletin, SEBF8566, "Track Data Charts"

    Decal, NEEG2430, "Track Assembly Specifications"

    Do not exceed the recommended assembly force. Higher assembly forces will result in damaged track components and damaged tooling.

15. Periodically check the calibration of the gauge on the track press. Refer to the Operation and Maintenance Manual for the track press for instructions on calibrating the gauge.

16. Make sure that the conveyor is perpendicular and level with the track press.

    Note: Improper alignment will cause the track to become twisted as more track links are assembled. The tooling may be damaged if the track links twist.

Illustration 45	g03427390
Nominal side of the track press (A) Inner diameter of the tooling for the track pin. (B) Pin projection. (C) Track link offset. (D) Bushing projection. (E) Inner diameter of the tooling for the bushing.

Note: Dimension C is measured once the shims / spacers are in place and tooling is attached to tool bar.

Assembly of the Track

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Illustration 46	g03747620

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NOTICE
During the assembly of the track links prevent the links from any contact with the saddle. Reference Illustration 46.

1. Determine if the bushing should be rotated to contact a different wear surface.
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   Illustration 47	g01212366
   Bushing with the marks in the original position

2. If the bushing does not need to be rotated, install the track pin and the bushing with the marks in the original position.
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   Illustration 48	g03747701
   Proper pin and bushing rotation.

3. If the pin and bushing needs to be rotated, horizontally rotate the track pin and the bushing by 180 degrees. Then, rotate the bushing around the track pin by 180 degrees.
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   NOTICE
   The track pin must always be installed so the cross drilled hole is towards the wear surface of the track links. The track pin must be installed in this position to ensure minimum load on the track pin in the area of the cross drilled hole. The track pin may break if installed with the cross drilled hole in any other position.

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   Illustration 49	g01212368

4. Make sure that the bushing is aligned correctly so the wear groove is located in the correct position.

   Note: Correct alignment of the track pin and bushing is necessary to allow the seal lip to run correctly in the wear groove.

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   Illustration 50	g03747707

5. Use a lint free cloth to clean the ends of the pin and bushing.

6. Bolt the split master links together toproperly alignthe bushing ends.
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   NOTICE
   Use only half of the assembly pressure when assembling the master track links.

   Note: Apply a thin coating of oil to the outer diameter of the bushing.

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   Illustration 51	g03747731
   The Illustration above displays the right-hand side being assembled first. The first assembly side whether (right hand or left hand) will be the Nominal side.

7. Lower the hold down shoe, ensure light contact with the bushings
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   NOTICE
   Alignment of the tooling / pin and bushing is critical and must be monitored during assembly.

8. Press the right-hand master track link onto the bushing.

   Assembling the right-hand side first makes the right-hand side the Nominal side.

9. Press the left-hand master track link onto the bushing.

   Assembling the left-hand side second makes the left-hand side the Non-Nominal side.

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   Illustration 52	g03747738
   Tooling (R) dial indicator.

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   Illustration 53	g01212377

10. Bushing projection must be maintained on both (Nominal and Non-Nominal) sides of the assembled master track link.

    Use Tooling (R) dial indicator to measure the bushing projection.

    Refer to Table 5 or Undercarriage Reconditioning Bulletin, SEBF8566, "Track Data Charts" for the correct dimensions.

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    Illustration 54	g03747741

11. Index the assembled track joint into the rear pocket of the saddle.

12. Install the thrust rings on the ends of the track pin.
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    NOTICE
    Use molybdenum grease or the facing group to lubricate the thrust rings. Do not use oil to lubricate the thrust rings. Oil will not provide the desired lubrication necessary to help prevent galling of the thrust ring.

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    Illustration 55	g03747750

13. Insert a track pin and a bushing in the front pocket of the saddle.

    Note: Apply a thin coating of oil to the outer diameter of the bushing.

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    Illustration 56	g03747753

14. Use a lint free cloth to wipe both ends of the bushing and faces of the seals.
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    NOTICE
    Caterpillar does not recommend use of a liquid gasket as a seal in the pin bores. Liquid gasket provides only a temporary seal, which will cause premature failure of the track joint.

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    Illustration 57	g03747777

15. Place the right-hand track link onto the tooling.

16. Lower the hold down shoe, ensure light contact with the bushing.
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    Illustration 58	g03747780

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    NOTICE
    Alignment of the tooling / pin and bushing is critical and must be monitored during assembly.

17. Move the right-hand track link with the track press until the track link contacts the track pin and the bushing.

18. Move the tooling on the left side of the track press until the tooling contacts the track pin and the bushing.

19. Use force from each ram to press the right-hand track link onto the track pin and the bushing.

    The assembly forces may vary based on part conditions and dimensions.

    Refer to Table 6 for the maximum allowed assembly forces.

    Note: Make sure that the track link does not contact the saddle.

    Do not exceed the recommended assembly force to assemble the track.

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    Table 6

    Specifications for Assembly Force
    Sales Model	Maximum Assembly Force
    D10T D10R D10N	840 kN (188840 lb)
    D10	870 kN (195585 lb)
    D9T D9R D9N	780 kN (175352 lb)
    D9L	740 kN (166360 lb)
    D9	745 kN (167483 lb)
    D8T D8R D8N D8L	660 kN (148375 lb)
    D7E D7R D7H HD 572R	710 kN (159615 lb)
    983	600 kN (134886 lb)
    D7H D7 977 973D 973C 973	530 kN (119150 lb)
    D6T D6R D6H HD 527 PL72 D6 HD	665 kN (149500 lb)
    D6H D6 963K 963C 963B 963	450 kN (101165 lb)
    D6K D6K2 D6N D6M D5R D5R2 D5H HD D5N D5M D4H HD 561N 561M 561H HD 517	590 kN (132638 lb)
    D5H D4H 561H D5K D5K2 D5G D5C 939C 939	400 kN (89924 lb)
    D5 955 953C 953B 953 951	365 kN (82055 lb)
    D4 943 941	330 kN (74187 lb)
    D4K D4K2 D3K D3K2 D4G D3G D4C D3C D4B D3B D3 935C 935B 933C 931C 931B 931	285 kN (64070 lb)

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    Illustration 59	g03747783

20. Repeat Steps 15 through 19 to assemble the left-hand track link.

    Note: Make sure that the track link does not contact the saddle.

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    Illustration 60	g03747817

21. Use Tooling (R) dial indicator to measure the bushing projection on both sides of the assembled track joint.

    Refer to Table 5 or Undercarriage Reconditioning Bulletin, SEBF8566, "Track Data Charts" for the correct dimensions.

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    Illustration 61	g03747844

22. Use Tooling (R) dial indicator to measure the pin projection on the nominal side of the assembled track joint.

    Refer to Table 5 or Undercarriage Reconditioning Bulletin, SEBF8566, "Track Data Charts" for the correct dimensions.

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    Illustration 62	g03745119

23. Check the end play of the track links.

24. Use a pry bar to apply force between the track links of one side of the assembled track joint. Refer to arrow (1) in Illustration 62

25. Maintain the applied force between the track links . Adjust the point of reference to 0.0 mm (0.00 in.) on Tooling (H) Dial Indicator Gp. Refer to arrow (2) in Illustration 62

26. A display of 0.0 mm (0.00 in.) on the Dial Indicator must be maintained prior to the removal of the applied force of the pry bar.

27. Use the pry bar to apply force between the track links of the opposite side of the assembled track joint. Refer to arrow (3) in Illustration 62

28. Maintain the applied force between the track links. The Dial Indicator will display total end play generation Refer to arrow (4) in Illustration 62

29. Acceptable end play is 0.03 mm to 0.20 mm (0.001 in. to 0.008 in.).

30. Repeat Steps 23 through 29 for the remaining track joints until the track is assembled.
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    Illustration 63	g03748003

31. All links assembly joints must have flexibility, even with measurable end play of 0.0 mm (0.00 in.). Flexibility is the ability for movement, from the weight of the joint.

Lubrication of the Track Joints

Illustration 64	g03757996
Tooling (K) 170-5664 Test and Fill Cart

Illustration 65	g03757997

1. Use Tooling (K) 170-5664 Test and Fill Cart to test the track joint and fill the track joint.

   Note: Caterpillar uses only synthetic oil for filling the track pins. This oil was previously used for arctic applications. This oil is now the standard oil from the factory. This oil is recommended for use at the turn of the bushing or during reseal. Refer to Table 7.

   Note: The synthetic oil is available in the following quantities:

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   Table 7

   Part Number	Part Description	Quantity
   242-3466	Gear Oil (75W-140)	19 L (5.0 US gal)
   242-3467	Gear Oil (75W-140)	208 L (55.0 US gal)

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   Illustration 66	g03757998

2. Use Tooling (L) plug installer to install the plastic plug in the rubber stopper.

   Note: Install the tapered end of the plug into the stopper first.

   Note: The plastic plug must protrude 0.0 mm to 5.0 mm (0.00 in. to 0.20 in.) out of the rubber stopper. The plug can vibrate into the oil reservoir of the track pin if the plug is pushed fully into the stopper hole.

3. Fill the remaining track joints with the same procedures.

   Note: If Tooling (K) 170-5664 Test and Fill Cart is not available, use the alternative method below to test and fill the track joint.

Alternative Method for Test and Fill

Refer to Undercarriage Reconditioning Bulletin, SEBF8594, "Nitrogen Pressure Test Unit".

Illustration 67	g03745151
Tooling (M) gauge connection.

1. Introduce nitrogen into the oil cavity to a pressure of 138 kPa (20.0 psi) with Tooling (M) gauge connection.

   Note: The cavity must be sealed and pressure must be observed for10 seconds.

   Note: A pressure drop of 3.5 kPa (0.50 psi) or less is acceptable.

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   NOTICE
   Do not allow a surge of air to enter the track joint and do not use pressure in excess of 138 kPa (20 psi).

2. Fill track joints with oil. Refer to Undercarriage Reconditioning Bulletin, SEBF8577, "Oil Volumes for Track Link Assemblies".

Preparation and Installation of the Track Shoes

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Illustration 68	g03748015

1. All paint, loose rust, metal debris, and dirt must be removed from the mating surfaces of the track components.

   The paint on the mating surfaces of new track link assemblies should be removed before installation of the track shoes. The correct clamping force cannot be achieved if all the paint is not removed. The following methods may be used to remove the paint:

   • Use a sandpaper of 24-grit to remove the paint from the mating surfaces of the track links and the track shoes. A light mist of water should be sprayed on the mating surface during sanding. The water will help keep the sandpaper clean during sanding.

   • A paint remover may be used to remove the paint from the mating surfaces of the track links and the track shoes. Make sure that the paint remover does not contact the track seal. The paint remover can damage the track seal.

   • Do not use a torch to remove the paint from the mating surfaces of the track links and the master track links. The high temperatures can damage the track seals.

   • Do not drag the track link assembly across the ground to remove the paint from the mating surfaces of the track links. Dragging of the track link assembly may damage the master track joint and other track components. High spots may be created on the track links. Dragging the track link assembly may cause the track joints to open.

   Note: The track bolt and threads of the track nuts must be in good condition.

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   Illustration 69	g03748019
   Caterpillar Track Torque Wrench

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   Illustration 70	g03748022
   443-7801 Pneumatic Wrench Gp

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   Illustration 71	g03748113

2. Place the track on the conveyor of the Caterpillar Track Torque Wrench to install the track shoes.

   Note: If the Caterpillar Track Torque Wrench is not available, 443-7801 Pneumatic Wrench Gp or 385-7874 Hydraulic Torque Wrench may be used to install the track shoes.

3. Lubricate the threads of the track bolts and lubricate the mating surface of the bolt head with Tooling (N) antiseize compound.

4. Align the holes in the track shoes with the holes in the track links.

   Note: The threads of the bolts will be damaged if the holes are not aligned.

5. Place a track bolt in each hole and start the nut by hand.
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   Illustration 72	g03748114

6. Turn the switch on the side of the Caterpillar Track Torque Wrench to the 120° position.
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   Illustration 73	g03748116

7. Press the "Set Pre Torque" button. Enter the correct preliminary torque value into the display panel. Press "Enter". Refer to Table 73 for the correct preliminary torque values.

8. Press the "Check Set Values" button to display and check the values that have been set.
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   Illustration 74	g02134179

9. Follow the correct pattern in Illustration 74 to torque the bolts.

   Note: A yellow light will illuminate when the preliminary torque is complete. A green light will illuminate when the torque turn is complete. The screen will display "Cycle Complete".

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   Table 8

   Torque Specifications for the Track Shoe Bolts
   				Method for Torque Turn
   Sales Model	Bolt Size and Threads per Inch	Part Number for the Socket	Part Number for the Worn Socket	Preliminary Torque	Additional Turn for the Master Track Bolt	Additional Turn for the Standard Track Bolt
   Full Links Standard Bolt - D10T D10R D10N D10	1 1/8" - 12	1U-8586	1U-8798	870 ± 90 N·m (642.0 ± 66.0 lb ft)	-	120°
   Five Tooth Master Bolts - D10T D10R D10N D10	1 1/8" - 12	1U-8586	1U-8798	870 ± 90 N·m (642.0 ± 66.0 lb ft)	120°	-
   Single Tooth Master Bolts - D10T D10R D10N	1 1/8" - 7	1U-8586	1U-8798	700.0 ± 70.0 N·m (516.29 ± 51.62 lb ft)	90° +- 5°	-
   D9T D9R D9N D9L	1" - 14	9S-6371	5P-3581	870 ± 90 N·m (642.0 ± 66.0 lb ft)	120°	120°
   D9	1" - 14	9S-6371	5P-3581	550 ± 70 N·m (405.0 ± 50.0 lb ft)	180°	120°
   D8T D8R D8N D8L	7/8" - 14	9S-6372	5P-3580	650 ± 70 N·m (480.0 ± 50.0 lb ft)	120°	120°
   D7E D7R D7H 572R 983 973D 973C 973	7/8" - 14	9S-6372	5P-3580	340 ± 70 N·m (250.0 ± 50.0 lb ft)	180°	120°
   D6K D6K2 D6T D6R D6R2 D6H HD D6N D6M D5R D5H HD 527 517 PL72 D6 HD	3/4" - 16	9S-6373	5P-3579	400 ± 70 N·m (295.0 ± 50.0 lb ft)	120°	120°
   D6H D7 D6 977 963K 963C 963B 963	3/4" - 16	9S-6373	5P-3579	300 ± 50 N·m (220.0 ± 35.0 lb ft)	180°	120°
   D5N D5M D4H HD 561N 561M 561H HD	5/8" - 18	9S-6370	6V-2002	170 ± 40 N·m (125.0 ± 30.0 lb ft)	120°	120°
   D5H D4H 561H D5 D4 D5K D5K2 D5G D5C 955 953C 953B 953 951 943 941 939C 939	5/8" - 18	9S-6370	6V-2002	170 ± 40 N·m (125.0 ± 30.0 lb ft)	180°	120°
   D4K D4K2 D3K D3K2 D4G D3G D4C D3C D4B D3B D3 935C 935B 933C 931C 931B 931	9/16" - 18	9S-6375	6V-4175	90 ± 20 N·m (66.0 ± 15.0 lb ft)	180°	120°