Shop Repair Procedure for Grease Lubricated Track {0729, 4169, 4170, 4175} Caterpillar

Caterpillar Products

Machines with Greased Lubricated Track (GLT)

Introduction

© 2018 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 questions when using this document, work with your Dealer Technical Communicator (TC).

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

Summary

Grease Lubricated Track was developed by Caterpillar to increase the wear life of the track for Hydraulic Excavators by lubricating the track pins and bushings. The information in this bulletin includes a procedure for disassembly and assembly of the track link assembly, specifications, and the required tooling. The correct tooling must be used. Each step should be carefully followed to ensure that each track joint has minimum end play and maximum service life.

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.

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Operating the track press incorrectly may result in a flying object hazard. Always operate the track press with protective guards installed and eye wear protection to prevent injury. Always read and understand the operator's manual for the track press before using.

Note: The shield on the track press has been removed in the illustrations for clarity. Always operate the track press with the shield.

References

Reference: Undercarriage Reconditioning Guide, SEBF8599

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

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

Reference: Tool Operating Manual, NEHS0650, "Caterpillar Track Press Manual"

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

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

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

Reference: Information Release Memo, PELJ0541

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

Reference: Parts Sales Kit, PECP3003

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

Safety

Illustration 1	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 one 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

The rigid track seal on the Sealed and Lubricated Track is also used on the following Grease Lubricated Track models.

• 345

• 349

• 365

• 374

• 385

• 390

• 568

• MD5150C

• MD6420

• MD6420B

• MD6420C

• MD6640

• MD6540

• MD6540C

• 5090

The seal design on the Grease Lubricated Track allows longer retention of the grease. Refer to Information Release Memo, PELJ0541. Refer to Illustration 2.

Illustration 2	g01208628
345, 349, 365, 374, 385, 390, 568, MD5150C, MD6420, MD6420B, MD6420C, MD6640, MD6540, MD6540C, and 5090

The other 300 Series Excavators still use the Poly W track seal.

Illustration 3	g01208642
Poly W track seal 307 through 336

Disassembly of the Track

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Illustration 4	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. Measure the track shoes, track links, and bushings and record the measurements.

   Note: Refer to Service Handbook, PEKP9400, "Caterpillar Track Service Handbook" for measurements of percent of wear.

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   Illustration 5	g03745717

3. Use the Caterpillar Track Torque Wrench to remove the bolts from the track shoes. Remove the track shoes.
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   Illustration 6	g03869705

4. Use a permanent pen to mark the track pins and bushings for proper reinstallation.
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   Illustration 7	g03869716

5. 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 the surfaces are peened, the tooling may need to be replaced.

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   Illustration 8	g02022171
   (A) Pin projection (B) Offset of the track link (C) Bushing projection

6. Reference Illustration 8 and Table 4 for Dimension (B) Track Link Offset.

7. For both disassembly and assembly tooling, calculate Dimension (B) Track Link Offset. This calculation will determine whether shims / spacers are needed. Then physically measure Dimension (B) once the shims / spacers are in place and tooling is attached to tool bar.
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   Illustration 9	g03870179

8. Measure the height of the track pin disassembly tooling use tooling (J) Calipers.
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   Illustration 10	g03870193

9. Measure the height of the bushing disassembly tooling use tooling (J) Calipers.

10. 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 (B) of the tooling are incorrect, spacers / shims can be used to the correct tooling dimensions.

11. Follow Steps 11.a through 11.f before the track pin or the bushing is pressed out of the track link.

    1. Ensure that the bushings are fully seated in the saddle of the track press.

    2. Confirm that the correct tooling is being used.
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       Illustration 11	g03870201
       Wear step on the bushing surface.

    3. 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 11.

       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.

    4. Ensure that the correct tooling is being used.

    5. Make sure that the face and the chamfer of the pin / bushing tooling are clean and smooth.
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       Illustration 12	g03870053

    6. Verify 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 13	g03745743

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

13. Remove the thrust rings from the track joints on the 345, 349, 365, 374, 385, 390, 568, MD5150C, MD6420, MD6420B, MD6420C, MD6640, MD6540, MD6540C, and 5090 as the track pin is pressed out of the bore of the track link.

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

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

15. 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".
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    Illustration 14	g03870807

16. Place the parts on a table during disassembly.

Preparation for Assembly

Caterpillar recommends cleaning the track pins and bushings. Cleaning the track components removes any foreign material and contaminated grease. Inspection of the track components is easier when the components are clean.

Note: Whenever ANY track joint is disassembled, ALWAYS replace the seal with a new seal.

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Illustration 15	g03870811

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

2. Inspect the master track pin of 345, 349, 365, 374, 385, 390, 568, MD5150C, MD6420, MD6420B, MD6420C, MD6640, MD6540, MD6540C, and 5090 for cracks, plugged crossholes, spalling, or galling.

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

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   NOTICE
   Do not grind the end of the pin. Any change in the pin end will adversely affect assembly and result in damage to the tooling and the track. Small burrs may be removed with light grinding.

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   Illustration 16	g03745782

3. Inspect each bushing for external cracks. Inspect each bushing for internal cracks by holding the bushing up to a bright light.
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   Illustration 17	g03870816

4. Remove all seals and thoroughly clean the counterbores of the track link. Clean the counterbores with Tooling (A) and Tooling (B).

   Note: Tooling (B) should be rated at the maximum rpm of Tooling (A).

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   Illustration 18	g03745759
   Tooling C 288-4209 Paper Towel

5. Wipe the counterbore of the track link with Tooling (C).

   Note: Tooling (C) is a lint free cloth.

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   Illustration 19	g03870865
   307 through 336

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   Illustration 20	g03871096
   345, 349, 365, 374, 385, 390, 568, MD5150C, MD6420, MD6420B, MD6420C, MD6640, MD6540, MD6540Cand 5090

6. Install new seals into the track link counterbore. Use firm, even pressure to seat fully the seal in the link counterbore. Use the proper seal installer on the 345, 349, 365, 374, 385, 390, 568, MD5150C, MD6420, MD6420B, MD6420C, MD6640, MD6540, MD6540C, and 5090 track seals.

   Note: Never reuse track seals. For ease of seal installation, the outer load ring should be lubricated with a lightweight oil.

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   Table 3

   Rigid Track Seal Installers
   Sales Model	Part Number
   345 349 568 MD5150C MD6420 MD6420B MD6420C	4C-8619
   365 374 MD6540 MD6540C	4C-8622
   385 390 5090 MD6640	4C-8622

Setup of the Track Press

The operator of the track press must use great care in the adjustment and operation of the track press and selecting the tools. 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-on 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 4 for the dimensions for the track link assemblies.

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Illustration 21	g03871116

1. Clean any foreign material off the tooling for the track press with Tooling (C).

2. Remove the springs from the tooling reinstall the plungers.
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   Illustration 22	g02022171
   (A) Pin projection (B) Offset of the track link (C) Bushing projection

3. Measure the tooling on both sides of the track press to verify the correct pin projection (A), track link offset (B), and bushing projection (C). Refer to Illustration 22 and Table 4 for the correct dimensions.
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   Table 4

   Dimensions for the Tooling on the Track Press
   Sales Model	Link Assembly	Dimension (A)	Dimension (B)	Dimension (C)
   307B 307C	168-6753	3.00 ± 0.70 mm (0.118 ± 0.030 in.)	25.2 mm (1.00 in.)	3.10 ± 0.25 mm (0.122 ± 0.010 in.)
   307D 307E2	323-0958	3.00 ± 0.70 mm (0.118 ± 0.030 in.)	25.2 mm (1.00 in.)	3.10 ± 0.25 mm (0.122 ± 0.010 in.)
   308C	194-1172	3.00 ± 0.70 mm (0.118 ± 0.030 in.)	25.2 mm (1.00 in.)	3.10 ± 0.25 mm (0.122 ± 0.010 in.)
   308D 308E 308E2	323-0956	3.00 ± 0.70 mm (0.118 ± 0.030 in.)	25.2 mm (1.00 in.)	3.10 ± 0.25 mm (0.122 ± 0.010 in.)
   311 311B 311C 311D	176-4874	3.03 ± 0.70 mm (0.120 ± 0.030 in.)	32.3 mm (1.28 in.)	3.33 ± 0.25 mm (0.131 ± 0.010 in.)
   311D 311F 312 312B 312C 312D 312D2 312E 312F 313B 313C 313D 313D2 313F 314C 314D 314E314F	176-4870	3.03 ± 0.70 mm (0.120 ± 0.030 in.)	32.3 mm (1.28 in.)	3.33 ± 0.25 mm (0.131 ± 0.010 in.)
   	445-0555
   313D2	445-0555	3.03 ± 0.70 mm (0.120 ± 0.030 in.)	32.3 mm (1.28 in.)	3.33 ± 0.25 mm (0.131 ± 0.010 in.)
   	445-0691	3.03 ± 0.70 mm (0.120 ± 0.030 in.)	32.3 mm (1.28 in.)	3.33 ± 0.25 mm (0.131 ± 0.010 in.)
   	176-4871	3.03 ± 0.70 mm (0.120 ± 0.030 in.)	32.3 mm (1.28 in.)	3.33 ± 0.25 mm (0.131 ± 0.010 in.)
   312B 312C 312D 314C 314D 314E	176-4871	3.03 ± 0.70 mm (0.120 ± 0.030 in.)	32.3 mm (1.28 in.)	3.33 ± 0.25 mm (0.131 ± 0.010 in.)
   312D2 312F 313F315F	176-4871 445-0691	3.03 ± 0.70 mm (0.120 ± 0.030 in.)	32.3 mm (1.28 in.)	3.33 ± 0.25 mm (0.131 ± 0.010 in.)
   312B 312C 312D	180-2689	2.39 ± 0.70 mm (0.094 ± 0.030 in.)	35.25 mm (1.388 in.)	2.94 ± 0.25 mm (0.116 ± 0.010 in.)
   	184-5859	2.39 ± 0.70 mm (0.094 ± 0.030 in.)	35.25 mm (1.388 in.)	2.94 ± 0.25 mm (0.116 ± 0.010 in.)
   315 315B 315C MD5-150C MD5075 MD5075C	194-1133	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   312D2 315 315B 315C 315D 316 316F 317 318D 318D2	194-1134	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   316F 317B 318E 318F 320 320B 320C 320D 320D2 321C 321D 323D2	194-1609	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   320D2	422-5505	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   313D2 316F 319C 319D 320 320B 320C 320D 320E 321C 321D 323D 323D2	194-1608	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   320D2 538B	194-1608	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   	206-1469	4.9 ± 0.8 mm (0.19291 ± 0.03150 in.)	42.5 mm (1.67323 in.)	1.80 ± 0.13 mm (0.07087 ± 0.00512 in.)
   	384-5478	2.0 ± 0.50 mm (0.07874 ± 0.01968 in.)	40.5 mm (1.59449 in.)	1.81 ± 0.25 mm (0.07126 ± 0.00984 in.)
   320F 325F	194-1608	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   	341-6797	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   	360-6818	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   318B 318C 322 322B 322C 324D 326D	337-9045	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   322 322B 322C 324D 326D	337-9044	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   323D2	210-1997 236-0816 341-6797 360-6818	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	36.5 mm (1.44 in.)	3.30 ± 0.25 mm (0.130 ± 0.010 in.)
   320 325	213-1933	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	42.0 mm (1.65 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   324D 325	213-1932	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	42.0 mm (1.65 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   320B 320C 323D 325B 325C 325D 329D	201-9116	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	42.0 mm (1.65 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   322C 325B 325C	201-9117	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	42.0 mm (1.65 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   325D 329D	236-8893	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	42.0 mm (1.65 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   330 336D2 336F 340D2	213-1972	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	43.5 mm (1.71 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   	213-1971	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	43.5 mm (1.71 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   330B 330C 330D 336D 336D2 336E 340D 340D2	201-9118	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	43.5 mm (1.71 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   	201-9119	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	43.5 mm (1.71 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   MD6290	201-9119	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	43.5 mm (1.71 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   	437-1969	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	43.5 mm (1.71 in.)	4.70 ± 0.25 mm (0.185 ± 0.010 in.)
   MD6240	430-3336	2.00 ± 0.70 mm (0.079 ± 0.030 in.)	43.5 mm (1.71 in.)	1.08 ± 0.25 mm (0.043 ± 0.010 in.)
   MD6420 MD6420B MD6420C	330-5417	2.20 ± 0.70 mm (0.087 ± 0.030 in.)	43.0 mm (1.69 in.)	1.08 ± 0.25 mm (0.043 ± 0.010 in.)
   330D	252-0617	2.20 ± 0.70 mm (0.087 ± 0.030 in.)	43.0 mm (1.69 in.)	1.08 ± 0.25 mm (0.043 ± 0.010 in.)
   	252-0618
   	301-2287
   	301-2307
   345B 345C 345D 349D 349E 349F 352F 568	301-2307	2.20 ± 0.70 mm (0.087 ± 0.030 in.)	43.0 mm (1.69 in.)	1.08 ± 0.25 mm (0.043 ± 0.010 in.)
   	301-2287	2.20 ± 0.70 mm (0.087 ± 0.030 in.)	43.0 mm (1.69 in.)	1.08 ± 0.25 mm (0.043 ± 0.010 in.)
   	301-2303(1)	2.20 ± 0.70 mm (0.087 ± 0.030 in.)	43.0 mm (1.69 in.)	1.08 ± 0.25 mm (0.043 ± 0.010 in.)
   	301-2297(1)	2.20 ± 0.70 mm (0.087 ± 0.030 in.)	43.0 mm (1.69 in.)	1.08 ± 0.25 mm (0.043 ± 0.010 in.)
   	395-3570	2.20 ± 0.70 mm (0.087 ± 0.030 in.)	43.0 mm (1.69 in.)	1.08 ± 0.25 mm (0.043 ± 0.010 in.)
   365B 365C 374D 374F	246-0504	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	51.0 mm (2.01 in.)	3.20 ± 0.25 mm (0.126 ± 0.010 in.)
   	294-3060(1)	2.70 ± 0.50 mm (0.106 ± 0.020 in.)	47.0 mm (1.85 in.)	3.20 ± 0.25 mm (0.126 ± 0.010 in.)
   MD6540 MD6540C	436-6202 514-4891	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	51.0 mm (2.01 in.)	3.20 ± 0.25 mm (0.126 ± 0.010 in.)
   MD6640	441-3692	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	63.0 mm (2.50 in.)	3.20 ± 0.25 mm (0.126 ± 0.010 in.)
   385B 385C 390D 390F 5090	246-0505	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	63.0 mm (2.50 in.)	3.20 ± 0.25 mm (0.126 ± 0.010 in.)
   	246-0506	2.70 ± 0.70 mm (0.106 ± 0.030 in.)	63.0 mm (2.50 in.)	3.20 ± 0.25 mm (0.126 ± 0.010 in.)
   	297-0130(1)	2.70 ± 0.50 mm (0.106 ± 0.020 in.)	51.0 mm (2.01 in.)	3.20 ± 0.25 mm (0.126 ± 0.010 in.)
   	297-0129(1)	2.70 ± 0.50 mm (0.106 ± 0.020 in.)	51.0 mm (2.01 in.)	3.20 ± 0.25 mm (0.126 ± 0.010 in.)
   6015B	430-4200	1.95 ± 0.13 N·m (1.438 ± 0.096 lb ft)	59 mm (2.32 inch)	1.66 ± 0.13 N·m (1.224 ± 0.096 lb ft)

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   (1)	Refer to Undercarriage Reconditioning Bulletin, REHS2586, "Field Service for Positive Pin Retention 2 (PPR2)" for the correct procedures to swage and unlock each track joint.

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   Illustration 23	g03871374

4. Measure the height of the tooling for the track pin.
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   Illustration 24	g03871376

5. Measure the height of the tooling for the bushing.

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

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

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   Illustration 25	g03871411

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   Illustration 26	g02077954

7. Use Tooling (D) to measure the tooling for the bushing on both sides of the track press to verify correct bushing projection (C).

   Note: If the dimensions for the bushing projection (C) of the tooling are incorrect, spacers / shims can be used to the correct tooling dimensions.

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   Illustration 27	g03871989

8. Assemble the tooling for the bushing.
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   Illustration 28	g03871991

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   Illustration 29	g02078053

9. Use Tooling (D) to measure the tooling for the track pin on both sides of the track press to verify the correct pin projection (A).

   Note: If the dimensions for the pin projection (A) of the tooling are incorrect, spacers / shims can be used to the correct tooling dimensions.

10. Perform the final quick check to verify that the tooling is set up properly. Refer to Step 10.a through Step 10.d.
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    Illustration 30	g03745960

    1. Place a track pin and a bushing in the two pockets of the saddle.
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       Illustration 31	g03745974

    2. Install the tooling on the track press.
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       Illustration 32	g03787993

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

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

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       Illustration 33	g03777137

    4. Move the cylinders toward the track pins and bushings until the tooling firmly presses the bushing.
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    Illustration 34	g03777159

11. Locate relief valves (1) and (2) on the operators station. Relief valves (1) will adjust the left ram and (2) will adjust the right ram assembly force.

    Adjust the setting on the relief valve to achieve the recommended force for assembly.

    Refer to Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts" or Table 6.

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

12. 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.

13. 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.

Assembly of the Track

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Illustration 35	g01185286

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Illustration 36	g03872054

1. Determine if the bushing should be rotated to contact a different wear surface.

   Note: If not rotating the bushing , install the track pin and the bushing with the marks in the original position. If the 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.

   Note: The master track pin on the 345, 349, 5150C, MD6420, MD6420B, MD6420C, MD6540, MD6540C, and MD6640 must be installed so the crosshole is parallel to the rail of the track link and the track shoe. Refer to Illustration 37.

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   Illustration 37	g02026401

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   Illustration 38	g03790377

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   Illustration 39	g03790396

2. Apply an even coat of grease to the track pin and bushing before assembly.

   Note: Do not allow contaminants to come into contact with the grease.

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   Table 5

   Specifications for the Grease
   Part Number	Grease	Quantity
   161-9203	Ultra 5 Moly Grease NLGI No. 1	Cartridge
   452-5999	Ultra 5 Moly Grease NLGI No. 1	16 kg (35.0 lb)
   161-0970	Ultra 5 Moly Grease NLGI No. 1	54 kg (120.0 lb)
   161-0971	Ultra 5 Moly Grease NLGI No. 1	181 kg (400.0 lb)

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   Illustration 40	g03790501

3. Place a track pin and a bushing in the saddle.
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   Illustration 41	g03790520

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   Illustration 42	g03872174

4. Wipe the ends of the track pin and bushing with Tooling (C) and solvent.

   Note: The hold down shoe must always be used for assembly of the track links. The hold down shoe was used during the development of this document. For better photo opportunity the hold down shoe may be retracted in the following illustrations.

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   Illustration 43	g03791017
   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.

5. Place the right-hand track link on the right-hand side assembly tooling.

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

6. Press the right-hand track link onto the bushing.

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

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   Illustration 44	g03791093

7. Place the left-hand link on the left-hand side assembly tooling.

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

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   Illustration 45	g03791877

8. Press the left-hand 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 46	g03872201

9. Make sure that the track links do not contact the saddle.
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   Illustration 47	g03872216

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   Illustration 48	g02026409

10. Use Tooling (D) to measure the bushing projection on the assembled track joint.

    Refer to Table 4 or Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts" for the correct dimensions.

11. Advance the track forward.

12. Apply an even coat of grease to another track pin and bushing.

13. Place the track pin and the bushing in the saddle and wipe the ends of the bushing and track pin with Tooling (C).

14. Place a track link on the nominal side of the track press.

    Align the track pin and the bore of the track pin on the track link.

    Move the track link with the track press until the track link contacts the bushing.

15. Move the tooling on the left side of the track press until the tooling contacts the track pin and the bushing.
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    Illustration 49	g03872259

16. Use force from each ram to press the track link onto the track pin and the bushing.

    Refer to Table 6 for the correct assembly force.

    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
    307B 307C 307D 307E2 308C 308D 308E 308E2	345 kN (77560 lb)
    311 311B 311C 311D(1) 311F 312 312B(1) 312C(1) 312D(1) 312D2(1) 312F 313B 313C 313D2 313F 314C 314D 314E 314F 315F	350 kN (78680 lb)
    312B(2) 312C(2) 312D(2) 312F 313F	365 kN (82060 lb)
    315 315B 315C 315D 316 317	500 kN (112405 lb)
    313D2(4) 316F 317B 318B 318C 318D 318D2 318E 318F 319C 319D 320(3) 320B(3) 320C(3) 320D(3) 320D2(3) 320E 320F 321C 321D 322 322D 322C 323D(3) 323D2(3) 324D(4) 325F 326D MD5150C MD5075 MD5075C 538B	565 kN (127020 lb)
    320D2	590 kN (132638 lb)
    320(5) 320B(6) 320C(6) 322C(7) 323D(6) 324D(8) 325 325B 325C 325D 329D	645 kN (145000 lb)
    328D 330 330B 330C 330D(9) 336D 336D2 336E 336F 340D 340D2 MD6290 MD6240	725 kN (162990 lb)
    330D(10) 345B 345C 345D 349D 349E 349F 352F 568 MD6420 MD6420B MD6420C MD5150C MD5075	615 kN (138260 lb)
    365B 365C 374D 374F MD6540 MD6540C	840 kN (188840 lb)
    385B 385C 390D 390F 5090 MD6640	1040 kN (233800 lb)
    6015B	1210 kN (272020 lb)

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    (1)	176-4870 Track Link As and 176-4871 Track Link As
    (2)	180-2689 Track Link As and 184-5859 Track Link As
    (3)	194-1609 Track Link As and 194-1608 Track Link As
    (4)	195-9343 Track Link As and 195-9344 Track Link As
    (5)	213-1933 Track Link As
    (6)	201-9116 Track Link As
    (7)	201-9117 Track Link As
    (8)	213-1932 Track Link As
    (9)	201-9118 Track Link As and 201-9119 Track Link As
    (10)	252-0617 Track Link As and 252-0618 Track Link As

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    Illustration 50	g03872261

17. Release the pressure on the left side of the track press. Install the left track link on the tooling.

18. Press the track link onto the track pin and the bushing.

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

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    Illustration 51	g03872216

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    Illustration 52	g02026409

19. Use Tooling (D) to measure the bushing projection on the assembled track joint. Refer to Table 4 or Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts" for the correct dimensions.
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    Illustration 53	g03748003

20. Check joints for flexibility / articulation.

    Flexibility is the ability for movement, from the joint weight.

    All links assembly joints must have flexibility, even with measurable end play of zero.

21. Unlock the assembled joints that display no flexibility.
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    Illustration 54	g03747850

22. Install the anvil assembly tooling onto both sides of the track press.
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    Illustration 55	g03747882

23. Index the assembled track joint to the middle pocket of the saddle

    The procedures for unlocking will be performed when the assembled joint is moved into the middle pocket of the saddle.

    Minimum force should be used for unlocking the joint. This action will ensure proper end play generation.

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    Illustration 56	g03748006

24. Place the joint to be unlocked in the center position of the saddle. Place the pin unlocking tool between the anvil assembly and the track pin.

25. Slowly move the cylinder toward the pin unlocking tool until the anvil contacts the back of the pin unlocking tool.

26. Ensure that tooling is properly aligned. Care must be taken to avoid misalignment.
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    Illustration 57	g03748008

27. Unlock the track joint by applying force to the track pin through the pin unlocking tooling.

28. Check the end play of the assembled track joint.

    Applying and releasing the unlocking force allows the links to move slightly outward. This action gives the joint end play and the ability to articulate.

    Make sure that the track links do not contact the saddle.

29. Frequently check the tooling for damage. Replace tooling if damaged.

30. Remove the pin unlocking tooling from the track press.

31. Check for end play generation for assembled joints that display flexibility.
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    Illustration 58	g03872263
    Tooling E 8T-5096 Dial Indicator Gp

32. Reference Illustration 58 for end play generation. Use a pry bar (1) to apply force on the track links at the assembled joint.

33. While force is applied, set Tooling (E) to zero.

34. Remove the force between these track links and apply force between the other two track links of the track joint.

35. Read the total end play on Tooling (E) while force is applied to the track links.

    Note: Acceptable end play is 0.02 mm (0.001 in.) to 0.20 mm (0.008 in.).

36. Repeat Steps 11 through 35 for the remaining track joints until the track is assembled.

37. Use a pry bar to check each assembled track joint for articulation. Articulation of the track joint will aid in installation of the track assembly.

Lubrication of the Master Track Joint on the 345, 349, 5150C, MD6420, MD6420B, MD6420C, MD6540, MD6540C, and MD6640.

The 345, 349, MD5150C, MD6420, MD6420B, MD6420C, MD6540, MD6540C, and MD6640 have a grease lubricated master track pin. The master track pin contains a lubricant reservoir and two crossholes to grease the master track joint. The master track pin eliminates grease from the pin ends which was a common cause of pin walking. Use 254-8168 Grease Pin Kit to fill master track pin with grease so that grease is applied to the inside clearance of the master track bushing and master track pin.

Illustration 59	g01208187
Cross view of master track pin showing lubricant reservoir and two crossholes

Illustration 60	g02788569
Tooling F 254-8168 Grease Pin Kit is used to lubricate master track link pins and master track link bushings with grease

1. Install 6Y-0473 Clear Plug into 7G-4332 Stopper with Tooling (H).

   Note: The plug must protrude 0.0 mm (0.00 in.) to 2.0 mm (0.08 in.) out of the rubber stopper. The plug can vibrate into the lubricant reservoir of the track pin if the plug is pushed fully into the stopper hole.

2. Install Tooling (F) into the lubricant reservoir on the master track pin.

3. Pump grease into the master track pin until the track joint is full of grease.

   Note: When the track joint is full of grease, the grease will come out of the relief hole on Tooling (F).

4. Use Tooling (G) to install the stopper into the lubricant reservoir.

   Note: The stopper must be installed 8.0 ± 2.0 mm (0.31 ± 0.08 in.) below the surface of the track pin.

Preparation and Installation of the Track Shoes

Illustration 61	g03748003

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Illustration 62	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 must 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 24-grit sandpaper 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 the 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 will 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 will 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 63	g03748019

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   Illustration 64	g03748022

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 194-7586 Pneumatic Wrench Gp depending on the model being serviced 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 Loctite Graphite 50 Anti-Seize lubricant.

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 65	g03748114

6. Turn the switch on the side of the Caterpillar Track Torque Wrench to the 120° position.
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   Illustration 66	g03748116

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

8. Press the "Check Set Value" button to display and check the values that have been set.
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   Illustration 67	g01160163

9. Follow the correct pattern in Illustration 67 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 "Value Complete" .