Shop Repair Procedure for Positive Pin Retention Track {4169, 4170, 4171, 4174, 4175} Caterpillar

Caterpillar Products

Machines with Positive Pin Retention (PPR) Track

Machines with Sealed Positive Pin Retention (PPR) Track

Machines with Sleeve Bearing Track

Introduction

Table 1

Revision	Summary of Changes in SEBF8546
19	Added serial number prefixes for New Product Introduction.
18	Added serial number prefixes for New Product Introduction. Updated introduction information.
17	Identified which tooling for Nominal and / or Non- Nominal side will be modified in Tables 5 through 9. Created illustrations and steps for measuring link offset for disassembly tooling. Located contact tooling measurement Illustration 3 and Table 4 before Tables 5 through 9 for easy reference. Added serial number prefixes for New Product Introduction.
16	Created Tables 5 through 9 for a reference for disassembly / assembly contact tooling used for Positive Pin Retention Track Link Assemblies. Created Illustration 14 and explained the proper use of the hold down shoe during disassembly of a worn bushing. Published Illustrations in color. Updated Table 4 confirmed all dimensions / sales model in Table. Updated Table 14 confirmed all dimensions / sales model in Table. Updated Table 16 confirmed all dimensions / sales model in Table.

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Cat 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 Cat 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

The Positive Pin Retention Track was developed by Caterpillar to reduce a common cause for loss of lubrication in track joints. Retaining rings are used to lock the track pin and the track links together. Refer to Illustration 1. The retaining ring prevents any motion between the track link and the track pin during machine operation. The ring also provides proper end play of the track joint. Proper end play allows the seals to maintain full compression against the ends of the bushings. The seals then keep oil inside the cavities of the track joints.

Illustration 1	g03745687
Positive Pin Retention Track

The information in this bulletin describes the tooling that will be used and the required service procedures. Follow each step to ensure that each track joint has minimum end play and maximum service life.

Note: Sleeve Bearing Track was introduced in 2002on D11 Track-Type Tractors. Sleeve Bearing Track is now standard on the D11. The Positive Pin Retention Track without the sleeve bearing is no longer available for the D11.

Refer to Undercarriage Reconditioning Bulletin, SEBF8609, "Shop Repair Procedure for Sleeve Bearing Track" to service D11 Sleeve Bearing Track.

A list of important reference and training materials is shown on the next page of this bulletin. The operator of the track press should become familiar with this material for training prior to servicing the Positive Pin Retention Track.

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: Service Letter, REBE9847, "Product Support Program for Replacing Master Links on Certain D10T, D10R, and D10N, Track Type Tractors"

Reference: Undercarriage Reconditioning Bulletin, SEBF8620, "Reusability Guidelines for Single Tooth Master Links"

Reference: Undercarriage Reconditioning Bulletin, SEBF8621, "Shop Disassembly and Assembly of Single Tooth Master Links"

Reference: Special Instruction, REHS3371, "Shop Procedure for the Correct Installation of Serrated Master Links on Large Track-Type Tractors"

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"

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

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

Reference: Shop Repair Procedures of Positive Pin Retention Track, PEVN4329

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

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

Reference: Parts Sales Kit, PECP3003

Reference: Catalog, NENG2500, "Dealer Service Tool 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 one below is used to identify to 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.

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NOTICE
When reconditioning track assemblies always wear normal safety equipment; such as, safety glasses and steel-toed shoes.

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NOTICE
The shield on the track press has been removed in the illustrations for clarity. Always operate the track press with the shield in the closed position.

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

Table 2

Required Tooling
Callout	Part Number	Part Description
(A)	222-3074	Die Grinder
(B)	5P-3010	Deburring Tool
(C)	FT-1238	Vacuum Tank Assembly
(D)	367-9109	Caliper
(F)	1U-9941 1U-9943	End Brush
(G)	5P-1725	Installation Tool
(H)	5P-7419	Plug Installer
(J)	288-4209	Lint Free Cloth
(K)	8T-5096	Dial Indicator Group
(L)	170-5664	Test and Fill Cart Group
(M)	FT-2724	Gauge Connection
(P)	Loctite C5–A	Copper Based Anti-Seize Compound
(R)	FT-1953	Dial Indicator Gauge Gp
Option	443-7801	Pneumatic Wrench
Option	385-7874	Hydraulic Torque Wrench

Table 3

Additional Tooling
Sales Model	Seal Installer (S)	End Groove Gauge (T)
D11T D11R D11N	4C-8623 241-1854(1)	4C-8613
5130 5130B	4C-8623	4C-8613
D10T D10R D10N	4C-8622 262-9822(1)	4C-8612
D10	4C-8622 262-9822(1)	4C-8611
5110 5110B	4C-8622	4C-8611
D9T D9R D9N	4C-8621	4C-8610
D9L 589	4C-8621	4C-8609
D8T D8R D8N 587T 587R 583T 583R 578 PL87 PL83	4C-8619	4C-8607

(1)	Post Turn Seal Installer

Illustration 3	g03427390
Nominal side of the track press. The first assembly side whether (right hand or left hand) will be the Nominal side. (A) Inner diameter of the tooling for the track pin. (B) Pin protrusion. (C) Track link offset. (D) Bushing protrusion (E) Inner diameter of the tooling for the bushing.

Table 4

Dimensions for the Tooling of Positive Pin Retention Track
Sales Model	A(1)	B(2)	C(3)	D(4)	E(1)
D11T D11R D11N 5130 5130B	69.85 ± 0.12 mm (2.750 ± 0.005 inch)	1.80 ± 0.13 mm (0.071 ± 0.005 inch)	59.0 mm (2.322 inch)	1.66 ± 0.13 mm (0.065 ± 0.005 inch)	109.73 ± 0.12 mm (4.320 ± 0.005 inch)
D10T D10R D10N	60.20 ± 0.12 mm (2.370 ± 0.005 inch)	1.97 ± 0.13 mm (0.078 ± 0.005 inch)	50.0 mm (1.968 inch)	1.66 ± 0.13 mm (0.065 ± 0.005 inch)	99.82 ± 0.12 mm (3.930 ± 0.005 inch)
D10	60.20 ± 0.12 mm (2.370 ± 0.005 inch)	1.97 ± 0.13 mm (0.078 ± 0.005 inch)	48.7 mm (1.917 inch)	1.66 ± 0.13 mm (0.065 ± 0.005 inch)	99.82 ± 0.12 mm (3.930 ± 0.005 inch)
5110 5110B	60.20 ± 0.12 mm (2.370 ± 0.005 inch)	1.95 ± 0.13 mm (0.077 ± 0.005 inch)	48.7 mm (1.917 inch)	1.66 ± 0.13 mm (0.065 ± 0.005 inch)	99.82 ± 0.12 mm (3.930 ± 0.005 inch)
D9T D9R D9N	53.97 ± 0.12 mm (2.125 ± 0.005 inch)	2.00 ± 0.13 mm (0.079 ± 0.005 inch)	46.0 mm (1.80 inch)	1.66 ± 0.13 mm (0.065 ± 0.005 inch)	85.09 ± 0.12 mm (3.350 ± 0.005 inch)
D9L 589	53.97 ± 0.12 mm (2.125 ± 0.005 inch)	2.00 ± 0.13 mm (0.079 ± 0.005 inch)	50.0 mm (1.968 inch)	1.66 ± 0.13 mm (0.065 ± 0.005 inch)	85.09 ± 0.12 mm (3.350 ± 0.005 inch)
D8T D8R D8N 587T 587R 583T 583R 578 PL87 PL83	50.80 ± 0.12 mm (2.000 ± 0.005 inch)	2.00 ± 0.13 mm (0.079 ± 0.005 inch)	43.0 mm (1.69 inch)	1.76 ± 0.13 mm (0.070 ± 0.005 inch)	77.72 ± 0.12 mm (3.060 ± 0.005 inch)

(1)	Reference dimensions. Non-Caterpillar tooling may have slightly different dimensions.
(2)	Pin protrusion is to be maintained for the Nominal side of the track press pin tooling. The Non-Nominal side will never (bottoms-out) against the base during assembly.
(3)	If the tools for assembly are reworked, make sure that the dimensions are maintained.
(4)	Bushing Protrusion is to be maintained for both Nominal and Non-Nomimal side of the track press bushing tooling.

Table 5

Caterpillar Contact Tooling Arrangements for PPR
Sales Model	Quantity	D11N D11R D11T
Link Assemblies	-	353-7387	369-5962	361-6776
	-	215-7494	215-7678	-
	-	316-3370	316-3369	-
	-	215-7678	-	-
Right-Hand Link Part Number	-	6T-8049	200-6325	320-3541
Pitch	-	317.5 mm (12.50inch)
Assembly Force	-	1210 kN (123.40 tons)
Offset of Link	-	59.0 mm (2.322 inch)
Protrusion of Pin	-	1.80 ± 0.13 mm (0.071 ± 0.005 inch)
Protrusion of Bushing	-	1.66 ± 0.13 mm (0.065 ± 0.005 inch)
Saddle	1	9U-7767
Pin Assembly Base	2	9U-7567
Pin Assembly Body	2	9U-7568
Pin Assembly Plunger (Nominal) (First Assembly Side)	1	9U-7564
Pin Assembly Plunger (Non-Nominal) (Second Assembly Side)	1	9U-7565
Bushing Assembly Base	2	9U-7570
Bushing Assembly Body	2	9U-7571
Bushing Assembly Plunger	2	9U-7569
Pin Disassembly	2	9U-7777
Bushing Disassembly	2	9U-7778
Socket Head Screw	8	9F-5975
Jam Nut	4	1B-2578
Spring	4	248-2069
Set Screw	4	5B-0448
Tee Slot Bolt	4	248-2072
Spacer Group - Spacer 2.0 mm (0.078 inch) Spacer 3.0 mm (0.118 inch) Spacer 4.0 mm (0.157 inch)	-	126-4041 - 126-4042 126-4043 126-4044
MODIFICATION Pin Protrusion Pin Tooling Assembly	-	NO MODIFICATION NEEDED Both Nominal and Non-Nominal sides
MODIFICATION Bushing Protrusion Bushing Tooling Assembly	-	NO MODIFICATION NEEDED Both Nominal and Non-Nominal sides
MODIFICATION Link Offset Bushing Tooling Assembly	-	Add 2.61 mm (0.102inch) Spacer / Shim Between Bushing Assembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
MODIFICATION Link Offset Bushing Tooling Disassembly	-	Add 1.3 mm (0.051inch) Spacer / Shim Between Bushing Disassembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
SWAGING TOOLING	-	-
Extruder Assembly	2	198-5341
Anvil Assembly	2	8T-3216
Stud	2	1U-6257
Handle Assembly	4	8T-3211
Unloading Pin	4	157-8547

Table 6

Caterpillar Contact Tooling Arrangements for PPR
Sales Model	Quantity	D10	D10N D10R D10T
Link Assemblies	-	239-0673	398-5234	380-5946
			320-3055	238-9851
Right-Hand Link Part Number	-	9W-5933	320-3053	7T-0715
Pitch	-	260.4 mm (10.25 inch)
Assembly Force	-	870 kN (88.7 tons)	835 kN (85.1 tons)
Offset of Link	-	48.7 mm (1.92 inch)	50.0 mm (1.97 inch)
Protrusion of Pin	-	1.97 ± 0.13 mm (0.078 ± 0.005 inch)
Protrusion of Bushing	-	1.66 ± 0.13 mm (0.065 ± 0.005 inch)
Saddle	1	9U-7768
Pin Assembly Base	2	9U-7580
Pin Assembly Body	2	9U-7585
Pin Assembly Plunger (Nominal) (First Assembly Side)	1	9U-7578
Pin Assembly Plunger (Non-Nominal) (Second Assembly Side)	1	9U-7579
Bushing Assembly Base	2	9U-7575
Bushing Assembly Body	2	9U-7577
Bushing Assembly Plunger	2	9U-7572
Pin Disassembly	2	9U-7779
Bushing Disassembly	2	9U-7780
Socket Head Screw	8	9F-5975
Jam Nut	4	1B-2578
Spring	4	248-2069
Set Screw	4	5B-0448
Tee Slot Bolt	4	248-2072
Spacer Group - Spacer 2.0 mm (0.078 inch) Spacer 3.0 mm (0.118 inch) Spacer 4.0 mm (0.157 inch)	-	126-4041 - 126-4042 126-4043 126-4044
MODIFICATION Protrusion Bushing D10 Bushing Tooling D10N,R,T Bushing Tooling Assembly	-	Add 0.24 mm (0.010 inch) Shim Between Bushing Assembly Tooling Base and Body Both Nominal and Non-Nominal sides
MODIFICATION Protrusion of Pin D10 Pin Tooling D10N,R,T Pin Tooling Assembly	-	Add 0.14 mm (0.005 inch) Shim Between Pin Assembly Tooling Plunger and Base Nominal side only
MODIFICATION Protrusion of Pin D10 Pin Tooling D10N,R,T Pin Tooling Assembly	-	NO MODIFICATION NEEDED Non-Nominal sides
MODIFICATION Link Offset Bushing Tooling Assembly	-	Add 2.0 mm (0.0787 inch) Spacer / Shim Between Bushing Assembly Tooling and Tool Bar Both Nominal and Non-Nominal sides	Add 3.0 mm (0.118 inch) Spacer / Shim Between Bushing Assembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
MODIFICATION Link Offset Bushing Tooling Disassembly	-	Add 3.0 mm (0.118 inch) Spacer / Shim Between Bushing Disassembly Tooling and Tool Bar Both Nominal and Non-Nominal sides	Add 4.0 mm (0.157 inch) Spacer / Shim Between Bushing Disassembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
SWAGING TOOLING	-	-
Extruder Assembly	2	198-5342
Anvil Assembly	2	8T-3216
Stud	2	1U-6257
Handle Assembly	4	8T-3211
Unloading Pin	4	157-8547

Table 7

Caterpillar Contact Tooling Arrangements for PPR
Sales Model	Quantity	D9N D9R D9T		D9L	589
Link Assemblies	-	199-5525	266-2899	199-5534	199-5532
Right-Hand Link Part Number	-	7T-2275		7T-4137
Pitch	-	240.0 mm (9.45 inch)		228.6 mm (9.00 inch)
Assembly Force	-	780 kN (79.5 tons)		740 kN (75.5 tons)
Offset of Link	-	46.0 mm (1.81 inch)		50.0 mm (1.97 inch)
Protrusion of Pin	-	2.00 ± 0.13 mm (0.079 ± 0.005 inch)
Protrusion of Bushing	-	1.66 ± 0.13 mm (0.065 ± 0.005 inch)
Saddle	1	9U-7769		9U-7770
Pin Assembly Base	2	9U-7830		9U-7601
Pin Assembly Body	2	9U-7605
Pin Assembly Plunger (Nominal) (First Assembly Side)	1	9U-7595
Pin Assembly Plunger (Non-Nominal) (Second Assembly Side)	1	9U-7596
Bushing Assembly Base	2	9U-7592
Bushing Assembly Body	2	9U-7594
Bushing Assembly Plunger	2	9U-7589		9U-7588
Pin Disassembly	2	9U-7782
Bushing Disassembly	2	9U-7783
Socket Head Screw	8	9F-5975
Jam Nut	4	1B-2578
Spring	4	248-2069
Set Screw	4	5B-0448
Tee Slot Bolt	4	248-2072
Spacer Group - Spacer 2.0 mm (0.078 inch) Spacer 3.0 mm (0.118 inch) Spacer 4.0 mm (0.157 inch)	-	126-4041 - 126-4042 126-4043 126-4044
MODIFICATION Protrusion Bushing Bushing Tooling Assembly	-	NO MODIFICATION NEEDED Both Nominal and Non-Nominal sides
MODIFICATION Protrusion of Pin Pin Tooling Assembly	-	NO MODIFICATION NEEDED Both Nominal and Non-Nominal sides
MODIFICATION Link Offset Bushing Tooling Assembly	-	Add 1.8 mm (0.071 inch) Spacer / Shim Between Bushing Assembly Tooling and Tool Bar Both Nominal and Non-Nominal sides		Add 6.07 mm (0.239 inch) Spacer / Shim Between Bushing Assembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
MODIFICATION Link Offset Bushing Tooling Disassembly	-	NO MODIFICATION NEEDED Both Nominal and Non-Nominal sides		Add 4.0 mm (0.157 inch) Spacer / Shim Between Bushing Disassembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
SWAGING TOOLING	-	-
Extruder Assembly	2	198-5343
Anvil Assembly	2	8T-3216
Stud	2	1U-6257
Handle Assembly	4	8T-3211
Unloading Pin	4	157-8547

Table 8

Caterpillar Contact Tooling Arrangements for PPR
Sales Model	Quantity	583R 583T 578R 587T	578	D8N D8L D8R D8T
Link Assemblies	-	136-6713	6I-8839	272-6009
Right-Hand Link Part Number	-	8E-4513
Pitch	-	215.9 mm (8.5 inch)
Assembly Force	-	660 kN (67.3 tons)
Offset of Link	-	43.0 mm (1.692 inch)
Protrusion of Pin	-	2.0 mm (0.078inch)
Protrusion of Bushing	-	1.76 mm (0.06929 inch)
Saddle	1	9U-7771
Pin Assembly Base	2	9U-7632
Pin Assembly Body	2	9U-7644
Pin Assembly Plunger (Nominal) (First Assembly Side)	1	9U-7622
Pin Assembly Plunger (Non-Nominal) (Second Assembly Side)	1	9U-7623
Bushing Assembly Base	2	9U-7613
Bushing Assembly Body	2	9U-7620
Bushing Assembly Plunger	2	9U-7606
Pin Disassembly	2	9U-7785
Bushing Disassembly	2	9U-7786
Socket Head Screw	8	9F-5975
Jam Nut	4	1B-2578
Spring	4	248-2069
Set Screw	4	5B-0448
Tee Slot Bolt	4	248-2072
Spacer Group - Spacer 2.0 mm (0.078 inch) Spacer 3.0 mm (0.118 inch) Spacer 4.0 mm (0.157 inch)	-	126-4041 - 126-4042 126-4043 126-4044
MODIFICATION Protrusion of Bushing Bushing Tooling Assembly	-	Add 0.37 mm (0.014 inch) Spacer / Shim Between Bushing Assembly Tooling Plunger and Base Both Nominal and Non-Nominal sides
MODIFICATION Protrusion of Pin Pin Tooling Assembly	-	NO MODIFICATION NEEDED Both Nominal and Non-Nominal sides
MODIFICATION Link Offset Bushing Tooling Assembly	-	Add 2.11 mm (0.083 inch) Spacer / Shim Between Bushing Assembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
MODIFICATION Link Offset Bushing Tooling Disassembly	-	Add 0.8 mm (0.031 inch) Spacer / Shim Between Bushing Disassembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
SWAGING TOOLING	-	-
Extruder Assembly	2	203-0982
Anvil Assembly	2	8T-3216
Stud	2	1U-6257
Handle Assembly	4	8T-3211
Unloading Pin	4	157-8547

Table 9

Caterpillar Contact Tooling Arrangements for PPR
Sales Model	Quantity	PL83 PL87	5110 5110B	5130 5130B
Link Assemblies	-	358-0443	125-9384	124-8473
Right-Hand Link Part Number	-	8E-4513	9W-5933	124-8469
Pitch	-	215.9 mm (8.5 inch)	260.4 mm (10.251 inch)	317.5 mm (12.5 inch)
Assembly Force	-	555 kN (62.4 tons)	870 kN (97.8 tons)	1210 kN (136 tons)
Offset of Link	-	43 mm (1.693 inch)	48.7 mm (1.917 inch)	59.0 mm (2.322 inch)
Protrusion of Pin	-	2.2 mm (0.086 inch)	1.95 mm (0.0767 inch)	1.8 mm (0.071 inch)
Protrusion of Bushing	-	8.11 mm (0.319 inch)	1.66 mm (0.0653 inch)	1.66 mm (0.0653 inch)
Saddle	1	9U-7771	9U-7768	9U-7767
Pin Assembly Base	2	9U-7632	9U-7580	9U-7567
Pin Assembly Body	2	9U-7644	9U-7585	9U-7568
Pin Assembly Plunger (Nominal) (First Assembly Side)	1	9U-7622	9U-7578	9U-7564
Pin Assembly Plunger (Non-Nominal) (Second Assembly Side)	1	9U-7623	9U-7579	9U-7565
Bushing Assembly Base	2	9U-7613	9U-7575	9U-7570
Bushing Assembly Body	2	9U-7620	9U-7577	9U-7571
Bushing Assembly Plunger	2	9U-7606	9U-7572	9U-7569
Pin Disassembly	2	9U-7785	9U-7779	9U-7777
Bushing Disassembly	2	9U-7786	9U-7780	9U-7778
Socket Head Screw	8	9F-5975
Jam Nut	4	1B-2578
Spring	4	248-2069
Set Screw	4	5B-0448
Tee Slot Bolt	4	248-2072
Spacer Group - Spacer 2.0 mm (0.078 inch) Spacer 3.0 mm (0.118 inch) Spacer 4.0 mm (0.157 inch)	-	126-4041 - 126-4042 126-4043 126-4044
MODIFICATION Protrusion of Bushing Bushing Tooling Assembly	-	Add 0.57 mm (0.022 inch) Spacer / Shim Between Bushing Assembly Tooling Plunger and Base Both Nominal and Non-Nominal sides	Add 0.24 mm (0.010 inch) Spacer / Shim Between Bushing Assembly Tooling Plunger and Base Both Nominal and Non-Nominal sides	NO MODIFICATION NEEDED Both Nominal and Non-Nominal sides
MODIFICATION Protrusion of Pin Pin Tooling Assembly	-	NO MODIFICATION NEEDED Both Nominal and Non-Nominal sides	- Add 0.16 mm (0.006 inch) Spacer / Shim Between Pin Assembly Tooling Plunger and Base Nominal side only	NO MODIFICATION NEEDED Both Nominal and Non-Nominal sides
MODIFICATION Protrusion of Pin Pin Tooling Assembly			NO MODIFICATION NEEDED Non-Nominal side only
MODIFICATION Link Offset Bushing Tooling Assembly	-	Add 2.11 mm (0.083 inch) Spacer / Shim Between Bushing Assembly Tooling and Tool Bar Both Nominal and Non-Nominal sides	Add 2.0 mm (0.078 inch) Spacer / Shim Between Bushing Assembly Tooling and Tool Bar Both Nominal and Non-Nominal sides	Add 2.61 mm (0.102 inch) Spacer / Shim Between Bushing Assembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
MODIFICATION Link Offset Bushing Tooling Disassembly	-	Add 0.8 mm (0.031 inch) Spacer / Shim Between Bushing Disassembly Tooling and Tool Bar Both Nominal and Non-Nominal sides	Add 3.0 mm (0.118 inch) Spacer / Shim Between Bushing Disassembly Tooling and Tool Bar Both Nominal and Non-Nominal sides	Add 1.3 mm (0.051 inch) Spacer / Shim Between Bushing Disassembly Tooling and Tool Bar Both Nominal and Non-Nominal sides
SWAGING TOOLING	-	-
Extruder Assembly	2	203-0982	198-5342	198-5341
Anvil Assembly	2	8T-3216
Stud	2	1U-6257
Handle Assembly	4	8T-3211
Unloading Pin	4	157-8547

Preparation for Disassembly

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

   Note: The 5130 and 5110 have the Grease Lubricated Track. Therefore, the track pin does not have an oil reservoir.

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   Illustration 5	g03744826

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   Illustration 6	g01232249

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   NOTICE
   When using Tooling (B) deburring tool, do not plunge tool 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 7	g03745709

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   Illustration 8	g03745715

4. Remove the stoppers from the track pins with a slow drill and a 12.5 mm (0.50 inch) 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 9	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 Servicing Handbook, PEKP9400, "Caterpillar Track Service Handbook"for the correct measurements needed to calculate the percentage of wear.

Disassembly of the Track

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Illustration 10	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 11	g03745722

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

3. Reference Tables 5 through 9 for correct disassembly / assembly contact tooling used for Positive Pin Retention Track Link Assemblies.

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

5. For both disassembly and assembly tooling, calculate Dimension (C) Track link offset. This calculation will determine whether shims / spacers are needed. Then physically measure Dimension (C) once the shims / spacers are in place and tooling is attached to tool bar.

6. Reference Tables 5 through 9 or Table 4 for track link offset dimensions.
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   Illustration 12	g03780110

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

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

9. 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. Reference Tables 5 through 9 for contact tooling modifications.

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

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

    1. Make sure that the bushings are seated in the saddle of the track press.
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       Illustration 14	g03748436
       Wear step on the bushing surface.

    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 14.

       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 15	g03745743

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

13. The retaining ring will break off as the track pin is pressed from the track link. If the retaining ring does not fall out of the groove on the track pin, use a hammer and a chisel to remove the retaining ring.

    Note: Do not damage the angle on the groove of the track pin. The angle and depth of the groove need to be in good condition.

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

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

    Note: The 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.

16. 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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NOTICE
Do not damage the seal face or the bushing ends. Cleaning the bushing ends with abrasives will damage the seal surface. It is critical that the bushing faces are not scratched from metal to metal contact or sliding them on any surface. If parts are to be put in storage, protect them from damage and corrosion. Corrosion in the seal band area will cause the seal to fail.

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NOTICE
All Caterpillar machines with Caterpillar undercarriage have phosphate coated track pins. Cleaning phosphate coated track pins with solvents exceeding 10.5 pH will remove the coating. Follow the statements below when cleaning phosphate coated track pins: Use a solvent or chemical cleaner with a pH level range between 7 and 10.5. Maximum solvent or chemical cleaner temperature of 71 °C (160 °F). Maximum cleaning time of 15 minutes. Refer to Undercarriage Reconditioning Bulletin, SEBF8562, "Procedure and Guidelines for Cleaning Phosphate Coated Track Pins" for more information and recommended solvents and chemical cleaners.

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Illustration 16	g03745749

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 17	g03745754

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   Illustration 18	g03745044

2. 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 inch) 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.

   Note: The 5130 and 5110 have the Grease Lubricated Track. Therefore, the track pin does not have an oil reservoir.

3. Remove any burrs, material, and any paint from the spot face of the track link that will interfere with the tooling on the track press.
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   Illustration 19	g03745758

4. 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 20	g03745759

5. Wipe the counterbore of the track link with a lint free cloth.
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   Illustration 21	g03745782

6. Hold each bushing up to a bright light to examine the bushings for cracks.
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   Illustration 22	g03745840

7. 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. Reference Table 3 for the correct end groove gauge.

   Post Turn Seals are now available for all D11T/R/N, D10T/R/N,and D10 track link assemblies.

   These new seals have a smaller diameter than the standard 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, PELJ0242, "New D11R/N Post Turn Seals" and Information Release Memo, PELJ0443, "D10R/N and D10 Post Turn Seals" for more information.

   Use the new 241-1854 Seal Installer with the D11T/R/N and D11 Post Turn Seal. Use the new 262-9822 Seal Installer with the D10T/R/N and D10 Post Turn Seal.

   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 10, Table 11, or Parts Sales Kit, PECP3003 for the seal part numbers.

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   Table 10

   D11T/R/N
   -	Standard Seal	Post Turn Seal
   Seal Assembly	222-7007	261-4338
   Seal Set	248-5531	261-4408

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   Table 11

   D10T/R/N D10
   -	Standard Seal	Post Turn Seal
   Seal Assembly	222-7001	252-6327(1)
   Seal Set	239-5272	252-6329

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   (1)	235-2213 Thrust Ring must be used with these seals.

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   Illustration 23	g03745843
   Standard Seal (1) Seal (2) Link (3) Bushing (4) Thrust ring (5) Pin

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   Illustration 24	g03745846
   Post Turn Seal (1) Seal (2) Link (3) Bushing (4) Thrust ring (5) Pin

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   Illustration 25	g03745061

8. Place the seal into Tooling (S) seal installer.
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   Illustration 26	g03745062

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

   Note: For ease of seal installation, the outer load ring should 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 27	g03745849
   (1) Facing group (S) Seal installer

10. Install the optional (1) facing group on Tooling (S) 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. However, unlocking the track joint is the best practice to achieve the proper end play.

    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 28	g03779081
    (1) Facing group (2) Thrust ring (S) Seal installer

11. Slide the (2) thrust ring onto Tooling (S) seal installer . Press firmly on the thrust ring until the (1) facing group adheres to the thrust ring.

12. Remove the thrust ring from Tooling (S).

13. Repeat Steps 10 through 12 for the reverse side of the thrust ring.

First and Second Assembly Side Concept

The Caterpillar assembly contact tooling requires that only one link be 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 protrusion, and the non-nominal shorter plunger allows the joint to be pressed to zero endplay. The shorter second side pin assembly plunger never “bottoms-out” against the base; therefore, the joint cannot be released from the zero endplay condition. The use of Molykote paste or facing groups establishes slight endplay. According to Caterpillar track assembly specifications, pin protrusion 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 protrusion is controlled on both sides of the track joint. Thus, the two bushing assembly plungers are both the same length resulting in the same protrusion. The establishment of proper bushing protrusion is critical to ensure that adjacent links do not scrub against one another.

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 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-on far enough to remove all the end play. Bushing protrusion will also be affected by any foreign material. Refer to or Table 4 for the dimensions for the track link assemblies.

Note: Reference Tables 5 through 9 for disassembly / assembly contact tooling used for Positive Pin Retention Track Link Assemblies.

Another reference is the Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts"

Illustration 29	g03427390
Nominal side of the track press. The first assembly side whether (right hand or left hand) will be the Nominal side. (A) Inner diameter of the tooling for the track pin. (B) Pin protrusion. (C) Track link offset. (D) Bushing protrusion. (E) Inner diameter of the tooling for the bushing.

Note: For both disassembly and assembly tooling, calculate Dimension (C). This calculation will determine whether shims / spacers are needed. Then physically measure Dimension C once the shims / spacers are in place and tooling is attached to tool bar.

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. Reference Tables 5 through 9 or Table 4 for the correct dimensions.
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   Illustration 30	g03780149

4. Measure the height of the track pin assembly tooling use tooling (D) calipers.
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   Illustration 31	g03780141

5. Measure the height of the bushing assembly tooling use tooling (D) calipers.

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, spacers / shims can be used to the correct tooling dimensions. Reference Tables 5 through 9 .

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   Illustration 32	g03745892
   Use Tooling (R) dial indicator to measure the tooling for the correct bushing protrusion.

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   Illustration 33	g02081093

7. Use Tooling (R) dial indicator to measure the correct bushing protrusion for the bushing tooling on both sides of the track press. Refer to Table 5 through 9 or Table 4 for the correct dimensions.

   Note: For incorrect bushing protrusion, spacers / shims can be added to the tooling. Reference Tables 5 through 9 for contact tooling modifications.

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   Illustration 34	g03745923

8. Consider inserting spacers / shims or machining the tooling if needed. Assemble the bushing tooling including the spring, plunger, and base.
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   Illustration 35	g03745931
   Use Tooling (R) dial indicator to measure the tooling for the correct track pin protrusion.

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   Illustration 36	g02081095

   Note: Maintain correct Dimension (B) pin protrusion on the nominal side of the pin assembly tooling only. The non-nominal side pin assembly plunger never "bottoms-out" against the base during pin assembly.

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 protrusion on the nominal side of track press. Refer to Table 5 through 9 or Table 4 for the correct dimensions.

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

    Note: For incorrect pin protrusion, spacers / shims can be added to the tooling. Reference Tables 5 through 9 for contact tooling modifications.

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    Illustration 37	g03745943

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

13. Perform the final check of the track press to verify that the tooling is set up properly. Refer to Step 13.a through Step 13.g.
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    Illustration 38	g03745960

    1. Place a track pin and a bushing in the front and rear pockets of the saddle.
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       Illustration 39	g03745974

    2. Install the tooling on the left and right-hand side of track press.
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       Illustration 40	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 41	g03777159

    7. 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
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    Illustration 42	g03747619

14. Adjust the setting on the relief valves to achieve the recommended force for assembly. Refer to Table 12 for the recommended assembly force.

    Other References:

    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 the 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.

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    Table 12

    Forces for the Track Press
    Sales Model	Maximum Assembly Force	Maximum Installation Force for the Retaining Ring	Maximum Force for Unlocking the Joint
    D11T D11R D11N 5130 5130B	1210 kN (123.4 tons)	1245 kN (140.0tons)	2220 kN (250 tons)(1)
    D10T D10R D10N	835 kN (85.1 tons)	1070 kN (120.2 tons)	1690 kN (190 tons)
    D10 5110 5110B	870 kN (88.7 tons)	1070 kN (120.2 tons)	1690 kN (190 tons)
    D9T D9R D9N	780 kN (79.5 tons)	1015 kN (114.1 tons)	1330 kN (150 tons)
    D9L 589	740 kN (75.5 tons)	600 kN (67.4 tons)	1330 kN (150 tons)
    D8T D8R D8N 587T 587R 583T 583R 578 PL87 PL83	660 kN (67.3 tons)	845 kN (65.0 tons)	1200 kN (135 tons)

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    (1)	The maximum allowed unlocking force may not achieve full articulation of the track joint. However, installing the optional facing group on the thrust ring may aid in proper articulation of the joint once the track is put into service on the tractor.

Assembly of the Track

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Illustration 43	g03747620

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NOTICE
During the assembly of the track links prevent the links from any contact with the saddle. Reference Illustration 43.

1. Determine if the bushing should be rotated to contact a different wear surface.
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   Illustration 44	g01233892
   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 45	g03747701
   Proper pin and bushing rotation.

3. 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.
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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 46	g01233943

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 47	g03747707

5. Use a lint free cloth to clean the bushing bores on the track link and the ends of the pin and bushing.

6. Bolt the split master links together in order to properly align the bushing ends.

   Note: The 5130 and 5110 have the Grease Lubricated Track. The track link assembly does not have a split master track link.

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   Illustration 48	g03747710

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   Illustration 49	g03747721

7. For the 5130 and 5110, apply an even coat of grease to the track pin and the inner diameter of the bushing. Wipe the excess grease off the ends of the track pin and the bushing with Tooling (J).

   Note: Refer to Table 13 for the correct part numbers for the grease.

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   Table 13

   Specifications for the Grease
   Part Number	Grease	Quantity
   161-9203	Ultra 5 Moly Grease NLGI No. 1	Cartridge
   183-3432	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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   NOTICE
   Use only half of the assembly force 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 50	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.

8. 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.

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

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

10. 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 51	g03747738
    Tooling (R) dial indicator.

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    Illustration 52	g01233961

11. Bushing protrusion must be maintained on both (Nominal and Non-Nominal) sides of the assembled track joint.

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

    Reference Tables 5 through 9 or Table 4 for the correct dimensions.

    Other Reference:

    Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts" for the correct dimensions.

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    Illustration 53	g03747741

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

13. 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 54	g03747750

14. 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 55	g03747753

15. 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 56	g03747777

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

17. Lower the hold down shoe, ensure light contact with the bushings.
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    Illustration 57	g03747780

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

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

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

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

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

    Refer to Table 12 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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    Illustration 58	g03747783

21. Repeat Steps 16 through 20 to assemble the left-hand track link.

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

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    Illustration 59	g03747817

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

    Reference Tables 5 through 9 or Table 4 for the correct dimensions.

    Other Reference:

    Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts" for the correct dimensions.

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    Illustration 60	g03747844

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

    Reference Tables 5 through 9 or Table 4 for the correct dimensions.

    Other Reference:

    Undercarriage Reconditioning Bulletin, SEBF8566, "Caterpillar Track Data Charts" for the correct dimensions.

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    Table 14

    Extruder Assembly Tooling
    Model	Part Number	Quantity
    D11T/R/N 5130 5130B	198-5341	2
    D10T/R/N D10 5110 5110B	198-5342	2
    D9T/R/N D9L 589	198-5343	2
    D8T/R/N 587T/R 583T/R 578 PL87 PL83	203-0982	2

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    Illustration 61	g03747850

24. Install the anvil assembly tooling onto both sides of the track press.
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    Illustration 62	g03747882

25. Index the assembled track joint to the middle pocket of the saddle. The procedures for extrusion and unlocking will be performed when the assembled joint is moved into the middle pocket of the saddle.
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    Illustration 63	g03747889

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    Illustration 64	g03747894

26. Insert a retaining ring into the track pin grooves on both sides of the link assembly. Lower the hold down shoe, ensure light contact with the bushings.
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    Illustration 65	g03747898

27. Position the extruder assembly tooling between the anvil assembly and the track pin.

    Refer to Table 14 for the correct extruder assembly.

28. Slowly move the cylinder toward the extruder until the anvil contacts the back of the extruder.

29. Pivot the extruder assembly tooling in place to make sure that the extruder is properly aligned. Care must be taken to avoid misalignment.

30. Repeat Steps 25 through 29 for the other side of the track joint.
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    Illustration 66	g03747900

31. Press the retaining rings into the grooves on the track pin.

    Refer to Table 12 for the maximum allowed forces.

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

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    Illustration 67	g03747921

32. Remove the extruder assemblies from the track press.

    Tap the extruder with a hammer if the extruder sticks to the track joint.

    Replace the extruder if the extruder is damaged.

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    Illustration 68	g03747995

33. Check the retaining rings for proper assembly.
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    Illustration 69	g03748003

34. Check joints for flexibility / articulation.

    Flexibility is the ability for movement, from its own weight.

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

35. Check for end play generation for assembled joints that display flexibility.

    Reference steps 44 through 49 for proper end play measuring procedures.

36. Unlock the assembled joints that display no flexibility.

    Reference steps 37 through 43 for unlocking procedures.

    After unlocking the joint, reference steps 44 through 49 for proper end play measuring procedures.

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    Illustration 70	g03748006

37. Position the pin unlocking tool between the anvil assembly and the track pin.

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

39. Ensure that tooling is properly aligned. Care must be taken to avoid misalignment.

40. Repeat Steps 37 through 39 for the other side of the track joint.
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    Illustration 71	g03748008

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    NOTICE
    Unlocking forces higher than 1334 kN (150.0 ton) can cause the hardened sleeve bearing in D11 track to fracture.

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    NOTICE
    The need to continually adjust this force indicates problems with component characteristics and / or assembly procedures.

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

    Maximum allowable forces for unlocking the track joints are listed in Table 12.

    This force is a reference value and may be adjusted to meet end play requirements.

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

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

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

43. Remove the pin unlocking tooling from the track press.
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    Illustration 72	g03745119

44. Check the end play of the track links.

45. 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 72.

46. Maintain the applied force between the track links . Adjust the point of reference to 0.0 mm (0.00 inch) on Tooling (K) Dial Indicator Gp. Refer to arrow (2) in Illustration 72.

47. A display of 0.0 mm (0.00 inch) for the Dial Indicator point of reference must be maintained prior to the removal of the applied force of the pry bar.

48. 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 72.

49. Maintain the applied force between the track links. The Dial Indicator point of reference will display total end play generation. Refer to arrow (4) in Illustration 72.

50. Acceptable end play is 0.03 mm to 0.20 mm (0.001 inch to 0.008 inch).

51. Repeat Steps 45 through 49 for the remaining track joints until the track is assembled.
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    Illustration 73	g03748003

52. All links assembly joints must have flexibility, even with measurable end play of 0.0 mm (0.00 inch). Flexibility is the ability for movement, from it's own weight.

Lubrication of the Track Joints

The 5130 and 5110 have the Grease Lubricated Track. Lubrication of the track joints should have been done during assembly of the track with the specified grease. This section of the service does not need to be performed.

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NOTICE
Before track joints can be filled with oil, the joint must be checked for leaks. The following methods are recommended to ensure a proper seal before lubrication.

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Illustration 74	g03745125
Tooling (L) 170-5664 Test and Fill Cart

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Illustration 75	g03745129

1. Use Tooling (L) 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 reseals. Refer to Table 15.

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

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   Table 15

   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 76	g03780921

2. Use Tooling (H) 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 inch to 0.20 inch) 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 (L) 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".

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Illustration 77	g03780937

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 the 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 78	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 needs to 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 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 master track links. The high temperatures can cause damage to 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 cause damage to 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 79	g03748019
   Caterpillar Track Torque Wrench

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   Illustration 80	g03748022
   443-7801 Pneumatic Wrench Gp

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   Illustration 81	g03748113
   385-7874 Hydraulic Torque Wrench.

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 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 (P) 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 82	g03748114

6. Turn the switch on the side of the Caterpillar Track Torque Wrench to the 120° position.
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   Illustration 83	g03748116

7. Press the "Set Pretorque" button. Enter the correct preliminary torque value into the display panel. Press "Enter". Refer to Table 16 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 84	g01234180

9. Follow the correct pattern in Illustration 84 to torque the bolts.

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

Table 16

Torque Specifications for the Track Shoe Bolts
-				Method for the 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 Track Bolt - D11T D11R D11N	1 3/8"-12	8T-9174	8T-9175	1500 ± 150 N·m (1106.3 ± 110.6 lb ft)	-	120°
Five Tooth Master Bolts - D11T D11R D11N	1 3/8"-12	8T-9174	8T-9175	1500 ± 150 N·m (1106.3 ± 110.6 lb ft)	180°	-
Single Tooth Master Bolts - D11T D11R D11N	M36-4	136-5189 Socket - 55mm hex	-	1500 ± 150 N·m (1106.3 ± 110.6 lb ft)	90°+-5°	-
Full Links Standard Track Bolt - D10T D10R D10N D10	1 1/8"-12	1U-8586	1U-8798	870 ± 90 N·m (640.0 ± 65.0 lb ft)	-	120°
Five Tooth Master Bolts - D10T D10R D10N D10	1 1/8"-12	1U-8586	1U-8798	870 ± 90 N·m (640.0 ± 65.0 lb ft)	120°	-
Single Tooth Master Bolts - D10T D10R D10N D10	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 589	1"-14	9S-6371(1)	5P-3581(1)	870 ± 90 N·m (640.0 ± 65.0 lb ft)	120°	120°
D8T D8R D8N 587T 587R 583T 583R 578 PL87 PL83	7/8"-14	9S-6372(1)	5P-3580(1)	650 ± 70 N·m (480.0 ± 50.0 lb ft)	120°	120°
5130 5130B	1 3/8"-12	8T-9174	8T-9175	1500 ± 150 N·m (1100.0 ± 110.0 lb ft)	--	120°
5110 5110B	1 1/8"-12	1U-8586	1U-8798	870 ± 90 N·m (640.0 ± 65.0 lb ft)	--	120°

(1)	Use with 9S-4026 Adaptor and 9S-4027 Extension