TT5000 to TT7000 Torque Turn Wrench Conversion{0374, 0599, 0602, 0677, 79NY} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

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Think Safety

European Union Compliant, CE marked

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.

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

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

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

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

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

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

Literature Information

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

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

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Crushing hazard (foot)

Crushing hazard (hand)

Pinch point

Fire hazard

Electrical Shock - Hazard

Fire hazard

General Information

Introduction

This Tool Operating Manual provides the procedure for converting a TT5000 Torque Turn Wrench to a TT7000 Torque Turn Wrench by upgrading the gearbox and electrical control unit.

The conversion kit for the TT7000 Torque Turn Wrench includes a new gear box, hydraulic hoses, and an electrical control box with a programmable logic controller (PLC).

Refer to Operators Manual, NEHS0703, "TT7000 Torque Turn Wrench" for additional information on how to operate a TT7000 Torque Turn Wrench.

These illustrations show a TT5000 Torque Turn Wrench in the original condition.

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TT5000 Torque Turn Wrench

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Close-Up of TT5000 Gearbox

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

Disassembly

1. Remove any dirt and debris from the TT5000 Torque Turn Wrench before disassembling any components or disconnecting hoses.

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Extend Arbor To A Solid Surface

2. Extend the arbor of the TT5000 Torque Turn Wrench until lit makes contact with a solid surface. The arbor helps support the gear box and prevents the gear box from dropping as it is disconnected from the main frame.

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NOTICE
Attach a lifting device to the gearbox before disconnecting from the main frame to avoid damaging the gearbox.

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Attach Lifting Device To Gearbox

3. Attach a lifting device to the gearbox before disconnecting from the main frame.

4. Remove the electrical control box and wiring.

   1. Disconnect the electrical supply to the TT5000 Torque Turn Wrench.

   2. Remove all wires from the electrical control box.
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   Disconnect Wiring From the Operator Handle (1) And Control Box (2)

   3. Disconnect wiring from the operator handle (1) and control box (2) .

   4. Pull the electrical control box and wiring from the TT5000 Torque Turn Wrench.

5. Disconnect hydraulic lines.
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   Remove Oil Lines (Indicated By Arrows)

   1. Plug the hydraulic lines after being disconnected from the control valves to prevent oil spills and/or movement of wrench spindle.
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   Remove Two Hydraulic Adapters (Indicated By Arrows) From Manifold Valve Body

   2. Disconnect all hoses from the manifold and remove two hydraulic adapters from the top of the manifold valve body.
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   Remove Two Hydraulic Adapters From Bottom Of Manifold Valve Body

   3. Remove two hydraulic adapters from the bottom of the manifold valve body.

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Remove Eight Nuts Retaining Gearbox To Main Frame

6. Remove eight retaining nuts from the gearbox and remove the gearbox.

7. Remove mounting adapter.
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   Remove Mounting Adapter (1) Mounting Adapter (2) Washer (3) Bolt

   1. Remove bolt (3) and washer (2) from the top and bottom of the mounting bracket to remove mounting adapter (1) .

   2. Drive the attachment pin out the bottom of the mounting bracket.

Assembly

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Attach Lifting Device

1. Attach a lifting device to the TT7000 Torque Turn Wrench gearbox and parallel arm assembly.

2. Install the mounting adapter.
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   Install Mounting Pin

   1. Align the new parallel arm assembly with the holes in the mounting bracket.

   2. Insert the mounting pin through the mounting bracket.

   3. Install a washer and bolt in the top and bottom of the mounting pin.

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Install New Couplings (Indicated By Arrows) In Manifold Valve Body

3. Install new hydraulic couplings on top of the manifold valve body.

4. Attach new hydraulic hoses. Refer to the Section ""Hydraulic Schematic" " for installation of the hydraulic hoses.
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   Attach A Hydraulic Hose To The Top Of The Hydraulic Cylinder

   1. Attach a hydraulic hose from the top of the manifold to the top of the parallel arm hydraulic cylinder.
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   Attach Second Hydraulic Hose To Bottom Of Hydraulic Cylinder

   2. Attach a second hydraulic hose from the top of the manifold valve body to the bottom of the parallel arm hydraulic cylinder.
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   Connect Three Hydraulic Hoses From Motor To Manifold Valve Body

   3. Attach three hydraulic hoses from the hydraulic motor to the top of the manifold valve body.

   4. Connect a hose from the side of the manifold valve body to the top of the hydraulic cylinder. Route this hose over the hydraulic motor.

5. Install a new electrical control box.

   1. Attach a new electrical control box to the TT7000 Torque Turn Wrench.

   2. Make appropriate wiring connections. Refer to the Section ""Electrical Schematic" " in this manual for additional information.

   3. Connect the TT7000 Torque Turn Wrench to the proper electrical supply

Hydraulic Schematic

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Electrical Schematic

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Electrical Diagrams

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Note: Operate the torque turn wrench with the Run/Shunt switch in the shunt mode. Change this switch to "Run" to check the center of the transducer.