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SEBF8516-04 NEHS0804 September 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and Reconditioning Stations NEHS0804 - Track Press Contact Tooling Manual

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Page 1: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 NEHS0804

September 2004

Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and Reconditioning Stations NEHS0804 - Track Press Contact Tooling Manual

Page 2: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

This file has been compiled to allow a Tooling list to be listed on the Undercarriage Information System. This file combines the contents of SEBF8516, “Equipment and Tools for Undercarriage Rebuilding and Reconditioning Stations” and NEHS0804, “Tool Operating Manual” for contact tooling offered by Caterpillar.

©2004 Caterpillar All Rights Reserved Printed in U.S.A.

Page 3: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 August 2004

SMCS Code: 4150

UNDERCARRIAGE RECONDITIONING BULLETIN Equipment and Tools for Undercarriage Rebuilding and Reconditioning Stations

Page 4: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 2

Table of Contents Introduction .............................................................2 Summary ................................................................2 References .............................................................2 Tooling and Equipment ...........................................3

Track Press Work Station....................................3 Non-PPR Sealed and Lubricated Track ..........4 Positive Pin Retention (PPR) Tooling..............4

Test and Fill Machine ..........................................5 Torque Turn Wrench ...........................................6 Idler/Roller Welding Equipment...........................7 Bearing Cup Removal Tooling ............................8 Bearing Cup Installation Tooling .........................9 Blast Cabinet .......................................................9 Roll Burnish .......................................................10 Hone..................................................................10 Roller/Idler Press Work Station .........................11 Roller Bushing Installation Tooling ....................11 Duo-Cone Seal Installation Tooling...................12

Idlers with Inverted Duo Cone Seals .............12 Rollers with Inverted Duo Cone Seals...........13 Idlers with Conventional Duo-Cone Seals .....14 Rollers with Conventional Duo-Cone Seals...15 Snap Ring Rollers..........................................15 Oval Track Rollers .........................................16 Excavator Track Rollers ................................16 Excavator Carrier Rollers ..............................16 Excavator Idlers.............................................16

Table 1

Summary of Revisions Page Description

All Revised the format and information throughout this bulletin.

Table 2

Machine Arrangement All Revised Format

Introduction This guideline enables dealers and their customers to benefit from cost reductions made possible through an established parts reusability and salvage program. Every effort has been made to provide the most current and relevant information known to Caterpillar Inc. Since the Company makes ongoing changes and improvements to its products, this guideline must be used with the latest technical information available from Caterpillar to ensure such changes and improvements are incorporated where applicable. For questions or additional information concerning this guideline, contact Caterpillar Service Support Division, Dealer Support (309) 675-6304. Summary In order to achieve optimum shop efficiency, each workstation should be equipped with all of the necessary tools. The following examples should be considered basic tools. Additional tools may be required in order to fill individual dealer needs. References Table 3

References Media Number Title

NENG2500 Tools and Shop Products Guide PECP3003 Parts Sales Kit – Undercarriage SERF8890 Undercarriage Service Guide CD ROM

Page 5: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 3

Tooling and Equipment Track Press Work Station

Illustration 1 Track Press Work Station

In addition to a Track Press that has a minimum capacity of 2650kN (300 tons), the following tools are required. Note: this Track Press is also available as 3300kN (375 tons).

Table 4

Required Tools Part Number Description

5P-3010 Deburring Tool FT1238 Vacuum Tank Assembly 5P-1725 Stopper Installation Tool 5P-7392 Stopper Installation Tool 6V-0136 Stopper Installation Tool 5P-7419 Plug Installer 1U-7593 Pry Bar FT1953 Gauge (Pin Projection) 1U-9979 Acid Brush 222-3074 Die Grinder 4C-9927 ½ inch Drill 1U-5617 ½ inch Drill Bit

-- Contact Tooling 1 -- Nut Wrenches 3 -- Track Bolt Sockets 3 -- Track Shoe Lifter 2 -- Conveyor (50 feet) 2 -- Torque Turn Wrench 3

170-5664 Test and Fill Machine

1 See NENG2500 for complete list. 2 Contact Dealer Service Tools Division for more information, (309) 636-1791. 3 Refer to the Torque Turn Wrench section within this document.

Page 6: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 4

Non-PPR Sealed and Lubricated Track Table 5

Seal Installers Machine Part Number

D4C, D3C 165-2571 D4E, 943 165-2573 D5C, D4H 4C-8615 D5M, D4HD 133-1532 D5 165-2575 D6M, D5H, D5HD 4C-8616 D6D, 963, 955 133-1533 D6R, D6H, D6HD 4C-8617 D7G, 977, 973, 571, 572 133-1534 D7H, D7R, D7HD 4C-8619 D8K, 983 4C-8618 D8R, D8N, D8L, 578 4C-8619 D9H, D9G 4C-8620 D9L, D9N, D9R, 589 4C-8621 D10, D10N, D10R, 591 4C-8622 D11R, D11N 4C-8623 Table 6

Bushing End Groove Gauge Machine Part Number

D4C, D3C 165-2572 D4E, 943 165-2574 D5C, D4H 4C-8602 D5M, D4HD 133-1535 D5 165-2576 D6M, D5H-HD 133-1536 D5H 4C-8603 D6D, 963, 955 133-1537 D6R, D6H-HD 133-1538 D6H 4C-8604 D7G, 977, 973, 571, 572 133-1539 D7H 4C-8605 D7H, D7R, D7HD 4C-8619 D8K, 983 4C-8606 D8R, D8N, D8L, 578 4C-8607 D9H, D9G 4C-8608 D9L, D9N, D9R, 589 4C-8621 D10, D10N, D10R, 591 4C-8622 D11R, D11N 4C-8623

Positive Pin Retention (PPR) Tooling

Illustration 2 Track Press using PPR Tooling

1. Handle Assembly 2. Unlocking Tool Anvil 3. Extruder Assembly

Illustration 3 Track Press using PPR unlocking tool

1. Handle Assembly 2. Unlocking Tool

Page 7: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 5

Table 7

PPR Track Press Tooling Machine Part Number Description

All 8T-3216 Anvil Assembly All 157-854 Unlocking Tool All 1U-6257 Stud All 8T-3211 Handle Assembly

D8N, 578 142-5896 Extruder Assembly D9L, D9N, 589 141-2395 Extruder Assembly

D10, D10N, 591 142-5894 Extruder Assembly D11N 1U-5746 Extruder Assembly

-- 9U-7829 Extruder Base 1

1 Only required for D11

Test and Fill Machine

Illustration 4

Table 8

170-5664 Test and Fill Machine Quantity Part Number Description

1 183-9302 Test Tube 1 183-9303 Test Tube 1 216-2856 Test Tube -- -- Nitrogen -- -- Track Oil 1 4C-8854 1 ¼ inch Combo

Regulator/Filter 1 4C-8855 1 3/8 inch Combo

Regulator/Filter 1 4C-7272 1 ½ inch Combo

Regulator/Filter 1 4C-7273 1 ¾ inch Combo

Regulator/Filter 1 9U-6038 Mounting Kit

1 Purchase the correct size Combo unit for your facility.

Page 8: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 6

Torque Turn Wrench

Illustration 5

Table 9

Nut Wrenches Part Number Size

4C-8207 1.51 and 1.32 inch 4C-8208 1.27 and 1.19 inch 4C-8209 1.15 and 1.03 inch 4C-8210 1.00 and 0.89 inch 188-0956 32 and 42 mm 188-0959 25 and 30 mm

Table 10

Impact Sockets Size Part Number Description Drive

19 mm 1U-7626 Tapered 1 inch ¾ inch 221-4352 Thin Wall ¾ inch

27/32 inch 6V-7929 Thin Wall 1 inch 22 mm 1U-7627 Tapered 1 inch 7/8 inch 221-4353 Thin Wall ¾ inch 7/8 inch 9S-6375 Thin Wall 1 inch

29/32 inch 6V-7928 Thin Wall 1 inch 29/32 inch 6V-2002 Standard 1 inch 15/16 inch 221-4354 Thin Wall ¾ inch 15/16 inch 9S-6374 Thin Wall 1 inch 15/16 inch 9S-6370 Standard 1 inch

24 mm 1U-7628 Tapered 1 inch 1 1/16 inch 221-4355 Thin Wall ¾ inch

27 mm 1U-7629 Tapered 1 inch 1 3/32 inch 5P-3579 Standard 1 inch 1 1/8 inch 9S-6369 Thin Wall 1 inch 1 1/8 inch 9S-6373 Standard 1 inch

30 mm 1U-7630 Tapered 1 inch 1 3/16 inch 221-4356 Thin Wall ¾ inch

1 ¼ inch 221-4357 Thin Wall ¾ inch 32 mm 1U-7631 Tapered 1 inch

1 9/32 inch 5P-3580 Standard 1 inch 1 5/16 inch 9S-6372 Standard 1 inch 1 15/32 inch 5P-3581 Standard 1 inch

1 ½ inch 9S-6371 Standard 1 inch 1 5/8 inch 1U-8798 Tapered 1 ½ inch

41 mm 1U-8789 Tapered 1 ½ inch 1 11/16 inch 1U-8586 Tapered 1 ½ inch

2 inch 8T-9175 Standard 1 ½ inch 2 1/16 inch 8T-9174 Standard 1 ½ inch

Page 9: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 7

Idler/Roller Welding Equipment

Illustration 6 Idler/Roller Welder Work Station

Table 11

Required Tools Part Number Description

-- Idler/Roller Welder 6V-6193 Diagonal Cutter Pliers 4S-9405 Caliper (12in) 5P-3920 Rule (12in) 6V-9410 Gauge Group 1U-9915 Wire Brush

-- Weld Chipping Hammer 223-1155 Air Scaler 164-3310 Infrared Thermometer 1U-6469 Cutting Torch – Oxy-Acetylene FT-1412 Wear Gauge FT-1431 Fabricated Roller Rack FT-1738 ¾-16 Stud 6V-7935 Screwdriver 8H-8577 Hammer, Ball Peen 4C-6150 Pneumatic Scribing Tool 1P-3036 ¾-16 Tap 1P-3048 Tap Wrench 5M-2080 Lubricator Nozzle 5P-1720 Seal Pick 222-3051 ½ inch Impact Wrench 2P-8312 Pliers – Retaining Ring 7H-1680 Lubrication Pump

Table 12

Additional Tooling for Water Cooled Work Stations Part Number Description

6V-0092 Plug Socket 6V-6140 Cooling Adapter 6V-6163 Cooling Adapter 1U-5530 Cooling Adapter 5V-8610 Quick Disconnect – (Female) 5V-8611 Quick Disconnect – (Male) 213-6930 14 mm Impact Socket 5P-6587 Lock Removal Socket 5P-6588 Lock Removal Socket 5P-6589 Lock Removal Socket 8H-8582 Vise Grip 1F-1161 Cold Chisel 8T-0447 Caliper, Dial 5P-7419 Plug, Install 1U-6396 O-Ring Compound 136-1452 Pliers, Snap Ring 2P-8312 Pliers, Retaining Ring FT0578 Bushing Alignment Tool

170-5664 Test and Fill Machine 222-3051 ½ inch Impact Wrench FT1535 Idler Bearing Puller 4C-6150 Pneumatic Scribing Tool

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SEBF8516-04 8

Bearing Cup Removal Tooling The following tools are necessary to service the carrier rollers. The tools listed below are part of 1P-0510 Bearing and Driver Group and 1P-0520 Bearing and Driver Group. Table 13

Machine Quantity Part Number Description D9 1 1P-0508 Plate D8 1 1P-0513 Plate D7, D6 1 1P-0493 Plate D5 1 1P-0494 Plate D4, D3 1 1P-0487 Plate All 5 4L-7124 Bolt All 5 1P-0529 Handle

Some of the tools require modification before use. The necessary modification dimensions are given in the following illustrations.

Illustration 7 Dimension to modify the 1P494 Plate

Illustration 8 Dimensions to modify the 1P487 Plate

Illustration 9 Dimension to modify the 1P493, 1P508 and 1P513 Plates

Page 11: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 9

Bearing Cup Installation Tooling

Illustration 10 Typical bearing cap installation tools

In addition to the tools already mentioned, the following tools are required: Table 14

Model Part Number Description 1P-0515 Plate 1P-0463 Plate 1P-0501 Plate 8B-2377 Bolt

D9

1P-0529 Handle 1P-0518 Plate 1P-0463 Plate 1P-0505 Plate 8B-2377 Bolt

D8

1P-0529 Handle 1P-0498 Plate 1P-0463 Plate 1P-0489 Plate 8B-2377 Bolt

D7, D6, D5

1P-0529 Handle 1P-0493 Plate 1P-0463 Plate 1P-0485 Plate 8B-2377 Bolt

D4, D3

1P-0529 Handle

Blast Cabinet

Illustration 11 Blast Cabinet

The blast cabinet is utilized when conditioning the shafts for the idlers with inverted duo-cone seals. For more information, refer to SEBF8597, “Reconditioning Procedure for Seal Ramps on Inverted Style Idler and Roller Shafts.”

Page 12: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SEBF8516-04 10

Roll Burnish

Illustration 12 Roll Burnish tooling for conditioning the bearing ID

The roll burnishing procedure is used when conditioning either the idler or the roller bearings. The conditioning of the bearings is necessary for the correct alignment of the shaft and the correct size and surface finish that is required. For more information, refer to SEBF8586, “Removal, Installation, and Conditioning of Idler Bearings and Track Roller Bearings.” Table 15

Roll-Burnish Process Hardware ELLIOTT Ref. No. Item

-- Radial Drill 5613-201-11410 D11 Burnish Tool (ø6.408 in) 5612-201-11344 D10 Burnish Tool (ø5.385 in) 5611-201-11320 D9 Burnish Tool (ø5.010 in) 5611-201-11272 D7/D8 Burnish Tool (ø4.254 in) 5408-211-11160 D5/D6 Burnish Tool (ø2.510 in)

Hone

Illustration 13 Honing Tooling

The honing procedure is used when conditioning either the idler or the roller bearings. The conditioning of the bearings is necessary for the correct alignment of the shaft and the correct size and surface finish that is required. For more information, refer to SEBF8586, “Removal, Installation, and Conditioning of Idler Bearings and Track Roller Bearings.” Table 16

Hone Process Hardware Part Number Description

FT-1688 Idler Stand 9U-6400 Drill FT-2683 Universal Pilot 6V-6094 Hone Body 177-9708 Stone Set (D5-D10) 177-9709 Stone Set (D11) 5P-8591 Holder

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SEBF8516-04 11

Roller/Idler Press Work Station

Illustration 14 Roller Press Workstation

In addition to a Roller/Idler press that has a minimum capacity of 445kN (50 tons), the following tools are required: Table 17

Part Number Description 6V-0092 Plug Socket 6V-7935 Screwdriver 8H-8577 Hammer – Ball Peen 214-6501 ½ inch Impact Socket 214-6503 9/16 inch Impact Socket 214-6507 ¾ inch Impact Socket

Roller Bushing Installation Tooling Table 18

Machine Part Number

D5M, D5C, D4H 126-4045, 166-5902

D6M, D5H, 953 123-6692 D6R, D6H, 963 123-6693 D7R, D7H, 973 123-6699

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SEBF8516-04 12

Duo-Cone Seal Installation Tooling Idlers with Inverted Duo Cone Seals Table 19

Duo-Cone Seal Installation Tooling Machine Part Number Description

8T-0945 Alignment Sleeve 8T-0943 Retainer Seal Installer 8T-0943 Shaft Seal Installer

D4H

FT1994 Spin Socket 8T-0945 Alignment Sleeve 8T-0941 Retainer Seal Installer 8T-0941 Shaft Seal Installer

D5H

FT1994 Spin Socket D5M, D6M 179-7208 Seal Installer Assembly

8T-0822 Alignment Sleeve 8T-0939 Retainer Seal Installer 8T-0939 Shaft Seal Installer

D6H

FT1911 Spin Socket 8T-0822 Alignment Sleeve 8T-0939 Retainer Seal Installer 8T-0939 Shaft Seal Installer

D7H

FT1911 Spin Socket 8T-0823 Alignment Sleeve 8T-0829 Retainer Seal Installer 8T-0929 Shaft Seal Installer

D8L

FT1910 Spin Socket 8T-0823 Alignment Sleeve 8T-0829 Retainer Seal Installer 8T-0829 Shaft Seal Installer

D8N

FT1910 Spin Socket 8T-0824 Alignment Sleeve 8T-0830 Retainer Seal Installer 8T-0830 Shaft Seal Installer

D9L

1U-9398 Spin Socket 8T-0823 Alignment Sleeve 8T-7640 Retainer Seal Installer 8T-7640 Shaft Seal Installer

D9N

FT1910 Spin Socket 8T-0825 Alignment Sleeve 8T-0826 Retainer Seal Installer 8T-0826 Shaft Seal Installer

D10

1U-9399 Spin Socket

Table 19 (continued)

Duo-Cone Seal Installation Tooling Machine Part Number Description

8T-0824 Alignment Sleeve 8T-0830 Retainer Seal Installer 8T-0830 Shaft Seal Installer

D10N

FT1909 Spin Socket 8T-0825 Alignment Sleeve 8T-7639 Retainer Seal Installer 8T-7639 Shaft Seal Installer

D11N

1U-9399 Spin Socket

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Rollers with Inverted Duo Cone Seals Table 20

Duo-Cone Seal Installation Tooling Machine Part Number Description

8T-0945 Alignment Sleeve 8T-0942 Retainer Seal Installer 8T-0942 Shaft Seal Installer

D4H

FT1994 Spin Socket 8T-0945 Alignment Sleeve 8T-0942 Retainer Seal Installer 8T-0942 Shaft Seal Installer

D5H

FT1994 Spin Socket 8T-0822 Alignment Sleeve 8T-0940 Retainer Seal Installer 8T-0940 Shaft Seal Installer

D6H

FT1911 Spin Socket 8T-0822 Alignment Sleeve 8T-0939 Retainer Seal Installer 8T-0939 Shaft Seal Installer

D7H

FT1911 Spin Socket 8T-0822 Alignment Sleeve 8T-0828 Retainer Seal Installer 8T-0828 Shaft Seal Installer

D8L

FT1994 Spin Socket 8T-0822 Alignment Sleeve 8T-0828 Retainer Seal Installer 8T-0828 Shaft Seal Installer

D8N

FT1911 Spin Socket 8T-0823 Alignment Sleeve 8T-0829 Retainer Seal Installer 8T-0829 Shaft Seal Installer

D9L

FT1910 Spin Socket

Table 20 (continued)

Duo-Cone Seal Installation Tooling Machine Part Number Description

8T-0822 Alignment Sleeve 8T-7641 Retainer Seal Installer 8T-7641 Shaft Seal Installer

D9N

FT1911 Spin Socket 8T-0824 Alignment Sleeve 8T-0827 Retainer Seal Installer 8T-0827 Shaft Seal Installer

D10

1U-9398 Spin Socket 8T-0823 Alignment Sleeve 8T-0829 Retainer Seal Installer 8T-0829 Shaft Seal Installer

D10N

FT1910 Spin Socket 8T-0824 Alignment Sleeve 8T-0827 Retainer Seal Installer 8T-0827 Shaft Seal Installer

D11N

1U-9398 Spin Socket 8T-0945 Alignment Sleeve 8T-0942 Retainer Seal Installer 8T-0942 Shaft Seal Installer

943

FT1994 Spin Socket 8T-0945 Alignment Sleeve 8T-0942 Retainer Seal Installer 8T-0942 Shaft Seal Installer

953

FT1994 Spin Socket 8T-0822 Alignment Sleeve 8T-0940 Retainer Seal Installer 8T-0940 Shaft Seal Installer

963

FT1911 Spin Socket 8T-0822 Alignment Sleeve 8T-0939 Retainer Seal Installer 8T-0939 Shaft Seal Installer

973

FT1911 Spin Socket

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Idlers with Conventional Duo-Cone Seals Table 21

Duo-Cone Seal Installation Tooling Machine Part Number Description

179-7208 Seal Installer 201-1582 End Collar Tooling 561

FT1994 Spin Socket 136-6813 Seal Installer 170-5412 End Collar Tooling 527

FT1911 Spin Socket 136-6813 Seal Installer 170-5411 End Collar Tooling 572

FT1911 Spin Socket 137-9443 Seal Installer 170-5408 End Collar Tooling 578 1U-9398, FT1910

Spin Socket

137-9443 Seal Installer 170-5408 End Collar Tooling 583R, 583X 1U-9398, FT1910

Spin Socket

179-7208 Seal Installer 201-1582 End Collar Tooling D4H

FT1994 Spin Socket 179-7208 Seal Installer 201-1581 End Collar Tooling D5H

FT1994 Spin Socket 179-7208 Seal Installer 201-1582 End Collar Tooling D5M

FT1994 Spin Socket 179-7208 Seal Installer 201-1581 End Collar Tooling D6M

FT1994 Spin Socket 136-6813 Seal Installer 170-5412 End Collar Tooling D6H

FT1911 Spin Socket 136-6813 Seal Installer 170-5412 End Collar Tooling D6R

FT1911 Spin Socket 136-6813 Seal Installer 170-5411 End Collar Tooling D7H, D7R

FT1911 Spin Socket

Table 21 (continued)

Duo-Cone Seal Installation Tooling Machine Part Number Description

137-9443 Seal Installer 170-5408, 170-5409

End Collar Tooling D8L

1U-9398, FT1910

Spin Socket

137-9443 Seal Installer 170-5408 End Collar Tooling D8N 1U-9398, FT1911

Spin Socket

137-9443 Seal Installer 170-5408 End Collar Tooling D8R 1U-9398, FT1910

Spin Socket

137-9443 Seal Installer 170-5408, 170-5409

End Collar Tooling D9N

1U-9398, FT1910

Spin Socket

137-9443 Seal Installer 170-5409 End Collar Tooling D9R 1U-9398, FT1910

Spin Socket

129-1340 Seal Installer 170-5406 End Collar Tooling D9L 1U-9399, FT1909

Spin Socket

129-1340 Seal Installer 170-5406 End Collar Tooling D10N 1U-9399, FT1909

Spin Socket

129-1340 Seal Installer 170-5406 End Collar Tooling D10R 1U-9399, FT1909

Spin Socket

159-9843 Seal Installer 170-5405 End Collar Tooling D11N, D11R 1U-9399, FT1909

Spin Socket

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SEBF8516-04 15

Rollers with Conventional Duo-Cone Seals Table 22

Duo-Cone Seal Installation Tooling Machine Part Number Description

136-6813 Seal Installer 170-5407 End Collar Tooling 578

FT1911 Spin Socket 136-6813 Seal Installer 170-5407 End Collar Tooling 583R, 583X

FT1911 Spin Socket 136-6813 Seal Installer 170-5407, 170-5410

End Collar Tooling D8L

FT1911 Spin Socket 136-6813 Seal Installer 170-5407 End Collar Tooling D8N

FT1911 Spin Socket 136-6813 Seal Installer 170-5407 End Collar Tooling D8R

FT1911 Spin Socket 136-6813 Seal Installer 170-5407, 170-5410

End Collar Tooling D9N

FT1911 Spin Socket 136-6813 Seal Installer 170-5410 End Collar Tooling D9R

FT1911 Spin Socket 137-9443 Seal Installer 170-5408 End Collar Tooling D9L

FT1910 Spin Socket 137-9443 Seal Installer 170-5408 End Collar Tooling D10N

FT1910 Spin Socket 137-9443 Seal Installer 170-5408 End Collar Tooling D10R

FT1910 Spin Socket 129-1340 Seal Installer 170-5404 End Collar Tooling D11N, D11R

1U-9399 Spin Socket

Snap Ring Rollers Table 23

Duo-Cone Seal Installation Tooling Machine Part Number

D7R, D7H D6R, D6H 983 973C, 973 963C, 963B, 963 572R 527

1U-8840

D6M D5M, D5H D4H 953C, 953B, 953 943 939C, 939 517

1U-8843

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SEBF8516-04 16

Oval Track Rollers Table 24

Duo-Cone Seal Installation Tooling Machine Part Number

D6R, D6M, D6H, D6D, D6C D5M, D5H, D5B, D5 D4H, D4D D3 963 961 955K, 955L, 955 953 951C, 951B, 951 943 941B, 941 939 931 561M, 561C 527 235 225 219 215SA, 215B, 215

1U-8843

D9H, D9G 594H, 594

1U-8842

D8K, D8H 583K, 583H

1U-8841

D7R, D7H, D7G, D7F D6D, D6C 983B, 983 977L, 977K, 977 973 572 245 235

1U-8840

D6R, D6M, D6H, D6D, D6C D5M, D5H, D5B, D5

1U-8843

Excavator Track Rollers Table 25

Duo-Cone Seal Installation Tooling Machine Part Number

307 123-3800 311, 311B, 312, 312B 1U-6144 330 9U-7537 Excavator Carrier Rollers Table 26

Duo-Cone Seal Installation Tooling Machine Part Number

307 123-2999 311, 311B, 312, 312B 1U-6145 315, 320, 320B, 322, 322B 9U-5985 Excavator Idlers Table 27

Duo-Cone Seal Installation Tooling Machine Part Number

307 123-3801 325 9U-6886 375 9U-7538

Page 19: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

©2004 Caterpillar All Rights Reserved Printed in U.S.A.

Page 20: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

SMCS: 0729, 4169

Caterpillar Track Press

Contact Tooling

R

TOOLOPERATINGMANUAL

NEHS0804-01July 2001

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ContentsSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Conversion Groups for Contact Tooling . . . . 5Caterpillar Tools on CompetitiveTrack Presses . . . . . . . . . . . . . . . . . . . . . . 5Competitive Tools on CaterpillarTrack Presses . . . . . . . . . . . . . . . . . . . . . . 5

Questions and Answers . . . . . . . . . . . . . . . . 5Setup of Contact Tooling . . . . . . . . . . . . . . . 8Caterpillar Plunger-Style Tooling. . . . . . . . . 9Centurion Plunger-Style Tooling . . . . . . . . . 9Wolff Plunger-Style Tooling . . . . . . . . . . . . 10OTC Plunger-Style Tooling . . . . . . . . . . . . 10

Tightening Saddles, Spacer Plates,and Wedge Bars . . . . . . . . . . . . . . . . . . . 11

Terminology and Assembly of Contact Tooling . . . . . . . . . . . . . . . . . . . . 12

First and Second AssemblySide Concept. . . . . . . . . . . . . . . . . . . . . . 13

Contact Tooling . . . . . . . . . . . . . . . . . . . . . 136.125 Inch Pitch. . . . . . . . . . . . . . . . . . . . 136.75 Inch Pitch. . . . . . . . . . . . . . . . . . . . . 146.91 Inch Pitch. . . . . . . . . . . . . . . . . . . . . 157.5 Inch Pitch. . . . . . . . . . . . . . . . . . . . . . 158.00 Inch Pitch. . . . . . . . . . . . . . . . . . . . . 168.50 Inch Pitch. . . . . . . . . . . . . . . . . . . . . 179.00 Inch Pitch. . . . . . . . . . . . . . . . . . . . . 189.45 Inch Pitch. . . . . . . . . . . . . . . . . . . . . 1810.25 Inch Pitch. . . . . . . . . . . . . . . . . . . . 1912.50 Inch Pitch. . . . . . . . . . . . . . . . . . . . 19

Tooling Part Numbers by Model . . . . . . . . . 20

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Safety

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ppiinncchhiinngg aanndd ccrruusshhiinngg.. WWhheenn ooppeerraattiinngg tthheettrraacckk sshhooee ppaadd lliifftteerr,, kkeeeepp hhaannddss aawwaayy ffrroomm tthheeccoonnvveeyyoorr rraaiillss.. TThhee ttrraacckk sshhooee ssuuppppoorrttssttrruuccttuurree ppaasssseess bbeettwweeeenn tthhee oouutteerr rraaiillss ooff tthheeccoonnvveeyyoorr..

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ddeebbrriiss bbeeffoorree aappppllyyiinngg pprreessssuurree oorr ssttrriikkiinngg aannyyoobbjjeecctt..

3

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WWhheenn uussiinnggccoonnttaacctt ttoooolliinngg iinnaa ttrraacckk pprreessss,,mmaakkee ssuurree aallll

pprrootteeccttiivvee gguuaarrddss aanndd ccoovveerrss aarree iinn ppllaaccee aannddsseeccuurreedd bbeeffoorree ooppeerraattiinngg aannyy eeqquuiippmmeenntt..

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aanndd cclleeaann uupp aallll ssppiilllleedd fflluuiiddss iimmmmeeddiiaatteellyy..

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Conversion Groups forContact Tooling

Caterpillar Tools on CompetitiveTrack PressesThe following chart illustrates the conversiongroups needed to use the Caterpillar plunger-style tooling on competitive brandtrack presses. It should be noted that theCaterpillar saddles are not intended for use oncompetitive presses. The Caterpillar saddlesare designed for use only on a Caterpillartrack press. Because the side tooling bars onthe Caterpillar press are vertically adjustable,only one saddle is required per pitch size.Competitive contact tooling and saddlemanufacturers require multiple saddles foreach pitch size due to the lack of verticaladjustability. Thus, the conversion groupsdocumented below do not contain anycomponents for allowing the use of Caterpillarsaddles on competitive track presses.Competitive saddles MUST still be used oncompetitive brand presses.

Competitive Tools on CaterpillarTrack PressesProvisions have also been made for dealersthat have recently invested heavily intocompetitive brand undercarriage contacttooling. The conversion groups allowing theuse of competitive tooling on a Caterpillartrack press are illustrated below. Thesegroups contain the necessary side tooling barsfor mounting the competitive tools. In addition,saddle adapter plates are included to permitthe use of competitive saddles on a Caterpillarpress. This ability to use competitive saddleson a Caterpillar press is due to the verticallyadjustable side tooling bars, a design featureseen only on a Caterpillar press.

Questions and AnswersWill the Caterpillar track press contact toolswithstand the high assembly forcesexperienced in track assembly anddisassembly?

The CAT tools are manufacturing from qualityheat treated steel and hardened to a specificRockwell C value to achieve the appropriatetoughness and durability. This retards toollapping or “mushrooming” while still avoidingbrittleness.

How many pieces do I need to purchase toservice a new model or link assemblydesign?

This question leads to one of the majorbenefits of the CAT tooling. In most cases,when a new undercarriage link assembly orequipment model is released, the link offset orpin projection changes. Nine times out of ten,a dealer owning a complete set of CAT toolingneeds to only purchase a new set of pin andbushing assembly bases, 4 bases total (notethat the bases are the least expensive items inthe tool setup). With the competition’s tooling,a near complete set of pieces must bepurchased to service that new model. Overall,it takes approximately 50% less pieces toservice the complete line of Caterpillar track-type equipment with CAT tooling that it doeswith competitive plunger-style tooling. Thisresults in less expensive tool replacementcosts and less required tool storage space.As for saddles (the most expensivecomponent), it takes only one saddle per pitchgroup (total of ten saddles) to service thecomplete line of CAT equipment. Thecompetition uses multiple saddles per pitchgroup resulting in an increased cost.Remember that new model releases couldresult in a new saddle purchase if you areusing competitive brand tooling.

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Contact Tooling For Conversion Groups

Competitive Track Press Conversion Group

Wolff 310, 200 1U-6261

OTC 200 9U-7750

Centurion 330, 250 1U-6259

Contact Tooling For Conversion Groups

Competitive Track Press Conversion Group

Wolff 1U-6265

OTC Trackmaster 1U-6264

Centurion 1U-6266

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Do I need to issue a special purchase orderto purchase the CAT tooling?

No. All purchases/orders can be placeddirectly through the dealer terminal and pulledfrom the available stock located in Morton.This will speed order processing, shipping,and response time. This feature helps to takeadvantage of the speed and order trackingcapabilities that the ANTARESTM PartsOrdering System offers.

Can the Caterpillar contact tools bereworked? If so, how?

Yes. Over a prolonged period of time, the pinassembly body, bushing assembly body, andthe bushing disassembler will experiencewear. This wear affects the service quality andtrack sealability. To extend the life of thesetools, the contact ends of the bodies can bemachined down approximately 3/16 to 1/4 in.After removing this material, the tool height hasbeen reduced and must be built back up by adonut-shaped 3/16 to 1/4 in thick spacerplaced between the base and the body. Forthe assembly bodies, the set screw and jamnut must be moved to the opposite side of thetooling and moved slightly closer to the baseplate to accommodate the key slot located onthe side of the plunger.

What is the cost involved in replacingreworked or damaged tools?

The cost varies across the entire spectrum ofmodels and pitches. The larger modelsgenerally require larger contact tools which willobviously be more costly. However, severaldifferent factors are built into the life of contacttooling...How easily are the side toolsadjusted?...Does the side tool mounting barson the track press compensate for track chainmovement during pressing?.. .What is therecommended pressing procedure (one link ata time or two)?...How much room is availablearound the contact tools and pressing area forvisually watching the tools engage the linkassembly? These are just a few of thequestions that need to be answered in order tojudge tool life.

How easily is the CAT tooling adjusted andinstalled on the press?

Three manual tooling adjustments can bemade instantly at the turn of a knob. The twoknurled knobs on the top of the side plateallow the front and back contact tools to beadjusted up and down independently. This isa tremendous time saver when dry joints areencountered. Dry joints generally have highinternal pin-to-bushing wear which causes thepin to sit lower in the saddle. Since the toolsmust be centered around the pin, a verticaladjustment of the tooling must be made ordamage to the link will most likely occur. Thethird knurled knob located on the front of thetool bar moves both tools forward andbackward. Competitive presses and toolingbars do not offer these quick adjustablefeatures. Quick installation time is achievedusing a one-piece T-Slot nut and stud. Thecontact tools can be quickly spun onto thestud and set to the correct pitch. Thus, toolsetup time is reduced by a remarkableamount. In addition, the side tool bar on aCAT track press is spring mounted. As thetrack chain raises (wear causes the bushingsurface to become curved not straight) duringpressing, the vertical displacement isabsorbed within the tool bar relieving the pressrams and seals of any unnecessary verticalforces. This vertical mobility also reduceswear on the bushing pockets of the saddle.Vertically adjustable side tool bars reduce thenumber of saddles required because newsaddles are not required when the bushingdiameter changes.

If I own a competitive press, can I still usethe CAT tooling?

Yes, Caterpillar offers three conversion groupswhich allow a competitive press owner toservice CAT undercarriage with CAT contacttools. These conversion groups are for Wolff,OTC, and Centurion track presses.

If I own competitive track press contacttooling, can I use this tooling on a CATtrack press?

Yes. A conversion group is required to mountcompetitive tooling on a CAT track press.Caterpillar offers conversion groups for Wolff;OTC, and Centurion tooling.

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What makes the Caterpillar plunger-styletooling different from the competition’stooling?

All Caterpillar track press assembly contacttools are plunger-style for accurate assembly.The CAT assembly tooling does not require theuse of shims to set the tooling offset. The CATtools are mounted on a sliding one-piece t-slotnut and stud. There are only about 3 to 4threads of actual stud engagement; therefore,the tooling can be spun on very quickly. Thereare no tool holders or PPR plates. The CATtooling is designed for “one link at a time”assembly. This means that the tooling on thefirst assembled side (longer pin plunger) setsthe critical link parameters such as pin andbushing projection. As the second side isassembled, the shorter pin assembly plungernever “bottoms out”. Thus, the established pinprojection is not altered. This is a criticalfeature and an absolute necessity whenservicing positive pin retention track. If the pinprojection is not closely controlled, the retainerrings will not be extruded into a properlyshaped groove (remember the groove aroundthe end of the pin and the groove in the Linkpin boss match to accept the retainer ring).By assembling the track joint one link at atime, considerably less assembly force isrequired and risk of crushing the thrust rings iseliminated. Reduced assembly force alsoextends the life of the track press (less stresson the seals and hydraulic components).

Are there additional CAT track pressfeatures that extend tool life other than theadjustable tool bar?

The hold down clamp is relief valve controlledto allow the unworn part of the bushing tomove in the saddle without gouging thebottom of the bushing support. This increasessaddle life. A CAT press has two fluorescentwork lights located above the tooling (one oneach side) to improve visual checks of toolingcontact and alignment. This helps to preventaccidental misalignment which causes toolingand track component damage. A one turnrelief valve offers two advantages over theoff-the-shelf relief valves used on competitivepresses. First, the relief valve can be adjustedwith the quick and simple turn of a dial on theinstrument panel. This avoids the practice ofleaving the relief valve set to the maximumtonnage and assembling the track by ear. Byassembling the track using the properassembly force, the life of the press hydraulicsystem is increased, the tooling life ismaximized, and damage to track componentsis minimized. Second, the tonnage can beeasily adjusted to half the full value whenassembling master joints, once againincreasing tool life and eliminating trackcomponent damage.

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Setup of Contact ToolingLocate and assemble the proper contacttooling bases, bodies, and plungers for thetrack group being serviced.

Illustration 1. Tooling For A Caterpillar Track Press.(1) Caterpillar Plunger-Style Tooling. (2) CenturionPlunger-Style Tooling. (3) Wolff Plunger-Style Tooling. (4) OTC Plunger-Style Tooling.

NOTE: Refer to “Tightening Saddles, SpacerPlates, and Wedge Bars” section in thismanual for procedures on bolting saddles,spacer plates, and wedge bars to the trackpress table.

Illustration 2. Tooling Alignment.The adapter plate shown in this illustration is for theCenturion Plunger-Style Tooling.

0803-71

0803-70

1

2

3

4

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Caterpillar Plunger-Style ToolingSaddles with a pitch range between 155.58 and 215.9 mm (6.125 and 8.50 in)require the use of a 9U-7749 Adapter Platebetween the saddle and the press table.Saddles within this pitch range do not have anangled flange and do not use the wedge bars.The larger saddles are mounted directlyagainst the press table and require the use ofnarrow wedge bars.

Use these steps to secure the CaterpillarPlunger-Style Tooling to the track press tableon a Caterpillar track press.

1. Remove the indexer extension arms.

2. Make sure the hold down clamp iscompletely raised.

3. If an adapter plate is required, center theadapter plate on the track press table.

4. Make sure the bolt holes are properlyaligned.

5. Bolt the saddle to the press table.(Use the procedures in the “TighteningSaddles, Spacer Plates, and Wedge Bars”section).

6. Attach the assembled contact tools to theadjustable side tooling bar using the 1U-6263 adjustable T-slot bolts.

7. Reattach the indexer extension arms.

Centurion Plunger-Style ToolingUsing Centurion tooling on a Caterpillar trackpress requires a 1U-6266 Conversion Group.The 1U-6266 Conversion Group includes a25.4 mm (1.00 in) 1U-6218 Spacer Plate and a12.7 mm (.50 in) 1U-6283 Spacer Plate. The1U-6218 Spacer Plate is used with all trackmodels. The 1U-6283 Spacer Plate is usedwith the 1U-6218 Spacer Plate when servicingD11N track. Spacer plates are used toincrease the height of the saddle, allowing thepressing forces to be applied through thecenter of the ram to avoid unnecessary trackpress seal and cylinder damage.

Use these steps to secure the CenturionPlunger-Style Tooling to the press table on aCaterpillar track press.

1. Remove the indexer extension arms.

2. Make sure the hold down clamp iscompletely raised.

3. Position the appropriate spacer plate(s) onthe press table so the slots in the spacerplates align with all 22 holes in the table.

4. Bolt the saddle, plate, and wedge bars tothe press table. (Use the procedures in the“Tightening Saddles, Spacer Plates, andWedge Bars” section).

NOTE: Some smaller pitch Centurion saddleshave no bolt holes, only an angled flange andrequire the use of a wider wedge bar includedin the 1U-6266 Conversion Group. The widerwedge bar bolts through the inside two rows ofholes on the press table.

5. Attach the contact tools for the assembledsealed and lubricated track to theadjustable side tooling bar using the 1U-6285 Adjustable T-Slot Bolts.

6. For positive pin retention tooling, use the1U-6263 Adjustable T-Slot Bolts.

7. Reattach the indexer extension arms.

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Wolff Plunger-Style ToolingUsing Wolff tooling on a Caterpillar track pressrequires a 1U-6265 Conversion Group. The1U-6265 Conversion Group contains a 1U-6280 Adapter Plate. This adapter plateallows the Wolff saddles to be used on aCaterpillar track press.

NOTE: All 8-bolt Wolff saddles can bemounted on the press table, but the 14-boltWolff D11N saddle cannot be used on aCaterpillar track press. Customers with WolffD11N tooling must purchase the CaterpillarD11N saddle or the Centurion D11N saddlewith the Centurion Conversion Group.

Use these steps to secure the Wolf Plunger-Style Tooling to the track press tableon a Caterpillar track press.

1. Remove the indexer extension arms.

2. Make sure the hold down clamp iscompletely raised.

3. Position the 1U-6280 Adapter Plate on thepress table so the outer two rows of holeson the adapter plate are centered andaligned with the middle four holes (refer toholes 1, 2, 3, and 4 in Illustration 2) of thetwo inner rows of holes on the press table.

4. Center the saddle on the adapter plate.

5. Bolt the adapter plate to the press tableand then the saddle to the adapter plate.Use the procedures in the “TighteningSaddles, Spacer Plates, and Wedge Bars”section.

6. Attach the assembled contact tools to theadjustable side tooling bar using the 1U-6282 Adjustable T-Slot Nuts.

NOTE: Both stationary and adjustable Wolfftooling holders will screw onto the T-slot nuts.

7. Reattach the indexer extension arms.

OTC Plunger-Style ToolingUsing OTC tooling on a Caterpillar track pressrequires a 1U-6264 Conversion Group. The1U-6264 Conversion Group contains a 1U-6278 Adapter Plate. This adapter plateallows the OTC saddles to be used on aCaterpillar track press.

Use these steps to secure the OTC Plunger-Style Tooling to the track press tableon a Caterpillar track press.

1. Remove the indexer extension arms.

2. Make sure the hold down clamp iscompletely raised.

3. Position the adapter plate on the presstable so the outer holes are centered andalign with those found in the press table.

4. Center the saddle on the adapter plate.

5. Bolt the adapter plate to the press tableand then the saddle to the adapter plate.Use the procedures in the “TighteningSaddles, Spacer Plates, and Wedge Bars”section.

6. Attach the OTC tool bar and contact toolingto the side tooling bar of a Caterpillar trackpress using the 9U-7681 Stud and 2J-3507 Nut.

NOTE: The 1K-7945 Dowels are used to alignthe OTC tool bar with the side mounting bar.

7. Reattach the indexer extension arms.

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Tightening Saddles, SpacerPlates, and Wedge Bars1. Correctly position and align the saddle,

spacer plate, and wedge bars as needed.

2. Hand tighten all the bolts in the saddle andthen in the wedge bar to hold them inplace.

3. A saddle, spacer plate, or wedge bar mayrequire five or six bolts depending on whichrow of bolt holes in the track press tableare aligned.

4. Secure the tooling to the track press tableby tightening the bolts in the order shownin Illustration 51. Tighten bolts 1 through12 to secure the saddle, then tighten 13through 22 to secure the wedges.

Illustration 3. Bolt Tightening Order.This adapter plate shows the order to tighten the bolts forsaddles, spacer plates, and wedge bars.

5. Tighten the bolts for the saddle, spacerplates, and wedge bars to 210 ± 70 N·m(150 ± 50 lb ft).

6. Tighten the bolts again (using the sameorder) to 840 ± 70 N·m (600 ± 50 lb ft).

7. For arrangements not using wedge bars,first bolt the adapter plate to the trackpress table, and then bolt the saddle to theadapter plate.

SADDLEBOLTS

WEDGE BAR BOLTS

21

17

13

15

19

11

7

3

1

5

9

12

8

4

2

6

10

22

18

14

16

20

0803-72

11

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Terminology and Assembly ofContact Tooling

Illustration 4. Disassembly Tooling. (1) BushingDisassembler. (2) Pin Disassembler. (3) T-Slot Bolt.

The solid pin and bushing disassembly toolsare shown in Illustration 4. Both disassemblersare screwed onto the T-Slot bolt which sidesalong the side tooling bars attached to thetrack press rams. The 126-4041 DisassemblySpacer Group is required to ensure that bothdisassemblers contact the pin and bushingends at approximately the same time. Thisprevents the track joint from twisting in thesaddle. The necessary spacers are placedbetween the disassembler and the T-Slot bolt.Only one disassembly spacer group is neededper operating track press. The plunger styleassembly contact tooling consist of a springloaded plunger, body, and base. The plungeris held within the body using a set screw andjam nut. The base is bolted to the body usinga pair of socket head set screws.

Illustration 5. Assembly Tooling. (1) Typical Pin OrBushing Assembly. (2) T-Slot Bolt. (3) Assembly Plunger.(4) Spring. (5) Jam Nut. (6) Set Screw. (7) AssemblyBody. (8) Socket Head Set Screw. (9) Assembly Base.

Illustration 5 shows how the contact assemblytooling components are assembled. The baseestablishes all the critical track assemblyparameters (offset, pin projection, and bushingprojection). Thus, when new track models areintroduced, in many cases the base is the onlynew piece required. This helps to reduce thetotal number of parts required for servicingtrack. In addition, undercarriage assemblyand disassembly tooling costs for new trackassemblies are held to a minimum.

Illustration 6. Typical Contact Tooling Parts.

Illustration 6 shows the full set of contacttooling parts required to service all 9.00 inchpitch track assemblies.

0802-04

1

2

3

4

5

68

9

7

0802-03

1

2 3

12

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First and Second AssemblySide ConceptThe Caterpillar assembly contact toolingrequires that only one link be pressed onto theassembly at a time. For example, to service atrack joint, the tooling on the left side is usedto hold the track assembly while the right linkis pressed COMPLETELY onto the pin andbushing. The right side tooling then remains inthe extended position while the left side link ispressed.

NOTE: During the assembly process, it isimportant that the links never hit the saddle.

The pin assembly plunger on the firstassembly side is longer than the pin assemblyplunger on the second assembly side. Thus,the longer plunger initially establishes thecorrect pin projection, and the shorter plungerallows the joint to be pressed to zero endplay.The shorter second side pin assembly plungernever “bottoms-out” against the base;therefore, the joint cannot be released from thezero endplay condition. The use of Molykoteor thin plastic coatings establishes the slightendplay. According to Caterpillar trackassembly specifications, pin projection isestablished and controlled on one side only.Due to the “stack-up” of tolerances throughoutthe track joint, it is necessary to assemble thejoint one side at a time. In contrast, bushingprojection is controlled on both sides of thetrack joint. Thus, the two bushing assemblyplungers are both the same length resulting inthe same projection. The establishment ofproper bushing projection is critical to ensurethat adjacent links do not scrub against oneanother.

Contact Tooling

6.125 Inch Pitch

13

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Sealed and D3B, D3C, 931 6Y-0935Lubricated

Sealed DS, 931, SF250, 6Y-0935, 6S-8343,TR225B 6S-3143, 6S-8682

— 307 6Y-0935

6.125 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-77761 Saddle

1 169-06442 Saddle

1 9U-7749 Saddle Spacer

2 9U-7686 Pin Assembly Base

2 9U-7687 Pin Assembly Body

1 9U-7684 Pin Assembly Plunger(first assembly side)

1 9U-7685 Pin Assembly Plunger(second assembly side)

2 9U-7689 Bushing Assembly Base

2 9U-7690 Bushing Assembly Base

2 9U-7691 Bushing Assembly Body

2 9U-76881 Bushing Assembly Plunger

2 169-06422 Bushing Assembly Plunger

2 9U-77901 Pin Disassembler

2 169-06432 Pin Disassembler

2 9U-77911 Bushing Disassembler

2 169-06412 Bushing Disassembler

1 9U-7824 Link Spacer

1 9U-7823 Link Spacer

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

2 9U-7748 Spring (pin assembly tools)

2 9U-7747 Spring (bushing assembly tools)

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

1 These part numbers apply to all models except the 307.2 These part numbers apply to 307 models only.

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6.75 Inch Pitch

14

6.75 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-7775 Saddle

1 9U-7749 Saddle Spacer

2 9U-7676 Pin Assembly Base

2 9U-7677 Pin Assembly Base

2 9U-7678 Pin Assembly Base

2 9U-7679 Pin Assembly Base

2 9U-7680 Pin Assembly Base

2 4C-8087 Pin Assembly Base

2 9U-7682 Pin Assembly Body

2 9U-7683 Pin Assembly Body

1 9U-7664 Pin Assembly Plunger(first assembly side)

1 9U-7665 Pin Assembly Plunger(second assembly side)

1 9U-7668 Pin Assembly Plunger(first assembly side)

1 9U-7669 Pin Assembly Plunger(second assembly side)

2 9U-7652 Bushing Assembly Base

2 9U-7656 Bushing Assembly Base

2 9U-7657 Bushing Assembly Base

2 9U-7658 Bushing Assembly Base

2 9U-7659 Bushing Assembly Base

2 9U-7660 Bushing Assembly Base

2 9U-7656 Bushing Assembly Base

2 4C-8055 Bushing Assembly Base

2 9U-7662 Bushing Assembly Body

2 9U-7647 Bushing Assembly Plunger

2 9U-7649 Bushing Assembly Plunger

2 9U-7650 Bushing Assembly Plunger

2 4C-6988 Bushing Assembly Plunger

2 9U-7788 Pin Disassembler

2 4C-8125 Pin Disassembler

2 9U-7789 Bushing Disassembler

1 9U-7815 Link Spacer

1 9U-7816 Link Spacer

1 9U-7818 Link Spacer

1 9U-7819 Link Spacer

1 9U-7820 Link Spacer

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

4 9U-7747 Spring

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Sealed and D4E, D4H-HD, 6Y-9261, 9G-8581,Lubricated D4H, D5C, 941, 108-0947, 9K-6629,

943 7T-4173

Sealed D4, D5, 561, 933 9K-6629, 2S-5959,941, 951B, 955, 7K-1825, 5K-9457,205, 211, 213, 5K-9423, 5W-4147,E110, E120, E140 8U-2927, 093-1978

099-0650

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6.91 Inch Pitch

7.5 Inch Pitch

15

6.91 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-7774 Saddle

1 9U-7749 Saddle Spacer

2 9U-7675 Pin Assembly Base

2 9U-7682 Pin Assembly Body

1 9U-7664 Pin Assembly Plunger(first assembly side)

1 9U-7665 Pin Assembly Plunger(second assembly side)

2 9U-7652 Bushing Assembly Base

2 9U-7654 Bushing Assembly Base

2 9U-7655 Bushing Assembly Base

2 9U-7662 Bushing Assembly Body

2 9U-7645 Bushing Assembly Plunger

2 9U-7788 Pin Disassembler

2 9U-7789 Bushing Disassembler

1 9U-7813 Link Spacer

1 9U-7814 Link Spacer

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

4 9U-7747 Spring

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Sealed and D5B, 951, 953 7T-4539, 3P-7153Lubricated

Sealed D5, 951, 955, 3P-7133, 7T-4539E180, EL180 095-7130

7.50 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-7773 Saddle

1 9U-7749 Saddle Spacer

2 9U-7672 Pin Assembly Base

2 9U-7673 Pin Assembly Base

2 9U-7674 Pin Assembly Base

2 9U-7675 Pin Assembly Base

2 9U-7682 Pin Assembly Body

1 9U-7664 Pin Assembly Plunger(first assembly side)

1 9U-7665 Pin Assembly Plunger(second assembly side)

1 9U-7666 Pin Assembly Plunger(first assembly side)

1 9U-7667 Pin Assembly Plunger(second assembly side)

1 9U-7670 Pin Assembly Plunger(first assembly side)

1 9U-7671 Pin Assembly Plunger(second assembly side)

2 9U-7652 Bushing Assembly Base

2 9U-7653 Bushing Assembly Base

2 9U-7654 Bushing Assembly Base

2 9U-7661 Bushing Assembly Base

2 9U-7662 Bushing Assembly Body

2 9U-7663 Bushing Assembly Body

2 9U-7645 Bushing Assembly Plunger

2 9U-7646 Bushing Assembly Plunger

2 9U-7648 Bushing Assembly Plunger

2 9U-7651 Bushing Assembly Plunger

2 9U-7788 Pin Disassembler

2 9U-7789 Bushing Disassembler

1 9U-7810 Link Spacer

1 9U-7811 Link Spacer

1 9U-7812 Link Spacer

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

4 9U-7747 Spring

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Sealed and D5H, D5H-HD, 106-1625, 3T-8405,Lubricated 6Y-9267

Sealed 225B, 225D, 315, 9W-3137, 7T-4043,320, 322, E200B, 096-6201, 096-5252,E240, EL240, E300 093-1981

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8.00 Inch Pitch

16

8.00 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-7772 Saddle

1 9U-7749 Saddle Spacer

2 9U-7636 Pin Assembly Base

2 9U-7637 Pin Assembly Base

2 9U-7638 Pin Assembly Base

2 9U-7639 Pin Assembly Base

2 9U-7640 Pin Assembly Base

2 9U-7641 Pin Assembly Base

2 9U-7642 Pin Assembly Base

2 9U-7643 Pin Assembly Base

2 9U-7644 Pin Assembly Body

1 9U-7628 Pin Assembly Plunger(first assembly side)

1 9U-7629 Pin Assembly Plunger(second assembly side)

1 9U-7630 Pin Assembly Plunger(first assembly side)

1 9U-7631 Pin Assembly Plunger(second assembly side)

2 9U-7616 Bushing Assembly Base

2 9U-7617 Bushing Assembly Base

2 9U-7618 Bushing Assembly Base

2 9U-7619 Bushing Assembly Base

2 9U-7621 Bushing Assembly Body

2 9U-7608 Bushing Assembly Plunger

2 9U-7610 Bushing Assembly Plunger

2 9U-7611 Bushing Assembly Plunger

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Sealed and D6D, D6H, 8E-7405, 9G-8735,Lubricated D6H-HD, 955, 963 8E-2355, 7T-4645,

3P-1112

Sealed D6, D7, D8, 955, 1S-1863, 1S-6433,977, 583, 225, 1S-8839, 3P-1112,325, EL300, 7S-9109, 8S-5231,EL300B 6Y-1607, 096-0264

8.00 Inch Pitch Tool Set

Qty. Part No. Description

2 9U-7786 Bushing Disassembler

1 9U-7801 Link Spacer

1 9U-7803 Link Spacer

1 9U-7805 Link Spacer

1 9U-7806 Link Spacer

1 9U-7807 Link Spacer

1 9U-7808 Link Spacer

1 9U-7809 Link Spacer

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

4 9U-7746 Spring

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

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8.50 Inch Pitch

17

8.50 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-7771 Saddle

1 9U-7749 Saddle Spacer

2 9U-7632 Pin Assembly Base

2 9U-7633 Pin Assembly Base

2 9U-7634 Pin Assembly Base

2 9U-7635 Pin Assembly Base

2 4C-9413 Pin Assembly Base

2 9U-7644 Pin Assembly Body

1 9U-7622 Pin Assembly Plunger(first assembly side)

1 9U-7623 Pin Assembly Plunger(second assembly side)

1 9U-7624 Pin Assembly Plunger(first assembly side)

1 9U-7625 Pin Assembly Plunger(second assembly side)

1 9U-7626 Pin Assembly Plunger(first assembly side)

1 9U-7627 Pin Assembly Plunger(second assembly side)

2 9U-7612 Bushing Assembly Base

2 9U-7613 Bushing Assembly Base

2 9U-7614 Bushing Assembly Base

2 9U-7615 Bushing Assembly Base

2 9U-7619 Bushing Assembly Base

2 4C-9412 Bushing Assembly Base

2 9U-7620 Bushing Assembly Body

2 9U-7621 Bushing Assembly Body

2 4C-9029 Bushing Assembly Body

2 9U-7606 Bushing Assembly Plunger

2 9U-7607 Bushing Assembly Plunger

2 9U-7609 Bushing Assembly Plunger

2 4C-9307 Bushing Assembly Plunger

8.50 Inch Pitch Tool Set (Cont’d)

Qty. Part No. Description

2 4C-9414 Pin Disassembler

2 9U-7785 Pin Disassembler

2 9U-7786 Bushing Disassembler

2 142-5896 Extruder Assembly

2 8T-3216 Anvil Assembly

2 8T-3211 Handle Assembly

1 9U-7787 Snap Ring Master Adapter

1 9U-7799 Link Spacer

1 9U-7800 Link Spacer

1 9U-7801 Link Spacer

1 9U-7802 Link Spacer

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

4 9U-7746 Spring

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Positive Pin D8N, 578 7T-8115, 8E-4513Retention

Sealed and D8N, D8L, D7H, 9W-3309, 8E-4505,Lubricated D7G, 973, 977, 8E-4519, 7T-2207,

235 9G-2417, 6I-9239,7T-4657, 8S-2589,9W-5939

Sealed D7, 973, 977, 7T-4657, 8S-2589,235, 330, E450 6Y-2589, 7T-9823,MS450 8E-8641, 096-9944

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9.00 Inch Pitch 9.45 Inch Pitch

18

9.00 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-7770 Saddle

2 9U-7599 Pin Assembly Base

2 9U-7601 Pin Assembly Base

2 9U-7602 Pin Assembly Base

2 9U-7603 Pin Assembly Base

2 9U-7604 Pin Assembly Base

2 9U-7605 Pin Assembly Body

1 9U-7595 Pin Assembly Plunger(first assembly side)

1 9U-7596 Pin Assembly Plunger(second assembly side)

1 9U-7597 Pin Assembly Plunger(first assembly side)

1 9U-7598 Pin Assembly Plunger(second assembly side)

2 9U-7592 Bushing Assembly Base

2 9U-7593 Bushing Assembly Base

2 9U-7594 Bushing Assembly Body

2 9U-7588 Bushing Assembly Plunger

2 9U-7590 Bushing Assembly Plunger

2 9U-7591 Bushing Assembly Plunger

2 9U-7782 Pin Disassembler

2 9U-7783 Bushing Disassembler

2 141-2395 Extruder Assembly

2 8T-3216 Anvil Assembly

2 8T-3211 Handle Assembly

1 9U-7796 Link Spacer

1 9U-7797 Link Spacer

1 9U-7798 Link Spacer

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

4 9U-7746 Spring

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Positive Pin D9L, 589 7T-4137Retention

Sealed and D8K, D9L, 583, 7T-7629, 7S-9181Lubricated 589, 983,

Sealed D87, 350, E650, 7S-9181, 8E-6091,MS580 093-1985

9.45 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-7769 Saddle

2 9U-7600 Pin Assembly Base

2 9U-7830 Pin Assembly Base

2 9U-7605 Pin Assembly Body

1 9U-7595 Pin Assembly Plunger(first assembly side)

1 9U-7596 Pin Assembly Plunger(second assembly side)

2 9U-7592 Bushing Assembly Base

2 9U-7594 Bushing Assembly Body

2 9U-7589 Bushing Assembly Plunger

2 9U-7782 Pin Disassembler

2 9U-7783 Bushing Disassembler

2 141-2395 Extruder Assembly

2 8T-3216 Anvil Assembly

2 8T-3211 Handle Assembly

1 9U-7784 Snap Ring Master Adapter

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

4 9U-7746 Spring

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Positive Pin D9N 7T-2275Retention

Sealed and D9N 9W-2743Lubricated

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10.25 Inch Pitch 12.50 Inch Pitch

19

10.25 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-7768 Saddle

2 9U-7580 Pin Assembly Base

2 9U-7581 Pin Assembly Base

2 9U-7582 Pin Assembly Base

2 9U-7583 Pin Assembly Base

2 9U-7584 Pin Assembly Base

2 9U-7585 Pin Assembly Body

1 9U-7578 Pin Assembly Plunger(first assembly side)

1 9U-7579 Pin Assembly Plunger(second assembly side)

2 9U-7575 Bushing Assembly Base

2 9U-7576 Bushing Assembly Base

2 9U-7577 Bushing Assembly Body

2 9U-7572 Bushing Assembly Plunger

2 9U-7573 Bushing Assembly Plunger

2 9U-7574 Bushing Assembly Plunger

2 9U-7779 Pin Disassembler

2 9U-7780 Bushing Disassembler

2 142-5894 Extruder Assembly

2 8T-3216 Anvil Assembly

2 8T-3211 Handle Assembly

1 9U-7794 Link Spacer

1 9u-7795 Link Spacer

1 9U-7781 Snap Ring Master Adapter

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

4 9U-7746 Spring

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Positive Pin D10N, D10, 591 7T-0715, 9W-5933Retention

Sealed and D9H, D10, D10N, 9S-1927, 6Y-6721Lubricated 594 9G-5507, 9W-5723

Sealed D9, 245, 375 9S-1927, 6Y-6721

12.50 Inch Pitch Tool Set

Qty. Part No. Description

1 9U-7767 Saddle

2 9U-7566 Pin Assembly Base

2 9U-7567 Pin Assembly Base

2 9U-7568 Pin Assembly Body

1 9U-7564 Pin Assembly Plunger(first assembly side)

1 9U-7565 Pin Assembly Plunger(second assembly side)

2 9U-7570 Bushing Assembly Base

2 9U-7571 Bushing Assembly Body

2 9U-7569 Bushing Assembly Plunger

2 9U-7777 Pin Disassembler

2 9U-7778 Bushing Disassembler

2 1U-5746 Extruder Assembly

2 8T-3216 Anvil Assembly

2 8T-3211 Handle Assembly

1 9U-7829 Extruder Base

1 9U-7792 Link Spacer

1 9u-7793 Link Spacer

8 9F-5975 Socket Head Screw

4 1B-2578 Jam Nut (package quantity 100)

4 9U-7746 Spring

4 5B-0448 Set Screw

1 126-4041 Disassembly Spacer Group

Type of Models Right-Hand LinkTrack Serviced Part Numbers

Positive Pin D11N 6T-8049Retention

Sealed 5130, MS1600 6I-8643, 096-0321

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20

Tooling Part Numbers by ModelModels Serviced

D3B, D3C, 931 D3, 931,Description 307 Sealed and SF250 TR225B D3, 931 D3

Lubricated Sealed Sealed Sealed Sealed

Right-Hand Link 6Y-0935 6Y-0935 6Y-0935 6S-8343 6S-3143 6S-8682Qty. Pitch 6.125 in 6.125 in 6.125 in 6.125 in 6.125 in 6.125 in

1 Saddle 169-0644 9U-7776 9U-7776 9U-7776 9U-7776 9U-7776

1 Saddle Spacer 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749

2 Pin Assembly Base 9U-7686 9U-7686 9U-7686 9U-7686 9U-7686 9U-7686

2 Pin Assembly Body 9U-7687 9U-7687 9U-7687 9U-7687 9U-7687 9U-7687

1 Pin Assembly Plunger1 9U-7684 9U-7684 9U-7684 9U-7684 9U-7684 9U-7684

1 Pin Assembly Plunger2 9U-7685 9U-7685 9U-7685 9U-7685 9U-7685 9U-7685

2 Bushing Assembly Base 9U-7689 9U-7689 9U-7690 9U-7690 9U-7690 9U-7690

2 Bushing Assembly Body 9U-7691 9U-7691 9U-7691 9U-7691 9U-7691 9U-7691

2 Bushing Assembly Plunger 169-0647 9U-7688 9U-7688 9U-7688 9U-7688 9U-7688

2 Pin Disassembly 169-0643 9U-7790 9U-7790 9U-7790 9U-7790 9U-7790

2 Bushing Disassembly 169-0641 9U-7791 9U-7791 9U-7791 9U-7791 9U-7791

1 Link Spacer — — 9U-7824 9U-7824 9U-7823 9U-7823

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (l00/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578

2 Spring 9U-7748 9U-7748 9U-7748 9U-7748 9U-7748 9U-7748

2 Spring 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

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21

Models Serviced

205, 211, E110, E110B, D5C,D4HDescription D4, 941 941, 955 933, 955 213 213 E140 E120 Sealed and

Sealed Sealed Sealed Sealed Sealed Sealed Sealed Lubricated

Right-Hand Link 7K-1825 5K-9457 5K-9423 5W-4147 8U-2927 093-1978 099-0650 6Y-9261Qty. Pitch 6.75 in 6.75 in 6.75 in 6.75 in 6.75 in 6.75 in 6.75 in 6.75 in

1 Saddle 9U-7775 9U-7775 9U-7775 9U-7775 9U-7775 9U-7775 9U-7775 9U-7775

1 Saddle Spacer 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749

2 Pin Assembly Base 9U-7678 9U-7680 9U-7680 9U-7678 9U-7678 9U-7678 9U-7679 9U-7677

2 Pin Assembly Body 9U-7683 9U-7683 9U-7683 9U-7683 9U-7683 9U-7683 9U-7683 9U-7683

1 Pin Assembly Plunger1 9U-7668 9U-7668 9U-7668 9U-7668 9U-7668 9U-7668 9U-7668 9U-7668

1 Pin Assembly Plunger2 9U-7669 9U-7669 9U-7669 9U-7669 9U-7669 9U-7669 9U-7669 9U-7669

2 Bushing Assembly Base 9U-7658 9U-7659 9U-7659 9U-7652 9U-7652 9U-7652 9U-7660 9U-7652

2 Bushing Assembly Body 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662

2 Bushing Assembly Plunger 9U-7649 9U-7650 9U-7650 9U-7649 9U-7649 9U-7650 9U-7650 9U-7647

2 Pin Disassembly 9U-7788 9U-7788 9U-7788 9U-7788 9U-7788 9U-7788 9U-7788 9U-7788

2 Bushing Disassembly 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789

1 Link Spacer 9U-7820 9U-7815 9U-7819 9U-7818 9U-7816 9U-7816 9U-7816 —

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (100/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578

4 Spring 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

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Models Serviced

D4H D4H-HD D4E, 941, 943 943 D5, 561, D5, 951,Description Sealed and Sealed and Sealed and Sealed and D4 951B 955 951

Lubricated Lubricated Lubricated Lubricated Sealed Sealed Sealed Sealed

Right-Hand Link 9G-8581 108-0947 9K-6629 7T-4173 9K-6629 2S-5959 3P-7153 7T-4539Qty. Pitch 6.75 in 6.75 in 6.75 in 6.75 in 6.75 in 6.75 in 6.91 in 6.91 in

1 Saddle 9U-7775 9U-7775 9U-7775 9U-7775 9U-7775 9U-7775 9U-7774 9U-7774

1 Saddle Spacer 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749

2 Pin Assembly Base 9U-7678 4C-8087 9U-7678 9U-7678 9U-7678 9U-7676 9U-7675 9U-7675

2 Pin Assembly Body 9U-7683 9U-7682 9U-7683 9U-7683 9U-7683 9U-7682 9U-7682 9U-7682

1 Pin Assembly Plunger1 9U-7668 9U-7664 9U-7668 9U-7668 9U-7668 9U-7664 9U-7664 9U-7664

1 Pin Assembly Plunger2 9U-7669 9U-7665 9U-7669 9U-7669 9U-7669 9U-7665 9U-7665 9U-7665

2 Bushing Assembly Base 9U-7652 4C-8055 9U-7657 9U-7657 9U-7652 9U-7656 9U-7654 9U-7654

2 Bushing Assembly Body 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662

2 Bushing Assembly Plunger 9U-7647 4C-6988 9U-7649 9U-7649 9U-7649 9U-7649 9U-7645 9U-7645

2 Pin Disassembly 9U-7788 4C-8125 9U-7788 9U-7788 9U-7788 9U-7788 9U-7788 9U-7788

2 Bushing Disassembly 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789

1 Link Spacer — — — — 9U-7816 9U-7815 9U-7813 9U-7813

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (100/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578

4 Spring 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

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Models Serviced

D5B, 951, 953 D5B, 951Description E180, EL180 Sealed and Sealed and 225B, 225D E240, E200B E240, E300 E300, EL240

Sealed Lubricated Lubricated Sealed Sealed Sealed Sealed

Right-Hand Link 095-7130 3P-7153 7T-4539 7T-4043 096-6201 096-5252 093-1981Qty. Pitch 6.91 in 6.91 in 6.91 in 7.50 in 7.50 in 7.50 in 7.50 in

1 Saddle 9U-7774 9U-7774 9U-7774 9U-7773 9U-7773 9U-7773 9U-7773

1 Saddle Spacer 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749

2 Pin Assembly Base 9U-7675 9U-7675 9U-7675 9U-7675 9U-7675 9U-7672 9U-7673

2 Pin Assembly Body 9U-7682 9U-7682 9U-7682 9U-7682 9U-7682 9U-7682 9U-7682

1 Pin Assembly Plunger1 9U-7664 9U-7664 9U-7664 9U-7664 9U-7664 9U-7666 9U-7666

1 Pin Assembly Plunger2 9U-7665 9U-7665 9U-7665 9U-7665 9U-7665 9U-7667 9U-7667

2 Bushing Assembly Base 9U-7652 9U-7655 9U-7655 9U-7654 9U-7653 9U-7652 9U-7653

2 Bushing Assembly Body 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662 9U-7662

2 Bushing Assembly Plunger 9U-7645 9U-7645 9U-7645 9U-7645 9U-7645 9U-7648 9U-7645

2 Pin Disassembly 9U-7788 9U-7788 9U-7788 9U-7788 9U-7788 9U-7788 9U-7788

2 Bushing Disassembly 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789 9U-7789

1 Link Spacer 9U-7814 — — 9U-7811 9U-7812 9U-7810 9U-7810

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (100/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578

4 Spring 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747 9U-7747

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

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Models Serviced

315, 320, D6, 955, EL300, D6H-HD D6HDescription 322 D6, D7, 977 D6, D7, 977 D8, 583 225 EL300B Sealed and Sealed and

Sealed Sealed Sealed Sealed Sealed Sealed Lubricated Lubricated

Right-Hand Link 9W-3137 1S-1863 1S-6433 1S-8839 3P-1112 096-0264 8E-7405 9G-8735Qty. Pitch 7.50 in 8.00 in 8.00 in 8.00 in 8.00 in 8.00 in 8.00 in 8.00 in

1 Saddle 9U-7773 9U-7772 9U-7772 9U-7772 9U-7772 9U-7772 9U-7772 9U-7772

1 Saddle Spacer 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749

2 Pin Assembly Base 9U-7674 9U-7640 9U-7640 9U-7641 9U-7639 9U-7636 9U-7637 9U-7638

2 Pin Assembly Body 9U-7682 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644

1 Pin Assembly Plunger1 9U-7664 9U-7628 9U-7628 9U-7628 9U-7628 9U-7628 9U-7628 9U-7628

1 Pin Assembly Plunger2 9U-7654 9U-7618 9U-7618 9U-7619 9U-7618 9U-7617 9U-7619 9U-7619

2 Bushing Assembly Base 9U-7652 4C-8055 9U-7657 9U-7657 9U-7652 9U-7656 9U-7654 9U-7654

2 Bushing Assembly Body 9U-7662 9U-7621 9U-7621 9U-7621 9U-7621 9U-7621 9U-7621 9U-7621

2 Bushing Assembly Plunger 9U-7645 9U-7610 9U-7610 9U-7610 9U-7610 9U-7610 9U-7608 9U-7608

2 Pin Disassembly 9U-7788 9U-7785 9U-7785 9U-7785 9U-7785 9U-7785 9U-7785 9U-7785

2 Bushing Disassembly 9U-7789 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786

1 Link Spacer 9U-7812 9U-7801 9U-7805 9U-7803 9U-7808 9U-7807 — —

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (100/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578

4 Spring 9U-7747 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

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Models Serviced

D6H D6D, 955, 963 D6D, 955 D7, 977,Description Sealed and Sealed and Sealed and 235 235 D7, 973 235 330

Lubricated Lubricated Lubricated Sealed Sealed Sealed Sealed Sealed

Right-Hand Link 8E-2355 7T-4645 3P-1112 7T-9823 8E-8641 7T-4657 8S-2589 6Y-2589Qty. Pitch 8.00 in 8.00 in 8.00 in 8.50 in 8.50 in 8.50 in 8.50 in 8.50 in

1 Saddle 9U-7772 9U-7772 9U-7772 9U-7771 9U-7771 9U-7771 9U-7771 9U-7771

1 Saddle Spacer 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749

2 Pin Assembly Base 9U-7638 9U-7639 9U-7639 9U-7633 9U-7635 9U-7633 9U-7633 9U-7634

2 Pin Assembly Body 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644

1 Pin Assembly Plunger1 9U-7628 9U-7628 9U-7628 9U-7622 9U-7622 9U-7622 9U-7622 9U-7626

1 Pin Assembly Plunger2 9U-7629 9U-7629 9U-7629 9U-7623 9U-7623 9U-7623 9U-7623 9U-7627

2 Bushing Assembly Base 9U-7619 9U-7616 9U-7616 9U-7615 9U-7615 9U-7615 9U-7615 9U-7619

2 Bushing Assembly Body 9U-7621 9U-7621 9U-7621 9U-7620 9U-7620 9U-7620 9U-7620 9U-7621

2 Bushing Assembly Plunger 9U-7608 9U-7610 9U-7610 9U-7607 9U-7607 9U-7607 9U-7607 9U-7609

2 Pin Disassembly 9U-7785 9U-7785 9U-7785 9U-7785 9U-7785 9U-7785 9U-7785 9U-7785

2 Bushing Disassembly 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786

1 Link Spacer — — — 9U-7800 9U-7800 9U-7801 9U-7801 9U-7799

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (100/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578

4 Spring 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

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Models Serviced

E450 D7G, 977, 235 973 D7G, 977, 973 D7H-HD D7H D8L D8LDescription MS450 Sealed and Sealed and Sealed and Sealed and Sealed and Sealed and Sealed and

Sealed Lubricated Lubricated Lubricated Lubricated Lubricated Lubricated Lubricated

Right-Hand Link 096-9944 8S-2589 9W-5939 7T-4657 6I-9239 9G-2417 8E-4519 7T-2207Qty. Pitch 8.50 in 8.50 in 8.50 in 8.50 in 8.50 in 8.50 in 8.50 in 8.50 in

1 Saddle 9U-7771 9U-7771 9U-7771 9U-7771 9U-7771 9U-7771 9U-7771 9U-7771

1 Saddle Spacer 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749 9U-7749

2 Pin Assembly Base 9U-7633 9U-7633 9U-7633 9U-7633 4C-9413 9U-7634 9U-7633 9U-7633

2 Pin Assembly Body 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644 9U-7644

1 Pin Assembly Plunger1 9U-7624 9U-7622 9U-7622 9U-7622 9U-7622 9U-7622 9U-7622 9U-7622

1 Pin Assembly Plunger2 9U-7625 9U-7623 9U-7623 9U-7623 9U-7623 9U-7623 9U-7623 9U-7623

2 Bushing Assembly Base 9U-7612 9U-7614 9U-7614 9U-7614 4C-9412 9U-7612 9U-7612 9U-7612

2 Bushing Assembly Body 9U-7620 9U-7620 9U-7620 9U-7620 4C-9029 9U-7620 9U-7620 9U-7620

2 Bushing Assembly Plunger 9U-7607 9U-7607 9U-7607 9U-7607 4C-9307 9U-7606 9U-7606 9U-7606

2 Pin Disassembly 9U-7785 9U-7785 9U-7785 9U-7785 4C-9414 9U-7785 9U-7785 9U-7785

2 Bushing Disassembly 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786 9U-7786

1 Link Spacer 9U-7802 — — — — — — —

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (100/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578

4 Spring 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

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Models Serviced

D8N D8N E650, D8K, 583, 983 D9L, 589Description Sealed and Sealed and D8N D8N, 578 D8 350 MS580 Sealed and Sealed and

Lubricated Lubricated PPR PPR Sealed Sealed Sealed Lubricated Lubricated

Right-Hand Link 9W-3309 8E-4505 7T-8115 8E-4513 7S-9181 8E-6091 093-1985 7S-9181 7T-7629Qty. Pitch 8.50 in 8.50 in 8.50 in 8.50 in 9.00 in 9.00 in 9.00 in 9.00 in 9.00 in

1 Saddle 9U-7771 9U-7771 9U-7771 9U-7771 9U-7770 9U-7770 9U-7770 9U-7770 9U-7770

1 Saddle Spacer 9U-7749 9U-7749 9U-7749 9U-7749 — — — — —

2 Pin Assembly Base 9U-7633 9U-7633 9U-7632 9U-7632 9U-7602 9U-7602 9U-7599 9U-7603 9U-7604

2 Pin Assembly Body 9U-7644 9U-7644 9U-7644 9U-7644 9U-7605 9U-7605 9U-7605 9U-7605 9U-7605

1 Pin Assembly Plunger1 9U-7622 9U-7622 9U-7622 9U-7622 9U-7595 9U-7595 9U-7597 9U-7595 9U-7595

1 Pin Assembly Plunger2 9U-7623 9U-7623 9U-7623 9U-7623 9U-7596 9U-7596 9U-7598 9U-7596 9U-7596

2 Bushing Assembly Base 9U-7612 9U-7612 9U-7613 9U-7613 9U-7592 9U-7592 9U-7592 9U-7593 9U-7592

2 Bushing Assembly Body 9U-7620 9U-7620 9U-7620 9U-7620 9U-7594 9U-7594 9U-7594 9U-7594 9U-7594

2 Bushing Assembly Plunger 9U-7606 9U-7606 9U-7606 9U-7606 9U-7590 9U-7590 9U-7591 9U-7590 9U-7588

2 Pin Disassembly 9U-7785 9U-7785 9U-7785 9U-7785 9U-7782 9U-7782 9U-7782 9U-7782 9U-7782

2 Bushing Disassembly 9U-7786 9U-7786 9U-7786 9U-7786 9U-7783 9U-7783 9U-7783 9U-7783 9U-7783

2 Extruder Assembly — — 142-5896 142-5896 — — — — —

2 Anvil Assembly — — 8T-3216 8T-3216 — — — — —

2 Handle Assembly — — 8T-3211 8T-3211 — — — — —

1 Snap Ring Master Adapter 9U-7787 9U-7787 — — — — — — —

1 Link Spacer — — — — 9U-7798 9U-7796 9U-7797 — —

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (100/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578

4 Spring 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

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Models Serviced

D9N D9H, 594 D10N D10 D10Description D9L, 589, Sealed and D9N D9, 245 375 Sealed and Sealed and Sealed and Sealed and

PPR Lubricated PPR Sealed Sealed Lubricated Lubricated Lubricated Lubricated

Right-Hand Link 7T-4137 9W-2743 7T-2275 9S-1927 6Y-6721 9S-1927 9W-5265 9G-5507 9W-5723Qty. Pitch 9.00 in 9.45 in 9.45 in 10.25 in 10.25 in 10.25 in 10.25 in 10.25 in 10.25 in

1 Saddle 9U-7770 9U-7769 9U-7769 9U-7768 9U-7768 9U-7768 9U-7768 9U-7768 9U-7768

2 Pin Assembly Base 9U-7601 9U-7600 9U-7830 9U-7584 9U-7581 9U-7581 9U-7582 9U-7583 9U-7583

2 Pin Assembly Body 9U-7605 9U-7605 9U-7605 9U-7585 9U-7585 9U-7585 9U-7585 9U-7585 9U-7585

1 Pin Assembly Plunger1 9U-7595 9U-7595 9U-7595 9U-7578 9U-7578 9U-7578 9U-7578 9U-7578 9U-7578

1 Pin Assembly Plunger2 9U-7596 9U-7596 9U-7596 9U-7579 9U-7579 9U-7579 9U-7579 9U-7579 9U-7579

2 Bushing Assembly Base 9U-7592 9U-7592 9U-7592 9U-7575 9U-7575 9U-7576 9U-7575 9U-7575 9U-7575

2 Bushing Assembly Body 9U-7594 9U-7594 9U-7594 9U-7577 9U-7577 9U-7577 9U-7577 9U-7577 9U-7577

2 Bushing Assembly Plunger 9U-7588 9U-7589 9U-7589 9U-7574 9U-7574 9U-7574 9U-7572 9U-7573 9U-7573

2 Pin Disassembly 9U-7782 9U-7782 9U-7782 9U-7779 9U-7779 9U-7779 9U-7779 9U-7779 9U-7779

2 Bushing Disassembly 9U-7783 9U-7783 9U-7783 9U-7780 9U-7780 9U-7780 9U-7780 9U-7780 9U-7780

2 Extruder Assembly 141-2395 — 141-2395 — — — — — —

2 Anvil Assembly 8T-3216 — 8T-3216 — — — — — —

2 Handle Assembly 8T-3211 — 8T-3211 — — — — — —

1 Snap Ring Master Adapter — 9U-7784 — — — — 9U-7781 9U-7781 9U-7781

1 Link Spacer — — — 9U-7795 9U-7794 — — — —

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (100/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578 1B-2578

4 Spring 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746 9U-7746

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

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29

Models Serviced

D10,Description D10N 591 5130 D11N

PPR PPR Sealed PPR

Right-Hand Link 6Y-0935 6Y-0935 6S-8343 6S-3143Qty. Pitch 6.125 in 6.125 in 6.125 in 6.125 in

1 Saddle 9U-7768 9U-7768 9U-7767 9U-7767

2 Pin Assembly Base 9U-7580 9U-7580 9U-7566 9U-7566

2 Pin Assembly Body 9U-7585 9U-7585 9U-7568 9U-7568

1 Pin Assembly Plunger1 9U-7578 9U-7578 9U-7564 9U-7564

1 Pin Assembly Plunger2 9U-7579 9U-7579 9U-7579 9U-7579

2 Bushing Assembly Base 9U-7575 9U-7575 9U-7570 9U-7570

2 Bushing Assembly Body 9U-7577 9U-7577 9U-7571 9U-7571

2 Bushing Assembly Plunger 9U-7572 9U-7573 9U-7569 9U-7569

2 Pin Disassembly 9U-7779 9U-7779 9U-7777 9U-7777

2 Bushing Disassembly 9U-7780 9U-7780 9U-7778 9U-7778

2 Extruder Assembly 142-5894 142-5894 — 1U-5746

2 Anvil Assembly 8T-3216 8T-3216 — 8T-3216

2 Handle Assembly 8T-3211 8T-3211 — 8T-3211

1 Extruder Base — — — 9U-7829

1 Link Spacer — — 9U-7793 —

8 Socket Head Screw 9F-5975 9F-5975 9F-5975 9F-5975

4 Jam Nut3 (l00/pkg.) 1B-2578 1B-2578 1B-2578 1B-2578

4 Spring 9U-7746 9U-7746 9U-7746 9U-7746

4 Set Screw 5B-0448 5B-0448 5B-0448 5B-0448

1 Disassembly Spacer Group4 126-4041 126-4041 126-4041 126-4041

1 First assembly side plunger.2 Second assembly side plunger.3 Order package quantity is 100 for this item (only 4 needed for assembly).4 Only 1 disassembly spacer group needed per track shop.

Page 49: Undercarriage Tooling Reference Manual · Septemb SEBF8516-04 NEHS0804 er 2004 Undercarriage Tooling Reference Manual SEBF8516 - Equipment and Tools for Undercarriage Rebuilding and

©2001 Caterpillar Inc.All Rights Reserved

NEHS0804-01Printed in U.S.A.

For information on service tools or shop supplies,contact Caterpillar Service Technology Group on:

Caterpillar Service Technology501 S.W. Jefferson Ave.Peoria, Illinois 61630-21841-800-542-8665 (USA)1-800-541-8665 (Illinois)1-800-523-8665 (Canada)404435 (Telex)1-309-675-6650 (Fax)Hotline Email “CSTG”

or

Caterpillar Service TechnologyCaterpillar Overseas S.A.P. O. Box 60001211 Geneva 6Switzerland+41 (22) 849 40 56 (Geneva Phone)+41 (22) 849 49 29 (Geneva Fax)36CSTG (COSA E-Mail Address)