PDF Handbook Manual Caterpillar Custom Track Service - 1 MB
The Caterpillar Custom Track Service Handbook is an authoritative guide for servicing and maintaining Cat undercarriages.
This manual provides extensive information on inspection, wear analysis, and repair procedures for track-type machines.
It is an essential resource for service technicians to properly manage and extend the life of undercarriage components, a critical factor in machine operating costs.
This handbook helps you make informed service decisions.
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Caterpillar®
Custom Track
Service Handbook
Custom Track Service Handbook
CUSTOM
TRACK
SERVICE
R
PEKP9400-03 Printed in U.S.A.
15th edition
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01.G.I.,M.&M (01-93) 7/11/03 3:40 PM Page 10
General Information
MEASUREMENT TOOLS
Ultrasonic Wear Indicator
The ultrasonic wear indicator measures component thickness by sending high frequency
sound waves through the material to be measured. The elapsed time between sending
and receiving the sound waves allows the tool to determine thickness.
This electronic CTS tool has the following key features and benefits:
• Ultrasonic wave emitting probe • Reduces time spent cleaning parts
(especially bushings and shoes).
• Eliminates measurement errors due to
dirt packing around parts.
• Measures bushings after turning.
• Eliminates errors due to measurement
technique differences among inspectors.
• Measures idler center flange wear.
• Memory • Reduces on-site measurement recording.
• Stores inspections for 64 machines.
• Downloads to CTS computer program for
automatic percent worn and projected
life calculations.
• Uploads previous inspections from CTS computer
program to improve speed and quality
• Language capability • English, French, German, Portuguese, Spanish
• Earphone connector • Allows users to hear “Coupled” beeping indicator
• Backlight feature • Allows users to see the display in poor lighting
conditions
10
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01.G.I.,M.&M (01-93) 7/11/03 3:40 PM Page 20
General Information
VIBRATION
2. To check front idler height, carefully
move the machine in REVERSE until a
track shoe grouser is directly below the
center of the idler shaft. See Illustration 2.
3. Measure the distance (dimension X),
between the bottom of the track shoe
grouser in full contact with the surface and
the bottom of the track shoe grouser directly
below the idler shaft.
Illustration 4. Add plates at point Y.
4. Repeat the procedure of aligning the track
shoe grouser directly below the center of the
idler shaft on the rear idler by carefully Chart B
moving the machine forward. Measure Plate Plate
Model Part No. Thickness
dimension X for the rear idler.
D8L 9P5543 5 mm (.196 in)
5. Idler height varies from model to model
D8N, D8R 7T4699 5 mm (.196 in)
and between front and rear idlers. Compare
D9N, D9R 7T5422 5 mm (.196 in)
dimension X with the recommended nominal
and minimum values for the front and rear D9L, D10N, 9P2704 5 mm (.196 in)
D10R
idlers that correspond to your model as
D10, D11N, 8P8884 5 mm (.196 in)
shown in Chart A. D11R
Prior to adding plates under the bogie pads,
raise the machine until the bogies are hang-
ing free. Carefully support the machine. See
the disassembly and assembly module in
your machine’s Service Manual for the cor-
Illustration 3. Measurement points on a soft surface.
rect procedure.
Note: In the event that a suitable hard
surface is not available for checking idler 8. If dimension X is less than the minimum
height, a less accurate method may be shown in Chart A, plates should be added
used. See steps 6 and 7 below. between the lower bogie pad and the top of
6. Carefully move the machine in the major bogie assemblies at point Y. The
REVERSE until a track shoe grouser is appropriate plates and their part number
directly below the center of the idler shaft. are listed in Chart B. See Illustration 4 for
the correct location to add plates.
7. Stretch a length of string along the top
edge of the track shoes. Dimension X is The addition of one plate installed under a
measured from the string to the point front or rear bogie pad increases idler
where the center line of the idler shaft height by approximately 7.50 mm (.295 in).
intersects the top of the track shoe which is In order to maintain uniform roller loading,
directly below it. See Illustration 3 for the equal number of plates must be installed
location of dimension X. under the intermediate bogie pads. Take
care not to install more plates than are nec-
essary to achieve the proper idler height
dimension. Excessive idler height results in
poor dozer control, particularly while per-
forming finish dozing operations.
20
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01.G.I.,M.&M (01-93) 7/11/03 3:40 PM Page 30
General Information
LINKS
Rail Side Wear (inside and/or outside)
Uneven (Scalloping) Wear CAUSES: Rolling and sliding contact
on Rail Top with roller and idler flanges.
CAUSES: No. 1 & 3: Faster wear rate due to ACCELERATED BY: Same as “Rail Top
reduced contact with rollers at narrower link Wear” plus uneven terrain, turning, side
overlap area (also see Face Wear on page 31). hill operation, misalignment, too wide
shoes and snakiness of unsealed or Sealed
CAUSES: No. 2: Sliding wear due to reduced Track.
contact area with idler at center of link rail.
EFFECT: Reduces rail wear life to service
ACCELERATORS: Same as Rail (Top) limit and rebuildability.
Wear above, particularly tight track.
REMEDIES: Reduce or eliminate control-
EFFECT: No. 1 & 3: Wear limit over pin lable accelerators, particularly snaky track,
boss reached prematurely. tight track and too wide shoes.
No. 1, 2 & 3: Reduces rebuildability and
causes vibration in extreme cases. Counter-
weighting machines will reduce wear. A
1/4" difference will cause a ride problem.
REMEDIES: Same as Rail Top Wear
above. Sealed and Lubricated Track will
have less wear in areas No. 1 & 3 due to no
pitch extension. Better balance will reduce
vibration and potential cracking in cab.
Rail Inside Gouged
CAUSES: Sprocket tooth tip interfering
due to snaky track and/or misalignment of
track or sprocket (see sprocket wear).
ACCELERATORS: Side hill or uneven
Pin Boss Side Wear terrain, turning, too wide shoes.
CAUSES: Sliding contact with guiding EFFECT: Reduced rebuildability of links
and/or roller guards plus abrasives (may and reusability of sprocket segments if
be seen at either or both ends of pin — severe.
usually more severe on outboard side). REMEDIES: Correct controllable causes
ACCELERATORS: Uneven terrain and and accelerators.
side hill operation. Too-wide shoes, worn
rolling component flange, misalignment and
snaky track are main controllable variables.
REMEDIES: Eliminate or reduce control-
lable accelerator variables, particularly
snaky track by turning pins and bushings.
30
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01.G.I.,M.&M (01-93) 7/11/03 3:40 PM Page 40
General Information
SEALED & LUBRICATED TRACK PINS & BUSHINGS
EFFECT: (1) Vertical position should
overtake either pocket as most worn
position in later hours if track is properly
adjusted and new segments are not
installed prematurely. (2) Track may jump
on sprocket if sprocket tooth tip height is
worn excessively and track remained too
loose.
Reverse and/or Forward Drive Side REMEDIES: (1) Eliminate or reduce con-
(30° to 60° from vertical) trollable accelerator variables. Turn bushing
CAUSES: Same as VERTICAL POSI- before this position reaches 120 percent
TION except degree of packing is moder- regardless of the vertical position percent
ately severe. worn. Do not install new segments prema-
turely. (See discussion on use of sprocket
ACCELERATORS: Same as VERTICAL reuse gauge.) (2) Adjust track as recom-
POSITION but particularly tight track. mended in the individual product sections.
EFFECT: VERTICAL POSITION should Install new segments only if tip height is
overtake FDS or RDS as most worn reduced significantly and there is no mod-
position in later hours if track is properly erate to severe packing. Turn bushings
adjusted and new segments are not before this position reaches 120 percent
installed prematurely. regardless of vertical position percent worn.
REMEDIES: Eliminate controllable accel-
erator variables, particularly tight track.
Bushing should be turned at or before
service limit.
Off Center Wear
CAUSES: Misalignment of track and
sprocket.
ACCELERATORS: (1) Various roller
frame and sprocket alignment problems.
Reverse and/or Forward Drive Side (2) Worn rear guiding and/or final drive-
Pocket Wear (60° to 90° from vertical) guiding guards. (3) Side-hill operation.
CAUSES: (1) Same as VERTICAL and EFFECT: Should not increase wear rate of
FDS/RDS except packing is very severe. bushing to wear limits, but may reduce
(2) Track is too loose causing “backjam- bushing retention if accompanied by impact.
ming” as reverse motion at bottom of
REMEDIES: (1) Correct alignment. (2)
sprocket on RDS only.
Replace guiding and final drive-guiding
ACCELERATORS: (1) Same as “Vertical guards.
Position” and FDS/RDS (2) Same as
“Vertical Position” and FDS/RDS except
track tension, which needs to be increased.
Uphill reverse loading of machine with
too loose track is biggest accelerator.
40
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01.G.I.,M.&M (01-93) 7/11/03 3:41 PM Page 50
General Information
SEALED TRACK PINS & BUSHINGS
replaced. The general guidelines discussed
in the section entitled “Track Manage-
ment” should be understood and practiced
before applying these specifics.
1. If a Sealed Track pin and bushing turn
and/or replacement is required to help
utilize total track link life it should be
done on or before either the internal
wear or external bushing service points
(100 percent worn) are reached, which-
Pin Breakage ever comes first.
2. If a pin and bushing replacement is
CAUSES: High static or impact loads
required to help utilize the projected
which cause crack to start at outer surface
total potential link life following the
(usually at pin wear step) and moves
turn of a previous set of pins and bush-
through entire pin at a fast rate.
ings, it should also be done on or before
Pin cracking and breaking is less severe either the internal wear exceeds the ser-
with Sealed and Lubricated Track during vice point (100 percent worn) or the
absence of internal wear. However, it may external bushing surface is run to destruc-
be more serious once lubricant is lost and tion (120 percent worn), regardless of
internal wear is present due to faster rate which occurs first.
of internal wear and loss of pin strength
3. When in doubt, turn early for best after
due to reservoir hole.
turn and after replacement wear and
ACCELERATORS: Horsepower, weight structural life performance contributing
and speed of machine. Impact and terrain to overall best total track life and parts
conditions. Amount of internal wear that reusability.
reduces pin diameter. Tight track, too-
Do not use these criteria to determine if
wide shoe, worn rear rollers and severe
and when to turn as they involve unreli-
packing loads caused by rocks between
able measurement techniques:
bushing and sprocket are main control-
lable variables. 1. Sprocket wear lines or general sprocket
tooth wear condition.
EFFECT: Immediate track separation.
Severe damage to other components. 2. Extent of idler adjustment used to remove
slack is determined by pitch extension
REMEDIES: Eliminate or reduce control-
from internal wear.
lable accelerator variables, particularly rocks
which are getting into spaces between 3. Waiting until other components (such
sprocket and bushings. as shoes) are ready for maintenance or
service based on previous experience of
phasing work at the same time.
Sealed Track Pins Remember, if pins and bushings are
& Bushing Turn and run to destruction internally prior to
replacement, then the replacement set
Replacement Guidelines may give as little as 80 percent life of
The following guidelines should be used the original set.
in determining if and when Sealed Track
pins and bushings should be turned and/or
50
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01.G.I.,M.&M (01-93) 7/11/03 3:41 PM Page 60
General Information
CARRIER ROLLERS
Swapping Carrier Rollers
Carrier rollers can be swapped from front
to rear and left to right to help balance
their wear life in cases where conditions
have caused unequal wear rates. Criteria
are: greater than 1.5:1 ratio and average
less than 60 percent worn.
Uneven Flange Side Wear and Off-
Carrier Roller Wear Patterns center Tread Wear
CAUSES: Rolling and sliding contact
There are three principle wear patterns
with link rail top and sides not aligned
found on carrier rollers. In each case the
with carrier roller.
effect on the links may be more critical,
considering total undercarriage life, than ACCELERATORS: Same as “Carrier
on the carrier rollers themselves. Roller Tread Wear” plus terrain and side-
hill; and misalignment of carrier rollers,
sprocket and/or idler. Offset shoes will
move track to outboard side.
EFFECTS: Loss of potential wear life and
rebuildability of carrier roller and links.
REMEDIES: Reduce or eliminate control-
lable accelerators. Swap carrier roller to
balance wear.
Tread Wear (Uniform)
CAUSES: (1) Rolling and sliding motion Flat Spots
with link rail (top) surfaces. (2) Sliding
contact with packing material on roller
frame.
ACCELERATORS: Machine speed.
Weight of track which is governed by shoe
width including packing material. Track
tension is primary controllable variable as Flat Spots on Tread
tight track increases loads and too loose
track causes impact between links and CAUSES: Sliding contact with link rail
tread surface, particularly in forward tops when carrier roller not turning.
motion. ACCELERATORS: Same as “Even Tread
EFFECT: Wear life of carrier roller and Wear.” Packing between roller frame and
links. No other components affected carrier roller is principle cause of seizing.
unless service limit exceeded, then flanges EFFECT: Reduced wear life and rebuild-
may strike bushings causing unusual wear ability of carrier rollers. Accelerated wear
pattern and premature failure. on links.
REMEDIES: Maintain proper track tension REMEDIES: Clean packing material away
and reduce or eliminate other controllable from carrier rollers.
accelerator variables. Rebuild or replace
carrier roller shell when service limit reached.
60
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01.G.I.,M.&M (01-93) 7/11/03 3:41 PM Page 70
General Information Information
SPROCKETS
Mud & Snow Segments How to Properly Torque
and Rims Segment Hardware
The principal cause of segment loosening,
and subject loss and/or damage to other
parts, is improper torque-turn tightening
method.
To install segment hardware, first, lubri-
cate the bolt threads and the washer face
of the nut with 5P3931 Antiseize Com-
pound or an equivalent lubricant.
Second, tighten all nuts on any one
segment to the specified initial torque. This
draws the mating parts tightly together.
Mud/snow sprockets, rims and segments
Third, tighten each nut a 1/3 additional
have the same tooth profile as standard
turn. This stretches the bolt properly for
segments. They provide an avenue to
good segment retention.
relieve the pocket of material through a
slot cut into the tooth root. The same The actual torque specifications can be
segment serves both Sealed and Sealed found in the “Management” section of
and Lubricated Track. each type machine.
They should be recommended only where
packing material is extrudable (see discus-
sion on “Packing” in section entitled
“Underfoot Conditions”) and is always
present.
In the absence of constant, extrudable type
packing material, the reduced contact area
in the root of the tooth will cause an accel-
erated “hour-glass” shaped wear pattern
on the bushing in the vertical position and
may result in reduced bushing wear life.
70
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01.G.I.,M.&M (01-93) 7/11/03 3:41 PM Page 80
Management & Merchandising
INSPECTION REPORT
80
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01.G.I.,M.&M (01-93) 7/11/03 3:41 PM Page 90
Management & Merchandising
COST PER HOUR
Total Cost Per Hour of New Track Groups
(a.) (b.) (c.)
10,000 12,000 13,500
Cost to
Replace P & B (Twice) (Once) (None)
Parts 3,000 1,500 0
Labor 1,000 500 0
Cost to Turn P & B (None) (Twice) (Once)
Parts 300 0
Labor 1,000 750
Cost to Replace Shoes (Twice) (Once) (None)
8,000 6,000
Cost to Remove & Install Shoes (Twice) (Once) (Once)
Labor (Inc. W/P&B Rep) (Inc. W/P&B Rep) (Inc. W/Bush Turn)
Hardware 200 100 100
Cost to Regrouser (None) (None) (In Shop) 1500
Cost of Handling & Transportation 400 (Twice) 200 (Once) 200 (Once)
Cost of Downtime 1,000 (Twice) 500 (Once) 500 (Once)
Trade in Value N/A N/A -600
Exchange Value N/A -1600 N/A
Scrap Value -400 N/A N/A
Total 23,200 20,500 15,950
TOTAL Track Group Cost
per hour of effective life 23,200 = 3.31
________ 20,500 = 2.93
________ 15,950 = 2.28
_______
7,000 SMU 7,000 SMU 7,000 SMU
This comparison could be expanded to include respective segment, roller, carrier roller,
idler and other wear part costs over the same link life or compared individually over
their own respective and effective total wear lives.
90
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02.1.Elev.(94-109) 7/11/03 3:42 PM Page 100
Elevated Sprocket Machines
COMPONENTS
Pins and Bushings
Wear Patterns — The undercarriage
design of elevated sprocket machines and
the absence of “snakiness” in Sealed and
Lubricated Track allow it to “track” very
straight. This straight tracking causes the
Elevated Sprocket Machines use Sealed
roller to wear with a slight ridge running
and Lubricated Track. See pages 36
down the center of the tread. This ridge
through 43 for details. The following
results from less wear occurring on the
points are specifically for elevated sprocket
center of the roller tread as it passes over
machines:
the links in their overlap area. The ridge
on the roller may in turn wear a groove Measurement — Use the caliper or the
down the center of the link rail. This wear Ultrasonic Wear Indicator to measure all
pattern is normal for these machines. It three bushing contact sides: forward,
may occur less often on machines with reverse, and vertical. Use the most worn
non-suspended undercarriage. D9R, position to make projections. This practice
D10R, and D11R machines with improved is necessary because wear can occur in all
alignment undercarriage also minimize or three positions, depending on the degree
eliminate this wear pattern. of packing. The depth gauge should not be
used before a bushing turn because it only
measures vertical bushing wear. After a
bushing turn, the depth gauge can be used
to approximate wear based on the vertical
dimension.
Bushing Allowable Wear — Bushing
allowable wear is based on the remaining
strength to resist cracks. For low sprocket
machines, the choice between two allow-
As elevated sprocket undercarriage wears, able wears is based on high or low impact
a larger scallop develops over the link conditions because the sprocket is close to
strut than on oval undercarriage machines. the ground and subject to impact.
This is because the track link goes around The choice between the two allowable
two idlers instead of one. This wear is not wears for elevated sprocket machines is
considered critical. Evaluate link wear different because the sprocket is not
based on wear directly over the pin area. subject to impact. For machines in under-
Split Master Links — Use the assembly foot conditions which have only fine
procedures on page 33 for split master granular materials, use the chart showing
links. Refer to “Shoes” on the following the greater allowable wear. For all other
page for bolt torque specifications. conditions use the chart with lesser allow-
able wear.
100
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02.Elev.(110-145) 7/11/03 3:43 PM Page 110
Elevated Sprocket Machines
D4H, D5M, D5N, 561H, 561M, 561N — 6.75" (171.5 mm)
Track Links
Heavy Duty Track
Rotating Bushing Track
108-0947 & 48
Depth Gauge Ultrasonic
Inches (mm) % Worn Inches (mm)
4.17 (106.0) 0 1.22 (31.0)
4.15 (105.5) 6 1.20 (30.5)
4.13 (105.0) 12 1.18 (30.0)
4.11 (104.5) 18 1.16 (29.5)
4.09 (104.0) 24 1.14 (29.0)
4.07 (103.5) 30 1.12 (28.4)
4.05 (103.0) 36 1.10 (27.9)
4.03 (102.5) 42 1.08 (27.4)
4.01 (102.0) 48 1.06 (26.9)
3.99 (101.5) 54 1.04 (26.4)
3.97 (101.0) 60 1.02 (25.9)
3.95 (100.5) 65 1.00 (25.4)
3.93 (100.0) 70 0.98 (24.9)
3.91 (99.5) 75 0.96 (24.4)
3.89 (99.0) 80 0.94 (23.9)
3.87 (98.5) 85 0.92 (23.4)
3.85 (98.0) 90 0.90 (22.9)
3.83 (97.5) 95 0.88 (22.4)
3.81 (97.0) 100 0.86 (21.8)
3.79 (96.5) 105 0.84 (21.3)
3.77 (96.0) 110 0.82 (20.8)
3.75 (95.5) 115 0.80 (20.3)
3.73 (94.5) 120 0.78 (19.8)
Undercarriage Code: 1108, 111, 1121, 1122, 1208, 121, 124, 125, 1251, 128, 129, 1291
110
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02.Elev.(110-145) 7/11/03 3:43 PM Page 120
Elevated Sprocket Machines
D4H, D5M, D5N, 561H, 561M, 561N — 6.75" (171.5 mm)
Idlers
Original Idler
5.31" (135 mm)
Depth Gauge
Inches (mm) % Worn
0.66 (17.0) 0
0.68 (17.5) 8