Installation (Set Up) Instruction For The Caterpillar 350 Ton Track Press{0685, 4170} Caterpillar


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Installation (Set Up) Instruction For The Caterpillar 350 Ton Track Press{0685, 4170} [NEHS0613]
FRAME AND BODY
TOOLS
Installation (Set Up) Instruction For The Caterpillar 350 Ton Track Press{0685, 4170}
1.1. Introduction
2.1. Special Tools Needed
3.1. Special Materials Needed
4.1. Component Identification
5.2. Front View Of Caterpillar 350T - With Operator's Door Raised
6.2. Rear View Of Caterpillar 350T - Showing The Indexer And Winch
7.2. Side View Of Caterpillar 350T - Showing The Track Press, Indexer, Winch, And Conveyor
8.1. Unpacking The Track Press
9.1. Locating The Track Press
10.1. Installing The Indexer Table
11.2. Rear View Of The Left Side Of The Track Press And Indexer
12.2. Closeup View Of The Rear Of The Track Press And Indexer
13.2. Closeup View Of The Rear Of The Track Press And Indexer
14.1. Installing The Hydraulic Hoses And Electric Cable
15.2. First Conveyor Leg - (To Be Installed In The Front Of Each Conveyor Section)
16.2. Plain Conveyor Leg - (To Be Installed In The Center Of 6 m (20 feet) Long Conveyor Sections And The End Of The Last Conveyor Section Next To The Ramp)
17.2. Shoe Lifter Cylinder And Valve Group
18.2. Shoe Lifter Cylinder And Valve Group
19.2. Shoe Lifter Cylinder And Valve Group
20.1. Assembling The Conveyor
21.2. First Conveyor Leg - Showing The Connections Between The Two Sections Of Conveyor
22.2. Last Conveyor Section - Showing The Brackets For The Ramp
23.2. Ramp
24.1. Operational Check Of The Track Press
25.2. Operator's Control Station
26.2. Control Panel For Shoe Lifter
27.2. Control Panel For Shoe Lifter
28.2. Drive Motor

Introduction

This instruction gives the installation (setup) procedures for the AVSpare 350T Track Press. If the track press is installed according to the procedures in this instruction, it will provide an excellent tool for track disassembly and assembly.

Do not perform any procedure, outlined in this instruction, or order any parts until you have read and understood the information contained within.

Particular emphasis is placed on the leveling of the track press and conveyor. The track press and all sections of the conveyor must be level in both directions, side to side and in the direction the track lays along the conveyor. The track press and the conveyor must be level. The indexer table must be level from side to side.

Any component which is not level will cause the track joints to become misaligned with the tooling. Misalignments with the tooling will cause the operator to continually adjust the tooling with each track joint. Extra steps waste time and contribute to tooling and track component damage. Misaligned and out-of-level conveyor sections make it more difficult to mount the track wrench to the conveyor and make it harder for the operator to move the wrench along the conveyor.

The track press system comes in three basic components:

* The first is the track press, which includes the track press, controls, operator door, five-bolt and six-bolt nut bars, hydraulic tanks and valves, winch control pendant, hold-down shoe, work lights, and dial adjustable tool mounts with T-slot bolts and center studs.
* The second component is the indexer table which includes the indexer engagement mechanism, the indexer drives, and the two speed winch with seventy feet of cable. There are three hydraulic circuits on the indexer table which must be attached. These are the indexer engagement cylinder, the indexer drive motors, and the winch. One electrical connection must be attached on top of the winch.
* The final component is the conveyor and shoe lifter mechanism. The hydraulic lines must be attached to the shoe lifter. All eight hydraulic hoses are identified with a number etched on each pair of hydraulic connectors - numbered 1 through 8. No other hydraulic attachments must be made.

The right side of the track press, indexer, and conveyor sections is defined while standing at the operator's station at the track press and looking down along the conveyor.

Special Tools Needed

The following special tools are needed for track press installation:

* Electric drill; suitable for drilling holes in concrete.
* Masonry drill bit; 25 mm (1.0 inch) diameter.
* Masonry drill bit; 19 mm (0.75 inch) diameter.
* Level; 457 mm (18.0 inch) long - minimum.
* Cord (string); 30.5m (100 feet) long for use as an alignment tool.
* Transit; for use in the alignment and leveling procedure.

Special Materials Needed

The following special materials are needed for track press installation:

* Six concrete anchors for the track press; 25 mm (1.0 inch) diameter.
* Two concrete anchors per conveyor leg; 19 mm (0.75 inch) diameter.
* Steel shim stock; both 1.6 mm (0.06 inch) thick and 3.2 mm (0.13 inch) thick are needed.

NOTE: The use of wedge lock concrete anchors is recommended. These anchors can be installed without moving the track press or conveyor once they are correctly positioned. The length of the concrete anchors and the amount of shims, including additional thicknesses, required will be determined by how level the floor is in the area where the track press is to be installed. See illustration 15.

Component Identification

Front View Of AVSpare 350T - With Operator's Door Raised
With Operator's Door Raised


Illustration 1

1. Main Hydraulic Cylinder

2. Operator's Controls

3. Operator's Door

4. Hydraulic Tank

5. Conveyor

6. 64 mm (2.5 inch) Top Plate (Shelf)

7. 150 mm (6 inch) Side Plates

8. 100 mm (4 inch) - Reinforced Base Plate

Rear View Of AVSpare 350T - Showing The Indexer And Winch
Showing The Indexer And Winch


Illustration 2

1. Track Press

2. Indexer Table

3. Indexer Engage Cylinder

4. Winch

5. Conveyor

6. Shoe Lifter Rail

Side View Of AVSpare 350T - Showing The Track Press, Indexer, Winch, And Conveyor
Showing The Track Press, Indexer, Winch, And Conveyor


Illustration 3

1. Track Press

2. Press Operator's Controls

3. Transformer Location for Power Hookup

4. Winch Control Pendant

5. Shoe Lifter Controls

6. Indexer

7. Winch

8. Temporary Fixture - Not Included with Track Press

9. Conveyor

10. Shoe Lifter Cylinder and Control Valve Assembly

Unpacking The Track Press

Remove the shipping bands, cardboard, and any other protective material that was used for shipping the track press. DO NOT remove the shipping bands that secure the indexer lift cylinder until the track press has been installed and ready to be hooked up to the indexer table.

Inspect the track press for any damage that may have been caused during shipping. Check also for any missing pieces that may have been lost during shipping.

The track press can be lifted by a lift truck. The operator's door must be raised and secured in place. The lift truck forks can be inserted under the top plate (shelf) on the track press. Care should be taken not to damage the work lights located at each end of the underside of the top plate (shelf).

The indexer can be released from the shipping materials and raised until the indexer table is approximately horizontal. The indexer table can be lifted by inserting lift truck forks or straps from an overhead hoist under the table on either side of the indexer engage cylinder. The indexer table is shipped mounted to the first conveyor leg and to a temporary leg under the front portion of the indexer table.

The conveyor sections are complete assemblies which include the gravity rollers, frame rails, wrench rails, shoe lifter rails, and shoe lifter linkage in one unit. The conveyor sections can be lifted by inserting the lift truck forks or lifting straps under the center portion of the section.

Locating The Track Press


NOTICE

When a hoist or lift truck is used to lift any part or assembly, stand clear of the area. Be sure the hoist or lift truck has the capacity to lift a heavy part or assembly.


The approximate dimensions of the track press and indexer are 3 m (9 feet) wide and 2.4 m (8 feet) long - in the direction of the conveyor.

It is recommended that a minimum side clearance of 1.2 m (4 feet) be provided to allow easy access to parts storage.

Clearance behind the track press (operator's side of the track press) should be 2.4 m (8 feet) minimum. This clearance allows room for work tables, etc.

Conveyor sections are available in 6 m (20 feet), 3 m (10 feet), and 1.5 m (5 feet) lenghts.

The ramp is approximately 1.5 m (5 feet) long installed, measured horizontally.

NOTE: Locate the track press so that the press, indexer, and conveyor are square inside the building, within reason. Measure from each side of the press frame to a fixed object (facility wall). The measured distance must be the same within 3.2 mm (0.13"). Move the press as necessary to obtain this position.

Installing The Indexer Table

Rear View Of The Left Side Of The Track Press And Indexer


Illustration 4

1. Track Press

2. Hold Down Shoe Assembly

3. Extension Bars

4. Indexer Lift Cylinder

5. Indexer Table

6. Winch

7. Electric Directional Control Valve for Winch

Closeup View Of The Rear Of The Track Press And Indexer


Illustration 5

1. Track Press

2. Indexer Table

3. Hold Down Shoe Cylinder

4. Indexer Lift Cylinder - Double Action

5. Indexer Engage Cylinder

6. First Conveyor Leg

Closeup View Of The Rear Of The Track Press And Indexer


Illustration 6

1. Track Press

2. 100 mm (4 inch) Base Plate

3. Hold Down Shoe Link

4. Indexer Table

5. Extension Bar

6. Support Pin for Extension Bar

7. Front Edge of Indexer Table

Install the extension bars on the front of the indexer table. Note the position of the undercuts on the bottom of the extension bars, shown in Illustration 1. Locate the indexer table parallel to the back surface of the 100 mm (4 inch) base plate on the track press. Locate the front edge of the indexer table 19 mm (0.75 inch) from the back surface of the base plate on the track press. Position the front of the indexer table between the links of the hold down shoe so that the indexer lift cylinder is positioned vertically. Attach the indexer lift cylinder to the indexer table.

Installing The Hydraulic Hoses And Electric Cable

Attach the hose connections using the numbers etched on the fittings. Hydraulic connections which can be made are as follows:

1. Indexer engage cylinder
2. Indexer drive motors
3. Winch. The electrical connection to the winch can be made at this time.

First Conveyor Leg - (To Be Installed In The Front Of Each Conveyor Section)
(To Be Installed In The Front Of Each Conveyor Section)


Illustration 7

1. First Conveyor Leg

2. Hydraulic Pipes for Shoe Lifter

3. Support Bracket for Hydraulic Pipes

4. Holes for Fastening the Leg to the Floor

5. First Conveyor Section Mounting Holes

The first leg for the conveyor is delivered attached to the rear of the indexer table. Two short hydraulic pipes are included which will be attached to the first conveyor leg using the support brackets. The hydraulic hoses from the track press are to be connected to the ends of the short hydraulic pipes. The shoe lifter cylinder and valve group will be connected to the fittings pointing towards the floor. The tube on the right has the pilot-operated check valve.

Plain Conveyor Leg - (To Be Installed In The Center Of 6 m (20 feet) Long Conveyor Sections And The End Of The Last Conveyor Section Next To The Ramp)
(To Be Installed In The Center Of 6 m (20 feet) Long Conveyor Sections And The End Of The Last Conveyor Section Next To The Ramp)


Illustration 8

1. Plain Conveyor Leg

2. Hydraulic Pipes for the Shoe Lifter

3. Support Bracket for the Hydraulic Pipes

4. Holes to Fasten the Leg to the Floor

5. Conveyor Section Mounting Holes

Position the conveyor legs along the floor in their approximate locations. Position the first conveyor leg at the front of each conveyor section and position a plain conveyor leg in the center of any 6 m (20 feet) conveyor section. Position each first conveyor leg such that the shoe lifter cylinder mounts face away from the track press. Position a plain conveyor leg at the extreme end of the conveyor next to the ramp.

Shoe Lifter Cylinder And Valve Group


Illustration 9

1. Shoe Lifter Cylinder

2. Pilot Operated Control Valve

3. Base End Connection - Raises Shoe Lifter Linkage

4. Rod End Connection - Lowers Shoe Lifter Linkage

The shoe lifter cylinder and valve group is shipped assembled.

Shoe Lifter Cylinder And Valve Group


Illustration 10

1. Conveyor Leg

2. Shoe Lifter Cylinder

3. Pilot Operated Control Valve

4. Right Hand Hydraulic Pipe - Attached to #2 Port in Manifold and out #3 Port - Raises Shoe Lifter Linkage

5. Left Hand Hydraulic Pipe - Attached to Rod End Connection - Lowers Shoe Lifter Linkage

The shoe lifter and valve group are mounted to the first conveyor leg. The fitting in the side of the control valve is plumbed into the right hand hydraulic pipe. The left hand hydraulic pipe is connected to the T-shaped fitting which is connected to the tube from the end of the control valve and the hose, which is routed to the rod end of the shoe lifter cylinders.

Shoe Lifter Cylinder And Valve Group


Illustration 11

1. Conveyor Leg

2. Shoe Lifter Cylinder

3. Pilot Operated Control Valve

4. Right Hand Hydraulic Pipe - Attached to Base End Connection - Raises Shoe Lifter Linkage

5. Left Hand Hydraulic Pipe - Attached to Rod End Connection - Lowers Shoe Lifter Linkage

Remove the plugs from the ends of the T fittings on the ends of the hydraulic pipe. Install the next section of hydraulic pipe into each T fitting. Be careful to choose hydraulic pipe with the same length as the next section of conveyor. The T fitting on the end of the hydraulic pipe must extend past the next first leg. Attach the hydraulic pipes to the legs using the support brackets. Do not tighten the support brackets so that the conveyor legs can be moved along the hydraulic pipes to line up with the ends of the conveyor.

Repeat the process until the last first leg is reached at the front of the last piece of conveyor section.

Assembling The Conveyor

First Conveyor Leg - Showing The Connections Between The Two Sections Of Conveyor
Showing The Connections Between The Two Sections Of Conveyor


Illustration 12

1. Shoe lifter rail

2. First Leg

3. Hydraulic Pipes

4. Shoe Lifter Linkage

5. Shoe Lifter Cylinder

Attach the conveyor sections to the tops of the first legs and the plain legs (6 m - 20 feet long conveyor sections). Install the 12 mm (0.5 inch) - 13 thread bolts provided. Do not tighten these bolts completely. Attach the ends of the shoe lifter cylinders to the ends of the shoe lifter linkage. Repeat the process until the conveyor is completely installed. Using 12 mm (0.5 inch) - 13 bolts provided, attach the ends of the shoe lifter rails together.

Last Conveyor Section - Showing The Brackets For The Ramp
Showing The Brackets For The Ramp


Illustration 13

1. Conveyor

2. Plain Conveyor Leg

3. Mounting Bracket for Ramp (with pin installed)

Ramp


Illustration 14

1. Ramp

2. Ramp Mounting Bracket

3. Conveyor

4. Ramp Mounting Pin

Line up the mounting holes in the end of the ramp with the holes in the ramp mounting bracket. Install the mounting pin. Retain the mounting pin with washers and keys, provided.

Make sure that the conveyor is located in a straight line which lines up with the centerline of the track press. Pull a tight string along the edge of the conveyor to assist in aligning conveyor sections. Tighten all bolts between the conveyor and the legs, in the hydraulic support brackets, and the shoe lifter rail connections.

The operating height for the conveyor is 864 mm (34 inches) from the floor to the top of the gravity rollers. The working height for the track press is 775 mm (30.5 inches) from the floor to the top of the base plate, the surface on which the saddles are mounted.

The indexer table is mounted on the first conveyor leg; the height is determined by the height of the conveyor. The other end of the indexer table, next to the track press, is adjustable to position the extension bars on top of the saddle bolts. Different combinations of saddles, such as a AVSpare Saddle or a Wolff saddle positioned on the conversion plate, require the front of the indexer table to be adjusted to different elevations. The indexer lift cylinder contains an adjustment mechanism which changes the collapsed height of the cylinder to determine the position of the fully lowered indexer table.

Determine the highest point of the floor under the track press, indexer, and conveyor. Calculate the amount of shims needed to raise the track press to this highest point. Install the required amount of shims under the track press to level it from front to back within 0.8 mm (0.030 inch) over the length of the work area on the base plate. Level the press from side-to-side within 0.8 mm (0.030 inch) across the width of the base plate from inside-to-inside of the 150 mm (6 inch) side plates.

Start at the indexer and level the conveyor using the same method. The conveyor must be level in both directions, from side-to-side and lengthwise. Install the required number of shims under the legs to level the conveyor within 0.8 mm (0.30 inch) from outside-to-outside of the conveyor and within 0.8 mm (0.30 inch) over 610 mm (24 inches) over the length of the conveyor. The shims under the conveyor legs should be the same shape and size as the plate at the bottom of the leg. This assures proper support of the leg and eliminates housekeeping problems.

Drill the holes in the concrete through the holes in the track press floor plate and the holes in the bottom of the conveyor legs. Secure the press and conveyor in position with concrete anchors. An anchor like the Phillips Wedge Lock is recommended.


Illustration 15

Operational Check Of The Track Press


Illustration 16

1. Hydraulic Tank

2. Sight Gauge

The two hydraulic tanks have a combined capacity of 114 liters (30 U. S. gallons). There is a crossover pipe between the tanks to equalize the levels in the tank. It is faster, however, to fill each tank. Add oil until the sight gauge is approximately 2/3 full. Use 10W premium hydraulic oil, JIC. The oil should contain anti-wear and anti-foaming additives. Use 8T9581 AVSpare Hydraulic Oil or 3E5783 AVSpare Biodegradable Hydraulic Oil. Both part numbers are 208 liter (55 U. S. gallon) quantities.

Operator's Control Station


Illustration 17

1. Control Lever for the Left Hand Main Hydraulic Cylinder

2. Control Lever for the Right Hand Main Hydraulic Cylinder

3. Main hydraulic Cylinder Pressure - Reads in Tons

4. One-Turn Main Relief Valve Control Knob

5. Press Control Box

6. Factory Set @ 2930 psi - 300 T.

The control buttons (from left to right, starting at the top) on the control box are as follows:

1. Hold Down Shoe - Raise
2. Indexer - Raise
3. Manual Index - Retract
4. Manual Index - Advance
5. Hold Down Shoe - Lower
6. Indexer - Lower
7. Automatic Index - Retract
8. Automatic Index - Advance
9. Motor Start
10. Assembly/Disassembly
11. Indexer Drive - Engage
12. Indexer Drive - Disengage
13. Mushroom - Pull on/Push off
14. Index Retract Timer
15. Index Advance Timer

The controls for the shoe lifter are located on the back side of the right hand main hydraulic cylinder, directly across from the operator's control station. The shoe lifter controls are located within easy sight of the shoe lifter for best operation. Included with the shoe lifter raise/lower spring centered blade switch are the indexer engage/disengage and indexer drive controls. See Illustrations 18 and 19.

Wire the transformer located on the right hand side of the track press below the main hydraulic cylinder. Use the following information as a guideline for supplying power to the track press:

NOTE: Use "Slow Blow" Fuses.

Control Panel For Shoe Lifter


Illustration 18

1. Conveyor

2. Indexer

3. Winch

4. Assessory Pressure Gauge

5. Shoe Lifter Control Panel

6. Winch Pendant

7. Flow Divider

Control Panel For Shoe Lifter


Illustration 19

1. Shoe Lifter Control Panel

2. Winch Control Pendant

3. Shoe Lifter - Raise/Lower

4. Indexer Engage/Disengage

5. Indexer Drive Advance/Retract

Drive Motor


Illustration 20

1. Electric Drive Motor

2. Hydraulic Pump

3. Access Panel

Remove the access panel from the housing between the electric drive motor and the hydraulic pump. Pull the Red Mushroom Button out, press the Motor Start Button, and quickly push in the Red Mushroom Button. This jogs the motor briefly. Have a second person observe the direction of the rotation of the coupling through the access window. The side of the coupling towards the window should rotate DOWNWARD. If the motor rotates upward, switch the center and one end wire at the transformer box.

Pull the Red Mushroom Button on the operator's control panel and press the Motor Start Button. The track press electric motor and hydraulic pump will start. Use the Main Hydraulic Cylinder Levers to move the main hydraulic cylinders from full retraction to full extension and return. Do this several times to remove air from these cylinders. Repeat this procedure for the Hold Down Shoe, Indexer Lift, Indexer Engage, Indexer Drive, and Shoe Lifter.

Perform a walk-around inspection of the track press components to inspect for leaks in any part of the various hydraulic circuits. Tighten any connection that may have become loosened during shipment. It is a good idea to perform a daily walk-around inspection.

Check the operation of the automatic indexer. Set 3.0 seconds on the advance timer and 1.2 seconds on the retract timer. Press and hold the Indexer Drive Disengage until the top portion of the indexer is raised to its full height. Insert a 100×100 mm (4×4 inch) or 150×150 (6×6 inch) wooden timber, 1.2 to 1.8 m (4 to 6 feet) long, on top of the indexer table between the indexer rollers. Make a pencil mark at one end of the wooden timber to measure the distance the automatic indexer moves it. Press Automatic Index Retract and the following sequence of operations will occur:

1. Raise Hold Down Shoe

2. Engage the Indexer

3. Raise the Indexer Table

4. Index approximately 230 mm (9 inches)

5. Lower the Indexer Table

6. Disengage the Indexer

Check to verify that the wooden timber has been moved approximately 230 mm (9 inches). Repeat the operation using the Automatic Index Advance. The indexer timers can be adjusted slightly to obtain almost exactly 230 mm (9 inches) of travel.

There are three limit switches which control functions of the track press. Each main hydraulic ram must be completely retracted before any of the indexer functions can be used. Check the function of the limit switches as follows:

1. Extend the right hand main hydraulic cylinder about one inch.

2. Press and hold the Indexer Lift Up button. The indexer table should not move.

3. Slowly retract the right hand main hydraulic cylinder. The right hand main hydraulic cylinder should be 3 to 6 mm (0.12 to 0.25 inch) from full retraction at the point the indexer table lifts.

4. Repeat the process using the left hand main hydraulic cylinder.

Check the operator's door limit switch as follows:

1. Set the Assemble/Disassemble switch on the operator's control panel to Disassemble.

2. Open the Operator's door.

3. Turn the Relief Valve Control Knob to the lowest setting.

4. Extend the right hand main hydraulic cylinder completely and hold the control lever to maintain full extension.

5. Slowly increase hydraulic pressure by turning the Relief Valve Control Knob clockwise.

6. The press should shut off at 80 tons.

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