Durapac TTP Series User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia
[e-mail] –Phone: [phone] –Fax: [phone]
Maximum Operating Pressure –700 bar
Instruction Manual
Track Link Pin Pusher & Installer
Model –TTP Series

Instruction Manual
TTP Series –Pin Pusher –V1.4 www.durapac.com Page 2 of 21
This is a safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid injury or death
1.0 Product Information
DURAPAC –Track Link Pin Pusher & Installers are engineered to meet Industrial Standards for
Performance and Safety. The TTP Series is specially designed for tracked machines, tractors, loaders,
shovels, excavators, etc. The Track Link Pin Pusher is suitable to use with most modern machines
including JCB, Caterpillar, Komatsu and Poclain make track machines. It is safe and simple to use.
Hydraulic force ensures smooth operation, thereby avoiding damage to the components of the track
assembly.
The Track Link Pin Pusher & Installer includes:
•1 x cast steel `C’ frame
•1 x double acting hydraulic cylinder –see specification table for details
•2 x tie rod and 2 x nuts for connecting `C’ frame and cylinder
•1 x tripod with chain pulley block, chain pulley block hook, lifting belt (set) for handling
The `C’ frame is of cast steel construction and has a `U’ cut out at the front end where the aligning
adapter is fitted. The frame has a through bore, through which the forcing pin and master pin
pusher passes out. The frame has eyebolts for fixing the ‘Chain pulley block hook’, for handling.
The double acting hydraulic cylinder is made in alloy steel and has long stroke with which the
master pin can be pushed or installed in one stroke. The cylinder has a threaded flange to which
the tie rods are fitted and connected to the `C’ frame. The tie rods and nuts are machined from an
alloy steel material. The tools provided are also of alloy steel, heat treated for strength.
Note - Durapac also offer a range of hydraulic pumps as an optional extra; hand, electric, petrol,
battery operated, etc.
Special skill, knowledge and training may be required for a specific task and the product may not be
suitable for all jobs. The user must ultimately make the decision regarding suitability of the product
for any given task and assume the responsibility of safety for all in the work area. Contact a Durapac
representative if you are unsure of your pin pusher’s suitability for a particular application.
2.0 Receiving Instructions
It is recommended prior to use that an inspection be done by qualified personnel and that any
missing or damaged parts, decals, warning/safety labels or signs are replaced with Durapac
authorised replacement parts only. Any pin pusher that appears to be damaged in any way, is worn,
leaking or operates abnormally should be removed from service immediately until such time as
repairs can be made. Any pin pusher that has been or suspected to have been subject to a shock
load should be removed from service immediately until inspected by a Durapac authorised service
centre. Owners and operators of this equipment should be aware that the use and subsequent
repair of this equipment may require specialised training and knowledge.

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3.0 Safety
Save these instructions. For your safety, read and understand the information contained within. The
owner and operator should understand this product and safe operating procedures before
attempting to use this product. Instructions and safety information should be conveyed in the
operator's native language before use of this product is authorised. Make certain that the operator
thoroughly understands the inherent dangers associated with the use and misuse of the product. If
any doubt exists as to the safe and proper use of this product as outlined in this factory authorised
manual, remove from service immediately.
DANGER:
•To avoid personal injury, keep hands and feet away from work area during operation
•Do NOT handle pressurised hoses. Escaping oil under pressure can penetrate the skin
causing serious injury. If oil is injected under the skin, see a doctor immediately
•Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting
device, should never be used as a load holding device. After the load has been raised
or lowered, it must always be supported mechanically
WARNING:
•The system operating pressure must not exceed the pressure rating of the lowest
rated component in the system. Install a pressure gauge in the system to monitor
operating pressure. It is your window to what is happening in the system
•Always wear appropriate personal protective equipment (PPE) when operating
hydraulic equipment. The operator must take precaution against injury due to failure
of the tool or work piece(s)
•Do NOT hold or stand directly in line with any hydraulic connections while pressurising
•Do NOT attempt to disconnect hydraulic connections under pressure. Release all line
pressure before disconnecting hoses
•All personnel must be clear before lowering load or depressurising the system
IMPORTANT:
•If at any stage, the safety related decals become hard to read, these must be replaced
•Minimum age of the operator must be 18 years. The operator must have read and
understood all instructions, safety issues, cautions and warnings before starting to
operate the equipment. The operator is responsible for this activity towards other
persons
•Do NOT lift hydraulic equipment by the hoses or couplers. Use the carrying handle or
other means of safe transport
•Hydraulic equipment must only be serviced by a qualified hydraulic technician. For
repair service, contact the Durapac authorised service centre in your area. To protect
your warranty, use only high-quality hydraulic oil

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CAUTION:
•KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT. Hydraulic fluid can
ignite and burn. Excessive heat will soften packings and seals, resulting in fluid leaks.
Heat also weakens hose materials and packings. For optimum performance do not
expose equipment to temperatures of 65°C (150°F) or higher. Protect all equipment
from weld spatter
•No alteration should be made to this device
3.1 Hydraulic Pin Pushers
•Do NOT exceed the rated capacity of the cylinder or any equipment in the system
•The pin pusher is designed to be used in temperatures ranging from -40°C to +54°C
(-40ºF to +130ºF)
•Do NOT tamper with the adjustment of the cylinders’ internal relief valve screw. To do
so may cause the hydraulics to fail
•Do NOT use in an unstable or hazardous position
•Centre the load on the cylinder. Off centre loads can damage seals and cause hydraulic
failure
•Keep non-essential personnel at a safe distance when using the pin pusher
•Ensure that the pin pusher is undamaged and in good working order. Do not use the
pin pusher if it is damaged
•Do NOT use the pin pusher for any purpose other than that for which it is intended
•Do NOT operate the system with bent or damaged couplers or damaged threads
•Use only Durapac approved accessories and components
3.2 Hydraulic Hoses & Fluid Transmission Lines
•Avoid short runs of straight-line tubing. Straight line runs do not provide for expansion
and contraction due to pressure and/or temperature changes
•Reduce stress in tube lines. Long tubing runs should be supported by brackets or clips.
Before operating the power unit, connections should be hand tightened securely and
leak-free. Over tightening can cause premature thread failure or high-pressure fittings
to burst
•Should a hydraulic hose ever rupture, burst or need to be disconnected, immediately
shut off the power unit and release all pressure. Never attempt to grasp a leaking
pressurised hose with your hands. The force of escaping hydraulic fluid can inflict
injury
•Do NOT subject the hose to potential hazard such as fire, sharp objects, extreme heat
or cold or heavy impact
•Do NOT allow the hose to kink, twist, curl, crush, cut or bend so tightly that the fluid
flow within the hose is blocked or reduced. Periodically inspect the hose for wear

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•Hose material and coupler seals must be compatible with the hydraulic fluid used.
Hoses also must not come in contact with corrosive materials such as battery acid,
creosote-impregnated objects and wet paint. Never paint a coupler or hose
•Use only Durapac or equivalent hoses
FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.
4.0 Installation
IMPORTANT:
•The complete fall protection system must be planned (including all components,
calculating fall clearance, and swing fall) before using
•Do not exceed the maximum capacity of the Tripod System including chain pulley
block, tools, etc. Maximum capacity of 50T = 210kg, 100T - 200T = 500 kg
•Only approved/ supplied components may be used with the Tripod System
4.1 System Inspection
4.1.1 All bolts and nuts must be securely attached. Check for missing, altered, or
substituted bolts, nuts and other parts. Inspect the Tripod System for signs
of corrosion which may weaken or affect parts in their function.
4.1.2 Check each leg to see that it can be telescoped in and out freely.
4.1.3 Inspect legs for straightness. Check the feet on each leg for any damage.
4.1.4 If inspection or operation reveals a defective condition, remove the Tripod
System from service immediately and contact supplier for repair.
4.2 System Setup
The entire Pin Pusher Assembly, and its subsystems, must be inspected prior to each
use
The Tripod System must be mounted on stable level surface for each leg
The tripod is shipped with the legs set at full retraction. Erect as follows:
4.2.1 Lay the tripod on the working surface.
4.2.2 Adjust legs to required working height.
4.2.3 Tilt the tripod into an upright position.
4.2.4 Ensure footing is solid under each leg and can support the intended loads.
Level the tripod by adjusting the leg height.
4.2.5 Adjust the leg chain by removing excess slack.
4.2.6 Position the chain pulley block directly under the U hook near the top of the
tripod.

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4.3 System Specifications
Familiarise yourself with the specifications and illustrations in this owner’s manual.
Know your pin pusher, its limitations and how it operates before attempting to use.
Refer to the specification chart below or if in doubt, contact a Durapac representative.
4.4 Pump Requirements
Refer to the instruction sheet included with each pump for complete installation and
operation details.
4.5 Remove air from the system
Remove air from the system –Position the cylinder so that the piston rod is pointed
down and the cylinder is lower than the pump. Advance and retract the cylinder
several times, avoiding pressure build-up. Air removal is complete when the cylinder
motion is smooth.
TTP-50 50 250 700 70.88 1,772 1,400 85
TTP-100 100 350 700 132.7 4,645 1,750 205
TTP-150 150 350 700 213.8 7,484 2,103 372
TTP-200 200 350 700 283.5 9,923 2,245 630
*Frame & Cylinder Assembly
Assembly
Length
(mm)
Approx.
Weight
(kg)*
Model
Number
Capacity
(ton)
Stroke
(mm)
Working
Pressure
(kg/cm2)
Effective
Area
(cm2)
Oil Capacity
(cc)

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5.0 Operation
CAUTION - For safety, the maximum load applied to a given pin diameter must be followed
as per the tables below:
Model
Track Pin
Diameter
(mm)
Max.
Load on
Pins
(tons)
Pressure
at Max.
Load
(bar)
ɸ19.3 - ɸ23.7 12.8 181
ɸ23.7 - ɸ30.1 19.5 275
ɸ30.1 - ɸ33.2 29 409
ɸ33.2 - ɸ36.4 36 508
ɸ19.3 - ɸ23.7 12.8
96
ɸ23.7 - ɸ30.1 19.5
147
ɸ30.1 - ɸ33.2 29
219
ɸ33.2 - ɸ36.4 36
271
ɸ36.4 - ɸ39.6 40
301
ɸ39.6 - ɸ42.8 51
384
ɸ42.8 - ɸ45.9 60
452
ɸ45.9 - ɸ52.3 70
528
ɸ52.3 - ɸ58.6 90
678
ɸ58.6 - ɸ60.2 93
700
ɸ23.7 - ɸ30.1 19.5 91
ɸ30.1 - ɸ33.2 29 136
ɸ33.2 - ɸ36.4 36 168
ɸ36.4 - ɸ39.6 40 187
ɸ39.6 - ɸ42.8 51 239
ɸ42.8 - ɸ45.9 60 281
ɸ45.9 - ɸ52.3 70 327
ɸ52.3 - ɸ58.6 90 421
ɸ58.6 - ɸ60.2 93 435
ɸ60.2 - ɸ63.3 128 599
ɸ63.3 - ɸ66.6 140 655
ɸ66.6 - ɸ70.0 148 692
ɸ36.4 - ɸ39.6 40 141
ɸ39.6 - ɸ42.8 51 180
ɸ42.8 - ɸ45.9 60 212
ɸ45.9 - ɸ52.3 70 247
ɸ52.3 - ɸ58.6 90 317
ɸ58.6 - ɸ60.2 93 328
ɸ60.2 - ɸ63.3 128 451
ɸ63.3 - ɸ66.6 140 494
ɸ66.6 - ɸ70.0 148 522
ɸ70.0 - ɸ73.9 185 652
Load Chart
TTP-100
TTP-200
TTP-50
TTP-150
Pressure
(bar)
50T
Load
(tons)
100T
Load
(tons)
150T
Load
(tons)
200T
Load
(tons)
25 1.8 3.3 5.3 -
50 3.5 6.6 10.6 14.2
75 5.3 9.9 16.0 28.4
100 7.1 13.3 21.3 42.5
150 10.6 19.9 32.0 56.7
200 14.2 26.5 42.7 70.9
250 17.7 33.2 53.4 85.1
300 21.2 39.8 64.1 99.2
350 24.7 46.4 74.8 113.4
400 28.3 53.1 85.5 127.6
450 31.8 59.7 96.2 141.8
500 35.4 66.4 106.9 144.3
550 38.9 73.0 117.5 155.9
600 42.5 79.6 128.2 170.1
650 46.0 86.2 138.9 183.1
700 49.6 92.9 149.6 198.5
Pressure / Load Chart

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5.1 Tool Selection
Select the tooling according to the appropriate TTP-Series model and the model of
track machine using the following guides and tables:
TTP-50 –Tool Selection Guide
Figure 1 –TTP-50 Tool Selection Guide
< End TTP-50 –Tool Selection Guide >
Track Pin
Diameter (mm)
Forcing Pin
(item)
Aligning Bushes
(item)
Master Pin
Pusher (item)
Aligning
Adapter (item)
19.3 - 23.7 1c 1b 11a
23.7 - 30.1 2c 2b 22a
30.1 - 33.2 3c 3b 33a
33.2 - 36.4 4c 4b 44a
Application Guide
Note - Your Durapac Distributor can supply, upon request, a Tooling Chart that will itemise
different brands of machines, model numbers and track pin diameter.

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TTP-100 –Tool Selection Guide
Figure 2 –TTP-100 Tool Selection Guide
< End TTP-100 –Tool Selection Guide >
Track Pin
Diameter (mm)
Forcing Pin
(item)
Aligning Bushes
(item)
Master Pin
Pusher (item)
Aligning Adapter
(item)
19.3 - 23.7 1c 1b 11a
23.7 - 30.1 2c 2b 22a
30.1 - 33.2 3c 3b 33a
33.2 - 36.4 4c 4b 44a
36.4 - 39.6 5c 5b 55a
39.6 - 42.8 6c 6b 66a
42.8 - 45.9 7c 7b 77a
45.9 - 52.3 8c (saddle) 8b 88a
52.3 - 58.6 9c (saddle) 9b 99a
58.6 - 60.2 10c (saddle) - 10 9a
Application Guide
Track Pin
Diameter (mm)
Items
19.3 - 33.2 Small Pin Group 3 Sets (1c,2c,3c)(1b,2b,3b)(1,2,3)(1a,2a,3a)
33.2 - 45.9 Medium Pin Group 4 Sets (4c,5c,6c,7c)(4b,5b,6b,7b)(4,5,6,7)(4a,5a,6a,7a)
45.9 - 60.2 Large Pin Group 3 Sets (8c,9c,10c)(8b,9b)(8,9,10)(8a,9a,9a)
Description
Basic Pin Groups

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TTP-150 –Tool Selection Guide
Figure 3 –TTP-150 Tool Selection Guide
Track Pin
Diameter (mm)
Items
22.0 - 41.9 Small Pin Group 4 Sets (1c,2c,3c,4c)(1b,2b,3b,4b)(1,2,3,4)(1a,2a,3a,4a)
41.9 - 57.1 Medium Pin Group 4 Sets (5c,6c,7c,8c)(5b,6b,7b,8b)(5,6,7,8)(5a,6a,7a,8a)
57.1 - 70.0 Large Pin Group 4 Sets (9c,10c,11c,12c)(9b,10b,11b,12b)(9,10,11,12)(9a,10a,11a,12a)(11d,12d)
Description
Basic Pin Groups

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< End TTP-150 –Tool Selection Guide >
Track Pin
Diameter (mm)
Forcing Pin
(item)
Aligning Bushes
(item)
Master Pin
Pusher (item)
Aligning
Adapter (item)
Forcing Pin
Pusher (item)
22.0 - 30.1 1c 1b 11a -
30.1 - 33.4 2c 2b 22a -
33.4 - 38.1 3c 3b 33a -
38.1 - 41.9 4c 4b 44a -
41.9 - 45.7 5c 5b 55a -
45.7 -50.8 6c 6b 66a -
50.8 - 53.8 7c 7b 77a -
53.8 - 57.1 8c 8b 88a -
57.1 - 60.3 9c 9b 99a -
60.3 - 63.3 10c 10b 10 10a -
63.3 - 66.6 11c 11b 11 11a 11d
66.6 - 70.0 12c 12b 12 12a 12d
Application Guide

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TTP-200 –Tool Selection Guide
Figure 4 –TTP-200 Tool Selection Guide
Track Pin
Diameter (mm)
Items
36.4 - 45.9 Small Pin Group 3 Sets (1c,2c,3c)(1b,2b,3b)(1,2,3)(1a,2a,3a)
45.9 - 63.3 Medium Pin Group 4 Sets (4c,5c,6c,7c)(4b,5b,6b,7b)(4,5,6,7)(4a,5a,6a,7a)
63.3 - 73.9 Large Pin Group 3 Sets (8c,9c,10c)(8b,9b)(8,9,10)(8a,9a,9a)(1d)
Basic Pin Groups
Description

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< End TTP-200 –Tool Selection Guide >
5.2 Pin Removal
5.2.1 To push master pin for track separation, the master link should be
positioned on the upper section of track, halfway between the sprocket and
idler. The `C’ frame is then positioned in place and aligned after which
master pin can be pushed out hydraulically.
5.2.2 After use, the pin pusher should be stored with the piston fully retracted.
Figure 5 –TTP-50, TTP-100 & TTP-200 Pin Removal
Track Pin
Diameter (mm)
Forcing Pin
(item)
Aligning Bushes
(item)
Master Pin
Pusher (item)
Aligning
Adapter (item)
Distance Piece
(item)
36.4 -39.6 1c 1b 11a -
39-6 - 42.8 2c 2b 22a -
42.8 -45.9 3c 3b 33a -
45.9 - 52.3 4c 4b 44a -
52.3 - 58.6 5c 5b 55a -
58.6 - 60.2 6c 6b 66a -
60.2 - 63.3 7c 7b 77a -
63.3 - 66.6 8c (saddle) 8b 88a 1d
66.6 - 70.0 9c (saddle) 9b 99a 1d
70.0 - 73.9 10c (saddle) - 10 9a 1d
Application Guide
Note - for ‘Large Pin Group’ refer
“RAM WITHOUT SADDLE” from
the above Tool Selection Guide.

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Figure 6 –TTP-150 Pin Removal Example A
Figure 7 –TTP-150 Pin Removal Example B
Figure 8 –TTP-150 Pin Removal Example C

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5.3 Pin Installation
5.3.1 To install the master pin, the master link should be positioned on the upper
section of track, halfway between the sprocket and idler. The `C’ frame is
then positioned in place and aligned after which master pin can be pushed
in hydraulically.
5.3.2 After use, the pin pusher should be stored with the piston fully retracted.
Figure 9 –TTP-50, TTP-100 & TTP-200 Pin Installation
Figure 10 –TTP-150 Pin Installation Example A

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Figure 11 –TTP-150 Pin Installation Example B
Figure 12 –TTP-150 Pin Installation Example C

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5.4 Flat Jack Setup for Bushing Removal
Figure 13 –Bushing Removal
Not to Scale

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Figure 14 –“Side Link” Bushing Removal

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6.0 Maintenance
IMPORTANT:
•Use only good quality hydraulic fluid. Do NOT use brake fluid, transmission fluid,
turbine oil, motor oil, alcohol, glycerine etc. Use of anything other than good quality
hydraulic oil will void warranty and damage the cylinder and application. We
recommend Durapac Hydraulic Oil or equivalent
•Equipment must only be serviced by a qualified hydraulic technician. For repair service,
contact your local Durapac authorised service centre
•Damage to hydraulic hoses may not be detected during visual inspections. For this
reason, Durapac recommends that hydraulic hoses be replaced on a regular basis
•Tighten connections as needed. Use non-hardening pipe thread compound when
servicing connections
Dirt, sand, etc. will quickly ruin any hydraulic system. Ensure that couplings are clean and free of
foreign matter. After each use, clean couplings and attach dust caps.
Maintenance is required when wear or leakage is noticed. Periodically inspect all components to
detect any problem that may require service and maintenance.
6.1 Check for loose connections and leaks.
6.2 Replace damaged parts immediately.
6.3 Do not exceed oil temperature above 60oC.
6.4 Keep all hydraulic components clean.
6.5 Use dust caps when cylinder is disconnected from the hose. Keep entire cylinder clean
to prolong cylinder life.
6.6 Wipe thoroughly clean and store cylinders upright (to prevent seal distortion) in a
clean, dry environment. Avoid temperature extremes.
6.7 Change hydraulic oil in your system as recommended in the pump instruction sheet.
6.8 The Pin Pusher should be stored in the box provided. Do not store in areas where
damage from environmental factors such as heat, light, excessive moisture, oil,
chemicals and their vapours, or other degrading elements may be present.
6.9 Do not store damaged equipment or equipment in need of maintenance in the same
area as product approved for use

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7.0 Troubleshooting
Problem
Cause
Solution
Pin Pusher will not
operate
Release valve not fully closed
•Close valve firmly
No oil or low oil level
•Top-up to correct level
Air-locked system
•Bleed air from system
Load is above capacity of system
•Use correct equipment
Erratic Action
Air in system
•Bleed air from system
Viscosity of oil too high
•Change to lower viscosity oil
Internal leakage in cylinder
•Replace worn seals
•Check for excessive
contamination or wear
Cylinder sticking or binding
•Check for dirt, gummy
deposits or leaks
•Check for misalignment, worn
parts or defective seals
Pin Pusher will not
operate smoothly
Oil level low
•Top-up to correct level
Air in system
•Bleed air from system
Cylinder sticking or binding
•Check for dirt, gummy
deposits or leaks
•Check for misalignment, worn
parts or defective seals
Pin Pusher advances
slowly
Pump not working correctly
•Rework pump
Leaking seals
•Replace seals
Pin Pusher advances but
does not hold load
Pump check valve not working
correctly
•Clean/replace check valve
Cylinder seals are leaking
•Replace seals
Overload valve leaking or not
adjusted correctly
•Replace / adjust overload
valve
Pin Pusher leaks oil
Worn or damaged seals
•Replace seals
Pin Pusher will not retract
or retracts slowly
Release valve is closed
•Open release valve
Cylinder damaged internally
•Send to a Durapac authorised
service centre for repair
Reservoir too full
•Drain oil to correct level