Suggested Equipment Layouts {0374, 0729, 4150, 7000, 7950} Caterpillar

Caterpillar Products

Machines with Grease Lubricated Track with Swage

Machines with Greased Lubricated Track (GLT)

Machines with Positive Pin Retention (PPR) Track

Machines with Positive Pin Retention 2 (PPR2) Track

Machines with Rotating Bushing Track

Machines with Sealed Positive Pin Retention (PPR) Track

Machines with Sealed Track

Machines with Sleeve Bearing Track

Machines with SystemOne Undercarriage

Machines with non-PPR Sealed and Lubricated Track

Introduction

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This Undercarriage Reconditioning Bulletin contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Undercarriage Reconditioning Bulletin must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Summary

To operate efficiently, the undercarriage reconditioning shop must be planned for smooth workflow with a minimum of material handling. Whether remodeling an existing undercarriage shop or building a new one, determine the work to be done, shop space required and equipment needed.

There is no single arrangement that can adequately fit the varying requirements of all dealers. Significant time savings can be achieved by planning equipment layout for the best workflow.

The examples shown in this bulletin should help stimulate ideas on how best to arrange and use your shop equipment. Included are illustrations of typical equipment arrangements. The workflow is indicated with arrows.

Reference: For more on equipment layout, crane placement, parts staging, contamination control, ventilation, and utilities needed, refer to Bulletin, SEBF8519, "Facility and Equipment Layouts".

For information on component reconditioning versus replacement (rebuilding versus reshelling), see table in the section "Individual Work Stations and Procedures" at the back of this bulletin.

Provide the media below close to the undercarriage work area:

Reference: Subscription, SEBF8599, "Undercarriage Reconditioning Guide" (The comprehensive binder containing all undercarriage reconditioning bulletins).

Reference: Handbook, PEKP9400, "Custom Track Service Handbook"

Reference: Catalog, PECP3003, "Parts Sales Kit Undercarriage" (Parts service catalog)

Safety

Illustration 1	g02139237

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

This bulletin may contain hazardous steps. A safety alert symbol like the one below is used to indicate a hazard.

Warning messages identify a specific, imminent, latent, hazard that has a reasonable probability of resulting in personal injury or death if the warning is ignored.

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Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death.

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Inspect all threaded components before use. Damaged threads may fail under hydraulic pressure. Broken threads may release flying objects that are propelled with great force. Personal injury or death can occur if struck by flying objects.

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Do not stand near the hydraulic press while the press is in operation. A component that slips or breaks under pressure may fly into the air with great force. Personal injury or death can occur if struck by flying objects.

Undercarriage Shop Work Areas

Efficiency is important in the undercarriage shop. Procedures are best performed on a group of components, rather than one at a time. A roller press operator can disassemble and clean rollers from one work order, whereas a welder operator welds rollers from another work order. Rollers are cleaned most efficiently in a cleaning tank. After the rollers are welded, the complete group of rollers is assembled. The transporting and storing of rollers is best done on conveyors. Conveyors reduce handling and provide storage space to let rollers accumulate between operations.

Rebuild Work Area (Conventional Dry Welding)

Rebuilding components includes a process of adding metal (welding) to build up surfaces of existing, acceptable rollers or idlers.

Conventional (dry) welding is likely the most common weld method. The dry welding steps in this bulletin are primarily for rollers however, many of the steps apply to idlers as well.

Illustration 2	g02384496
Workflow of a rebuild work area (conventional dry welding)

Rollers are cleaned with high-pressure water as an initial step. Review the rebuild work-flow by comparing steps below with illustration 2.

1. The incoming (assembled) roller is moved to the press and disassembled.

2. The internal parts are inspected and non-reusable parts are discarded. The salvageable internal components are placed in a parts basket cart.

3. The roller assembly (roller shell) with acceptable remaining life is placed on a conveyor leading to the agitating cleaner. The rollers are then cleaned.

4. After a basket cart is sufficiently full of internal roller components, the components are cleaned. After cleaning, the internal components are placed in a storage area. New parts are acquired to replace parts that were discarded.

5. The roller shells move along the conveyor to the roller buffer.

6. The flange and tread surfaces are cleaned in the roller buffer. After buffing, rollers are conveyed to the dry welder.

7. At the welder, the tread surface and the flange area are built-up to original dimensions.

8. After welding, place rollers on a conveyer and allow time to cool.

   Note: To avoid cracking, Idlers must be placed in an insulated cool down box. Allow the Idlers to cool slowly over multiple days. Idlers should not be removed until cool enough to handle by hand.

9. Bore size can change after welding. Check bore dimensions after welding and resize to specifications if needed.

10. The basket cart of previously cleaned internal components is brought to the press. Any new internal components are brought to the press. The rollers are assembled, tested, and lubricated.

    Note: Generally a set of rollers will be allowed to accumulate before the assembly process is started.

11. The roller is moved to dip tank where a protective coating is applied.

12. After the preservative is dry, place the group of assembled rollers on a roller rack for storage or return to customer.

For detailed information on the above, see "Individual Work Stations and Procedures" at the back of this bulletin.

Rebuild Work Area (Water-Cooled Welding)

Water-cooled welding is another method of adding metal to build up surfaces of acceptable rollers or idlers.

Illustration 3	g02384538
Workflow of a rebuild area (single head water-cooled welding and two welders)

Illustration 4	g02384539
Workflow of a rebuild area (twin head, water-cooled welding)

Review the rebuild work-flow by comparing steps below with illustration 3 and illustration 4.

1. Rollers in the incoming rack are moved to the roller buffer for clean-up.

2. After clean-up, the low sprocket roller is placed in the end collar puller to remove the end collars to permit seal and bearing inspection. The end collars are replaced and, if the welder has an external water probe, the probe is installed. Elevated sprocket rollers must be disassembled and a cooling adapter installed to permit water-cooled welding.

3. The roller is moved to the welder where water lines are attached for cooling during the weld cycle. Some weld equipment setups allow for extra cooling after the weld cycle is complete. Residual water is removed from roller and area using compressed air.

4. The roller is placed on a short section of conveyor, cooled to room temperature, and filled with oil per procedure.

5. The roller is conveyed to the dip tank and dipped in preservative.

6. After the preservative is dry, the assembled rollers are placed on the outgoing roller rack.

For detailed information on the above, see "Individual Work Stations and Procedures" at the back of this bulletin.

Illustration 5	g02384541
Workflow of a rebuild area (twin head, water-cooled, two welders)

Review the rebuild work-flow by comparing steps below with illustration 5. This equipment layout shows roller and idler rebuilding in parallel.

A short section of conveyor allows rollers prepared by the operator to be transported and held for welding. The work-flow for this area is shown in Illustration 5.

1. Idlers are prepared at the roller/idler press by removing bearings, checking Duo-Coneseals and bearing clearance. Idlers are then assembled and transported to the welder. The idlers are rebuilt at the welder to original dimensions. Idlers are cooled in a special cooling box for multiple days to avoid cracking. After cool to the touch, the idler is coated with a preservative.

2. (While waiting on an idler, the idler welder operator can prepare rollers for welding). The rollers are cleaned in the roller buffer.

3. The idler welder operator places the roller on the end collar puller and partially disassembles the roller for inspection of Duo-Cone seals and bearings. The roller is assembled and the water probe installed to test for leaks.

4. The operator of the roller welder places the prepared roller in the welder and rebuilds the roller to original dimensions.

5. The roller is placed on the conveyor and cooled. Remaining cooling water is removed using compressed air.

6. Roller is filled with oil per procedure.

7. Roller is then dipped to apply a protective coating.

8. After the preservative has hardened, the roller is placed in the outgoing roller rack.

For detailed information on the above, see "Individual Work Stations and Procedures" at the back of this bulletin.

Reshell Work Area (Track Rollers)

(Reshelling) of track rollers requires that the rollers be disassembled and then reassembled.

Illustration 6	g02384543
Workflow of reshell area (track rollers)

Review the track roller (reshell) work-flow by comparing steps below with illustration 6.

1. The roller is placed in the press and disassembled.

2. The internal parts are inspected and non-reusable parts are discarded. The salvageable internal components are placed in a parts basket cart. New parts are acquired to replace parts that were discarded.

3. The worn roller assembly (shell) is placed in the scrap tub.

4. When the basket of used internal parts is full, place the basket in the agitating cleaning tank.

5. After all rollers have been disassembled, a new roller assembly (shell) is placed in the press.

6. The roller is assembled, using the cleaned and new internal components.

7. The roller is lubricated and placed on the outgoing roller rack.

For detailed information on the above, see "Individual Work Stations and Procedures" at the back of this bulletin.

Reshell Work Area (Carrier Rollers)

(Reshelling) of carrier rollers requires that the rollers be disassembled and then reassembled.

Illustration 7	g02384545
Workflow of reshell area (carrier rollers)

The work-flow is shown in Illustration 7.

1. The worn carrier roller is placed on the table and press and disassembled.

2. The internal parts are inspected and non-reusable parts are discarded. The salvageable internal components are placed in a parts basket cart. New parts are acquired to replace parts that were discarded.

3. The worn roller assembly (shell) is placed in the scrap tub.

4. When the basket of used internal parts is full, place the basket in the agitating cleaning tank.

5. After all carrier rollers have been disassembled, a new roller assembly (shell) is placed on the assembly table.

6. The carrier roller is assembled, using the cleaned and new internal parts and filled with oil.

7. The carrier roller is then dipped in a preservative.

8. The carrier roller is placed on the outgoing work roller rack.

For detailed information on the above, see "Individual Work Stations and Procedures" at the back of this bulletin.

Track Work Area (Turning Track Bushings)

Illustration 8	g02384546
Typical track press station.

Most of the track bushing work is performed on the track press. A typical track press station is shown in Illustration 8.

Illustration 9	g02384547
Track press conveyor with shoe lifting capability.

Some general requirements should be considered.

• The press should be located in line with a large outside door so that the track can be pulled onto and off the press.

• A shoe lifting device, as shown in illustration 9, or other means of handling track shoes is required.

• A turntable or similar area for storage of links, and the pins and bushings of sealed track is necessary.

• The pins and bushings of sealed and lubricated track should be placed in a parts basket on a cart. These parts can be transported to and from the cleaning tank easily. The frequency of use of this cleaning tank is not as great as when reconditioning rollers therefore, the track press does not need to be next to the cleaning tank.

For detailed information on turning track bushings of sealed and lubricated track (wet or dry joints), see table in "Individual Work Stations and Procedures" at the back of this bulletin.

Typical Undercarriage Reconditioning Shop Arrangements

The undercarriage reconditioning shop work areas (or bays) previously discussed can be arranged in several combinations to provide the most efficient work-flow for your shop.

The mix of products to be serviced and wear patterns normally occurring in the territory must be considered when planning work-flow. A dealer using a water-cooled roller welder and servicing mostly larger track rollers should arrange the shop so that the roller welder operator does all the preparation and finishing tasks. If smaller products predominate, welding time will be reduced since the operator cannot perform these related tasks during the time required to weld the roller.

In planning work-flow and resulting equipment location in any shop. The dealer may make various compromises, particularly in locating equipment which will be used by more than one area of the shop. Frequency of use is usually the overriding consideration. The cleaning tank should be located closer to the roller, idler, and carrier (reshell) area. Rather than near the track press.

Arrangements that make effective use of the equipment and personnel are shown in the three examples that follow.

Illustration 10	g02384550
Typical dry-weld roller welder shop.

A typical shop layout using dry-weld roller welder is shown in Illustration 10. The work-flow shown is for rollers being welded. If track or carrier rollers were being (reshelled), the work-flow would be as in Illustration 6 and Illustration 7. At the same time track or carrier rollers are being (reshelled), a set of rollers being rebuilt (welded) could be on the conveyors leading to and from the welder.

Illustration 11	g02384551
Typical shop with one water-cooled roller welder.

A typical shop layout with one water-cooled roller welder is shown in Illustration 11. The work-flow shown is for roller welding, turning bushings of sealed and lubricated track and for track roller (reshelling).

The equipment and arrangement, shown in Illustration 11, is suited for reconditioning, by welding, large track rollers, from D7's and larger machines. The large-size rollers permit this arrangement to be efficiently operated by two welder operators. The shop in this example uses a high pressure, automated roller washer to clean rollers before the rollers are brought into the shop. Also, the management of this shop prefers that the roller end collars be removed after welding.

Illustration 12	g02384552
Roller/idler rebuild area with various types of welders.

Various types of equipment can be incorporated into an undercarriage shop as shown in Illustration 12. This shop has a dry-type welder for idlers, two single head water-cooled welders, and one dual head water-cooled welder for rebuilding rollers. The work-flow shown in Illustration 12 is typical for idler and roller welding and roller (reshell) operations.

Individual Work Stations and Procedures

Illustration 13	g02384516
Illustration of rollers on conveyor near a conventional welder.

Illustration 14	g02384517
Illustration of roller flange surface being dry-welded.

Illustration 15	g02384536
Illustration of conventional (dry) welder being used to rebuild an idler.

For detailed rebuilding information, refer to Bulletin, SEBF8506, "Conventional (Dry) Welding Procedure for Rollers and Idlers".

For detailed rebuilding information, refer to Bulletin, SEBF8552, "Idler Weld Rebuild Procedure".

For detailed dimensional information, refer to Bulletin, SEBF8569, "Reconditioning Dimensions for Track Rollers".

For detailed dimensional information, refer to Bulletin, SEBF8570, "Reconditioning Dimensions for Carrier Rollers".

For detailed dimensional information, refer to Bulletin, SEBF8571, "Reconditioning Dimensions for Idlers".

Illustration 16	g02384537
Illustration of twin head water-cooled roller/idler station.

Illustration 17	g02384540
Twin head water-cooled station with two welders. Typical arrangement where one welder is primarily used to rebuild idlers, the other to rebuild rollers.

For detailed rebuilding information, refer to Bulletin, SEBF8507, "Procedure for Water-Cooled Welding of Track Rollers".

Illustration 18	g02384542
Illustration of roller/idler press.

Illustration 19	g02384544
Illustration of carrier roller (reshell) station.

The following table contains important undercarriage procedures to assist with decisions regarding work-flow and equipment layout.