- Cold Planer:
- PM-200 (S/N: P1C1-UP; P1M1-UP)
Introduction
This Special Instruction provides a rework procedure to replace the idler assembly on certain PM-200 Cold Planer.
The existing idler assembly (Bitelli part number:498023004) has been converted to a new part number (Caterpillar part number : 453-3379 Idler As ).
The new 453-3379 Idler As is adaptable to machines S/N:P1C1-UP and ; S/N:P1M1-UP.
Important Safety Information
Note: Do not perform any procedure in this Special Instruction until you read the information and you understand the information.
Clean all surfaces and remove burrs from all areas where parts are to be installed. Chase all tapped holes used for mounting purposes.
Work safely. 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 must also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.
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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death. |
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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on. |
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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed. |
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Required Parts
| Required Part List | |||
| Item | Qty | Part | Description |
| 1 | 1 | 453-3379 | Idler As |
| 2 | 2 | 465-9221 | Ball Bearing |
Rework Procedure
- Park the machine on a flat ground.
- Remove bolts (A) and swing open access panel (B) on the left side of the machine. Save the parts for reuse.
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| Illustration 1 | g03662143 |
- Use two people to remove access panel (C). The weight of access panel (C) is approximately 34 kg (75 lb). Remove access panel (C) and bolts. Save the part for reuse.
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| Illustration 2 | g03662144 |
- Inspect each welding line around indicated area (D), (E), and (F). If there is no crack, go to Step 6. If there is a crack, make necessary repair and welding.
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| Illustration 3 | g03662145 |
- Remove the V-belt (drum drive). Save the part for reuse. Refer to Disassembly and Assembly, KENR8197, "V-Belt (Rotor Drive) - Remove and Install" for removal procedure.
- Rotate pulley (G) by hand. If there is no balance hole as indicated on the left top area in Illustration 4 on the pulley, remove the whole tensioning group from the machine. Discard the part. Refer to Disassembly and Assembly, KENR8197, "Rotor Drive Idler - Remove and Install" and also remove each component including fork, pin, spacers, bolt, and washers from the tensioning group. Save the parts for reuse.
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| Illustration 4 | g03662149 |
- Place fork (H) that was saved in Step 6 on a flat working surface. Clean each bores and holes of fork (H) .
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| Illustration 5 | g03662188 |
- Place new 453-3379 Idler As (1) on the working surface. The idler assembly (1) should have balance hole.
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| Illustration 6 | g03662192 |
- Install new 465-9221 Ball Bearing (2) into the idler assembly (1). Use a plastic hammer to press the bearing (2) in place.
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| Illustration 7 | g03662193 |
- Repeat the Step 9 for installing bearing (2) in opposite side.
- Install idler assembly (1) between fork (H) arms.
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| Illustration 8 | g03662203 |
- Clean and apply grease to wide spacer (J) and thin spacer (K) that was saved in Step 6.
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| Illustration 9 | g03662212 |
- Apply grease to pin (L) that was saved in Step 6 and install pin (L) into the bore of folk (H) .
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| Illustration 10 | g03662214 |
- Install wider spacer (J) and thin spacer (K) between one side of fork (H) arm and idler (1), and insert pin (L) into idler (1) .
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| Illustration 11 | g03662642 |
- Clean and apply grease to another wide spacer (J) and thin spacer (K) that was saved in Step 6. Install them between another side of fork (H) arm and idler (1), and push pin (L) go through all pieces, using a plastic hammer if necessary.
- Install bolt (M) and washer (N) into the hole and tighten to 100 N·m (74 lb ft) to complete the tensioning group installation.
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| Illustration 12 | g03662643 |
- Install the whole tensioner group on the machine. Refer to Disassembly and Assembly, KENR8197, "Rotor Drive Idler - Remove and Install" for installation procedure.
- Install the V-belt (drum drive) that was saved in Step 5. Refer to Disassembly and Assembly, KENR8197, "V-Belt (Rotor Drive) - Remove and Install" for installation procedure.
- Use two people to install access panel (C). The weight of access panel (C) is approximately 34 kg (75 lb). Install access panel (C) and bolts that was saved in Step 3.
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| Illustration 13 | g03662644 |
- Install and close access panel (B) and install bolts (A) that was saved in Step 2.
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| Illustration 14 | g03662645 |