Idler Service Evaluation Checklist {4159, 4167} Caterpillar


Idler Service Evaluation Checklist {4159, 4167}

Usage:

D6D 01Y
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
Track Drills
MD5150C (S/N: SEY1-UP)

Introduction

Table 1
Revision  Summary of Changes in SEBF8592 
15–19  Added serial number prefixes for New Product 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.

References

Reference: Undercarriage Reconditioning Guide, SEBF8599

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

Reference: Parts Sales Kit, PECP3003

Reference: Catalog, NENG2500, "Dealer Service Tools Catalog"

Reference: Undercarriage Reconditioning Bulletin, SEBF8585, "Disassembly and Assembly Procedures for Idlers with Conventional Duo-Cone Seals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8582, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals"

Reference: Undercarriage Reconditioning Bulletin, SEBF8552, "Idler Weld Rebuild Procedure"

Reference: Undercarriage Reconditioning Bulletin, SEBF8506, "Conventional (Dry) Welding Procedure for Rollers and Idlers"

Reference: Undercarriage Reconditioning Bulletin, SEBF8555, "Duo-Cone Seal Assembly and Installation Procedure for the 963 and 973 Track-Type Loaders"

Reference: Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers"

Reference: Special Instruction, SEHS8364, "Assembly and Installation of Conventional Duo-Cone Seals"

Reference: Special Instruction, SEHS8483, "Assembly and Installation of Inverted Duo-Cone Seals"

Reference: Special Instruction, SEHS8484, "Tool and Specification Chart for Conventional Duo-Cone Seal Gp"

Reference: Special Instruction, SEHS8707, "Installation of Replacement Track Roller/Idler Bearings"

Reference: Special Instruction, SEHS8974, "Tool and Specification Chart for Inverted Duo-Cone Seals"

Reference: Wall Chart, RENR3960, "Disassembly and Assembly Procedures for Idlers with Conventional Duo-Cone Seals"

Reference: Wall Chart, RENR2052, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals"

Undercarriage Shop

Table 2
Description 
(1) Is the undercarriage shop clean and orderly? 
 
 
(2) Is the tooling stored orderly, clearly identified and easily accessible? 
 
 
(3) Are the drawers and shelves used for storing the tooling clearly labeled? 
 
 
(4) Is the tooling organized by part number? 
 
 
(5) Are tools and materials necessary for idler rebuilds accessible and stored near the workstation? (Impact wrench with regulator or socket/end wrenches, torque wrench, 99% isopropyl alcohol, clean lint free towels, seal installers.) 
 
 
(6) Does the technician wear eye protection? 
 
 
(7) Does the technician wear ear protection while using the impact wrench? 
 
 
(8) Is the undercarriage shop equipped with adequate lighting for effective operation of the equipment? 
 
 
(9) Is adequate floor space available for servicing the idlers efficiently? 
 
 
(10) Does the layout of the undercarriage shop allow for efficient workflow processing? 
 
 
(11) Are the rebuild processes free from bottlenecks? 
 
 
Comments: 
 
 
 
 

Idler Service

Preparation for Disassembly

Table 3
Description 
(1) Is Wall Chart, RENR2052, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals" and Wall Chart, RENR3960, "Disassembly and Assembly Procedures for Idlers with Conventional Duo-Cone Seals" current and available? 
 
 
(2) Are the idlers thoroughly washed before the idlers are brought into the undercarriage shop? 
 
 
(3) Are the plastic plugs and rubber stoppers removed using a 12.7 mm (0.50 inch) drill bit? 
 
 
(4) Is the oil drained or vacuumed from the idlers? 
 
 
(5) Are the idlers measured for wear and the wear measurements recorded? 
 
 
(6) Is the service documented in a work order? (leaking seals, assembly measurements, reuse information, CTS inspection report) 
 
 
Comments: 
 
 
 
 

Disassembly and Inspection

Table 4
Description 
(1) Are the retainer bolts removed and stored in a container? 
 
 
(2) Are the thrust washers inspected for reuse? 
 
 
(3) Is the inside and outside diameters of the end collar checked for reusability on conventional idlers? 
 
 
(4) Are the Duo-Cone seals inspected for reuse? 
 
 
(5) Are the seals kept in matching pairs if reused? 
 
 
(6) Is the shaft-to-bearing clearance measured? 
 
 
Comments: 
 
 
 
 

Idler Welding

Table 5
Description 
(1) Is the idler worn between 70% and 120%? 
 
 
(2) Is the wear measured accurately with the 168-7720 Ultrasonic Wear Indicator or 6V-9413 CTS Tool Kit? 
 
 
(3) Is new flux used during the weld process? 
 
 
(4) Is the idler placed securely in the idler weld machine? 
 
 
(5) Are the treads and center flange cleaned prior to welding? 
 
 
(6) Is the idler preheated to the correct temperature? 
 
 
(7) Is the weld performed in a continuous manner? 
 
 
(8) Are the idlers welded to obtain the correct specifications? 
 
 
(9) Are the idlers protected from drafts during and after the welding process? 
 
 
(10) Are the idlers placed into a cool down box immediately after the weld was performed? 
 
 
(11) Is the idler inspected for cracks? 
 
 
Comments: 
 
 
 
 

Roll Burnishing Procedure

Table 6
Description 
(1) Is the roll burnish tool in good condition? 
 
 
(2) Is there sufficient coolant flow through the burnishing tool and the bore of the idler? 
 
 
(3) Is the roll burnishing tool lowered at a constant slow speed, then quickly removed from the bore? 
 
 
(4) Is a dial bore indicator used to check the diameter of the bearing? 
 
 
Comments: 
 
 
 
 

Honing Procedure

Table 7
Description 
(1) Are the bearings pressed into the bore until the stopper plate bottoms out? 
 
 
(2) Are the holding brackets fabricated correctly? 
 
 
(3) Is the hone assembled properly? 
 
 
(4) Is the drill assembled properly? 
 
 
(5) Is the idler strapped down onto the stand? 
 
 
(6) Is a dial bore indicator used to determine the amount of material that should be removed? 
 
 
(7) Is the honing stone adjusted correctly? 
 
 
(8) Are the torsion bars put in place? 
 
 
(9) Is the coolant flow sufficient? 
 
 
(10) Is the coolant clean? 
 
 
(11) Are the front and rear stops placed to the correct honing depth to avoid injury or damage to the tooling? 
 
 
Comments: 
 
 
 
 

Preparation for Assembly

Table 8
Description 
(1) Is Wall Chart, RENR2052, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals" and Wall Chart, RENR3960, "Disassembly and Assembly Procedures for Idlers with Conventional Duo-Cone Seals" current and available? 
 
 
(2) Is all of the debris removed from the idler and the idler components? 
 
 
(3) Are the idler components properly cleaned with 99% isopropyl alcohol or another approved cleaning agent? 
 
 
(4) Is 369-9451 Petro Gel Grease (O-Ring Assembly Compound) used to install the new O-rings? 
 
 
(5) Are the Duo-Cone seals inspected for reuse? 
 
 
Comments: 
 
 
 
 

Assembly

Conventional Duo-Cone Seals

Table 9
Description 
(1) Are the shop personnel using Wall Chart, RENR3960, "Disassembly and Assembly Procedures for Idlers with Conventional Duo-Cone Seals" for the correct procedures and specifications? 
 
 
(2) Are the toric rings properly installed onto the seal rings? 
 
 
(3) Are the Duo-Cone seals correctly installed into the end collars and retainers? 
 
 
(4) Is 99% isopropyl alcohol used for assembly of the Duo-Cone seals. 
 
 
(5) Is the seal height and runout measured on the assembled seal? The difference in height must not exceed 1.0 mm (0.04 inch)
 
 
(6) Are the bearings lubricated with SAE30 oil? 
 
 
(7) Are the thrust washers inspected and installed correctly? 
 
 
(8) Are the retainer bolts tightened to the proper torque using a socket/end wrench or regulated impact wrench? 
 
 
(9) Are the ring faces on the Duo-Cone seals cleaned using a lint free towel? 
 
 
(10) Is a thin film of oil applied to the entire ring face of the Duo-Cone seals (using a horse hair brush or other contaminant free applicator)? 
 
 
(11) Is the correct tooling used to install the end collars? 
 
 
(12) Is the end play measured on the assembled idler? 
 
 
(13) Is the process completed in a timely manner to minimize contamination? 
 
 
(14) Is the idler shaft spun 20 times in each direction? 
 
 
Comments: 
 
 
 
 

Inverted Duo-Cone Seals

Table 10
Description 
(1) Are the shop personnel using Wall Chart, RENR2052, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals" for the correct procedures and specifications? 
 
 
(2) Is the seal ramp on the shaft in good condition (not too smooth)? 
 
 
(3) Are the toric rings in good condition? 
 
 
(4) Is the toric stabilizer installed on the shaft? 
 
 
(5) Is the Duo-Cone seal installed on the shaft with the correct seal installer? 
 
 
(6) Is the Duo-Cone seal installed onto the seal ramp of the shaft using a rotary motion? 
 
 
(7) Are the Duo-Cone seals installed without deforming the toric ring? 
 
 
(8) Is the Duo-Cone seal straight on the shaft with a height difference of no more than 0.8 mm (0.03 inch)
 
 
(9) Are the Duo-Cone seals installed in the retainers and measured for the correct height? 
 
 
(10) Is the Duo-Cone seal height from the shaft thrust face measured at four locations 90 degrees apart? 
 
 
(11) Are the bearings lubricated with SAE30 oil? 
 
 
(12) Is a thin layer of oil applied to the entire seal ring face? 
 
 
(13) Is 99% isopropyl alcohol used for assembly of the Duo-Cone seal in the retainer? 
 
 
(14) Is the process completed in a timely manner to minimize contamination? 
 
 
(15) Are the retainer bolts tightened to the correct torque? 
 
 
(16) Is the end play measured on the assembled idler? 
 
 
(17) Is the idler shaft spun 20 times in both directions? 
 
 
Comments: 
 
 
 
 

Accessory Equipment

Cleaning

Table 11
Description 
(1) Are the idlers cleaned using either high-pressure wash or steam? 
 
 
(2) Is washing of the idlers a one-man operation? (One man should be able to perform this function) 
 
 
(3) Is the wash area located near the workstation to ensure efficient workflow? (Minimum steps and time between operations) 
 
 
(4) Is the washing equipment used for cleaning the idler components also used for cleaning the track and roller components? (Minimum steps and time between operations) 
 
 
(5) Is the cleaning process for idler components shared with other cleaning operations such as track and roller components? Do these cause time delays? 
 
 
Comments: 
 
 
 
 

Miscellaneous

Table 12
Description 
(1) Do the lifting cranes provide adequate coverage for lifting heavy equipment and tooling? 
 
 
(2) Is the hydraulic press used for servicing the idlers adequate to perform the necessary procedures for reconditioning? 
 
 
(3) Is 99% isopropyl alcohol used to install the Duo-Cone seals and clean the idler components? 
 
 
Comments: 
 
 
 
 

Integrity of the Idler Joint

170-5664 Test and Fill Cart Gp

Table 13
Description 
(1) Is the air pressure regulated at 552 kPa to 690 kPa (80.0 psi to 100.0 psi)
 
 
(2) Is the oil pressure regulated at 28 kPa to 41 kPa (4.0 psi to 6.0 psi)
 
 
(3) Is the nitrogen regulated at 275 kPa to 345 kPa (40.0 psi to 50.0 psi) at the tank? 
 
 
(4) Is the nitrogen regulated at 10 kPa to 14 kPa (1.5 psi to 2.0 psi) at the holding tank? 
 
 
(5) Is the oil heated for at least 10 minutes? 
 
 
(6) Is the system purged? 
 
 
(7) Are the service indicators for the oil filters checked periodically? 
 
 
(8) Is the overall condition of the machine good? 
 
 
Comments: 
 
 
 
 

FT-2724 Pressure Gauge Tool Gp

Table 14
Description 
(1) Is the nitrogen pressure maintained at 138 kPa (20.0 psi) throughout test cycle? 
 
 
(2) Is the ball valve and pressure differential valve closed? 
 
 
(3) Is the pressure observed for 10 seconds without a pressure drop of 3.4 kPa (0.5 psi)
 
 
Comments: 
 
 
 
 

Filling

Table 15
Description 
(1) Are the shop personnel using Wall Chart, RENR2052, "Disassembly and Assembly Procedures for Idlers with Inverted Duo-Cone Seals" and Wall Chart, RENR3960, "Disassembly and Assembly Procedures for Idlers with Conventional Duo-Cone Seals" for the correct oil fill volumes? 
 
 
(2) Is the rubber stopper lubricated with a light-weight oil to promote expansion and installed with the proper stopper installer? 
 
 
(3) Is the idler filled to 80% to 90% with SAE30 oil and the plastic plug installed? 
 
 
(4) Is the oil filtered properly to prevent contamination? 
 
 
(5) Do air bubbles exist in the stream of oil? Air bubbles can be caused by a worn out pump, low oil level, and broken pipes. 
 
 
(6) Is there a loss of vacuum? Create a vacuum with finger over the lubricator tip, release the vacuum button, and check for loss of vacuum by viewing the gauge. (If loss of vacuum is observed, check all connections between the button (valve) and the tip.) 
 
 
(7) Check the accuracy of gauges. Do the gauges zero? Are the gauges broken or have a broken glass? Replace any damaged gauges. 
 
 
(8) Is the overall condition of the hoses and related equipment in good condition? 
 
 
(9) Does the fill and vacuum button have an over center finger or palm pad to reduce fatigue? 
 
 
(10) Is the regulator set at a maximum of 552 kPa (80.0 psi)? Pressure above 552 kPa (80.0 psi) will blow the seals. 
 
 
(11) Electrical controls auto lubricator
(a) Is vacuum set at a minimum of 138 kPa (20.0 psi)?
(b) Is pressure set at a minimum of 379 kPa (55.0 psi)?
(c) Is partial vacuum set at zero? 
 
 
(12) Is the idler shaft gently tapped with a hammer to ensure that the idler contains oil? 
 
 
Comments: 
 
 
 
 

Quality and Contamination

Table 16
Description 
(1) Do the current methods and procedures comply with the procedures outlined in the Undercarriage Reconditioning Bulletins and Wall Charts? 
 
 
(2) Are the disassembled components protected from contamination of dirt or debris? 
 
 
(3) Is the general condition of the work area clean and orderly? 
 
 
(4) Is any welding or grinding separated from the Disassembly and Assembly area? 
 
 
(5) Is the area dirty with airborne contamination? 
 
 
(6) Are the work benches neat and clean? 
 
 
(7) Do all the components being reconditioned meet the specifications that are outlined in the Undercarriage Reconditioning Bulletins? 
 
 
(8) Are periodic inspections on the components performed during the rebuild process? 
 
 
(9) Are the idlers cleaned with high-pressure water before disassembly? 
 
 
(10) Is the end play measured on each assembled idler? 
 
 
(11) Is a pressure test performed on each idler prior to lubrication? 
 
 
(12) Are the idlers isolated during the welding process to protect the other areas of the shop from contamination? 
 
 
Comments: 
 
 
 
 

Literature and Materials

Table 17
Description 
(1) Is Undercarriage Reconditioning Guide, SEBF8599 current and complete? 
 
 
(2) Is Servicing Handbook, PEKP9400, "Custom Track Service Handbook" current and available to the technicians? 
 
 
(3) Is Parts Sales Kit, PECP3003 current and available to the technicians? 
 
 
(4) Is the technician or supervisor maintaining a Service Logbook? 
 
 
(5) Is the media listed in the "Undercarriage Shop" section current and available? 
 
 
Comments: 
 
 
 
 

Recommendations

Table 18
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Notes

Table 19
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

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