Facility and Equipment Layouts {4150} 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

Track Drills

MD5150C (S/N: SEY1-UP)

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.

Facility Planning Summary

Undercarriage service is essential for dealers to meet the needs of customers. Typically, during the life of a Track Type Tractor (TTT) 35% to 50% of the parts dollars spent are for undercarriage components. Undercarriage service also provides the opportunity for the dealer to perform service on other systems of the machine. For these reasons the facility must be planned, properly equipped, and efficient. This bulletin is intended to provide information that will assist the plans to build new or remodel existing undercarriage service areas. Caterpillar offers services to assist the planning and development of service areas.

References

Reference: Reuse and Salvage Guidelines, SEBF8363, "Examples of Parts Cleaning Racks and Baskets"

Reference: Reuse and Salvage Guidelines, SEBF8356, "Introduction to the Cleaning Guide"

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

Reference: Undercarriage Reconditioning Bulletin, SEBF8562, "Procedure and Guidelines for Cleaning Phosphate Coated Track Pins"

Reference: Undercarriage Reconditioning Bulletin, SEBF8595, "Track, Track Roller, and Track Idler Cycle Times"

Reference: Undercarriage Reconditioning Manual, SEBF8599, "Undercarriage Reconditioning Guide" available by subscription from Media Logistics

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.

Show/hide table

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.

Show/hide table

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.

Show/hide table

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.

Location

The undercarriage service facility should be positioned to allow the following criteria:

• Receiving and shipping

• Unrolling of track assemblies

• Proximity to equipment wash area

• Contamination control

• Ventilation control

The above criteria are discussed in following sections.

Floor Space

The floor space required for the undercarriage reconditioning shop depends on the services offered and the products normally serviced. The volume of work does not greatly affect space requirements for a particular machine. However, significant volumes may justify multiple machines to perform the same operations. Employing multiple shifts and efficient scheduling can solve some service volume problems.

The floor space requirements in Table 2 provide minimal allowance for the service function of individual machines including storage. Access to the work areas must be sufficient to allow a suitable fork truck to transport components to be serviced.

Recommendation: Evaluate the service market and determine the necessary floor space required.

Crane Coverage

Jib Crane

One or more jib cranes may be needed to provide adequate crane coverage for the track press and the roller/idler service area. The jib crane facilitates moving components, tooling, and washing baskets in the immediate work area. A hook height of 3 m (10 ft) is adequate for an undercarriage shop.

Bridge Crane

Bridge cranes provide lifting and handling versatility. Jib cranes are limited to the area that the jib can reach. Bridge cranes are typically capable of servicing multiple bays of a service area. The bridge crane allows the components to be moved easily from one service area to another. Track can be positioned on the track press conveyor by using a bridge crane or by winching.

If a bridge crane is used, the capacity must be sufficient to handle the assembled weight of the tracks. A crane with the capacity of 9072 kg (20000 lb) should handle all tracks. Refer to Table 3 for approximate assembled weights, including shoes and hardware. Make sure that the bridge crane rating is sufficient for the largest models serviced in your area.

Recommendation: Review all lifting requirements to ensure that lifting devices are suitable for the application.

Utilities

The undercarriage service area should have the typical utilities available.

Basic utilities required for each area include:

• 3-phase electrical power

• Single phase electrical power

• Pressure air

• Ventilation

• Adequate lighting

• Water

• Drain-Check local environmental regulations.

Parts Staging

Provide a designated area for the parts department to deliver new parts. The parts staging area should allow for the separation of various orders by shift and technician.

Contamination Control

Contamination control has been demonstrated to increase the life of a component and reduce rebuild failures. Caterpillar Inc. has also set forth an evaluation for contamination control that illustrates best practices.

Contact: District Caterpilar Service Operations Representative (SOR) to evaluate or plan for contamination control.

Recommendation: Evaluate service area conditions based on the Caterpillar Inc. “Contamination Control Self-Review”.

Ventilation

Ventilation of a track service area is necessary due to the extreme odor of the used oil. Dealers have received complaints from the local area and complaints from within the dealership. The distinct odor of the used track oil is similar to the odor of natural gas. Used oil containment, is essential to reduce the amount of odor. If necessary, products are available to provide additional control of the odor. North Woods ChemicalDumpster Breath is one example of an available product.

Recommendation: Utilize methods to contain used oil and if necessary apply odor control agents.

Storage

Adequate storage space is necessary to facilitate the service processes. Service tooling and consumables are both examples of items that should have designated storage space. Because Caterpillar Inc. offers a large variety of machines equipped with tracked undercarriage, there is also a large amount of service tooling.

Tooling

Recommendations: Meet the following criteria for storage of service tooling:

• Safe handling

• Easily accessible

• Labeled for identification

• Protected from contamination

• Lift devices for heavy tooling

Consumables

Track oil, roller oil, welding wire, and welding flux are all examples of consumables that are used to service undercarriage.

Recommendation: Provide suitable storage that will maintain the quality of the product while in storage.

Information Resource Center

Service information should be readily accessible in the undercarriage service area.

Recommendation: The following items should be available within the service area:

• Service information terminal (SIS)

• Parts Sales Kit (PSK), PECP3003

• Service Handbook, PEKP9400, "Custom Track Service (CTS) handbook"

• Undercarriage Reconditioning Guide, SEBF8599

• Information Release Memos (IRMs)

• Catalog, NENG2500, "Dealer Service Tool Catalog"

Staging

The facility should have a sufficient area for staging of undercarriage components that are in process, being received and shipped.

Capacity for lifting and handling the components should not be ignored. Lifting a D11 track assembly requires a suitable lifting device to handle approximately 7258 kg (16000 lb).

The amount of staging area needed depends the volume of undercarriage being serviced.

Congestion in the staging area can create problems that reduce service efficiency.

Recommendation: Provide sufficient area for staging, shipping, and receiving of undercarriage components. Lifting capacity should accommodate all undercarriage components.

Component Cleaning

Automation is an essential process to clean undercarriage components efficiently. Technician efficiency is negatively impacted if manual washing is utilized. Some companies that offer automated washing systems are Proceco Ltd., Hotsy, and Insta-Clean.

Recommendation: Install automated washing equipment in each area to allow efficient uninterrupted cleaning for each area. Use specialized parts baskets for wash cabinets to ensure a complete wash process. Refer to Reuse and Salvage Guidelines, SEBF8363, "Examples of Parts Cleaning Racks and Baskets"

Recommendation:Check with your local governing bodies when considering what type of cleaning system will be used. The employee health and safety, cost, and environmental requirements of each should be considered before making a selection.

Solvent cleaning may result in hazardous waste due to flash points or contaminants. Refer to all local, state, federal, and other applicable environmental laws and regulations.

Note: Use all Personal Protective Equipment (PPE) and controls to ensure employee health and safety. Refer to all local, state, federal, and other applicable safety laws and regulations.

Note: For a list of cleaning chemical suppliers, telephone numbers, and addresses refer to Reuse and Salvage Guidelines, SEBF8356, "Introduction to the Cleaning Guide".

Note: For appropriate cleaning methods used for cleaning track pins refer to Undercarriage Reconditioning Bulletin, SEBF8562, "Procedure and Guidelines for Cleaning Phosphate Coated Track Pins".

Suggested Equipment Layouts

To operate efficiently, the undercarriage reconditioning shop must be planned for smooth work flow with a minimum of material handling. The first step in planning work flow is to determine shop requirements based on three factors:

• Machine population

• Operating conditions and resulting undercarriage shop demand

• Available floor space and equipment

There is no single arrangement that can adequately fit the varying requirements of all dealers. However, significant time savings can be achieved through planned equipment layout tailored to your shop load and work flow. The examples shown in this bulletin are intended to guide you on how best to arrange and utilize your shop equipment.

Track Service

Illustration 2	g02390416
Caterpillar 375T track press

Most track work is performed on the track press. A typical track press station is shown in Illustration 2.

Refer to Illustration 3 to view a track service area floor plan.

Illustration 3	g02390417
Track service area

General Track Press Requirements:

• The press should be located in line with a large outside door. The door will allow the track to be easily loaded onto and taken off the track press conveyor.

• A hydraulic torque turn wrench should be used to remove and install track shoe bolts.

• Track conveyor should be equipped with a track shoe lifter. The track shoe lifter eliminates the need for the technician to lift the track shoes off the link assembly.

• The length of the track conveyor should accommodate the length of the largest model in the dealer territory.

• The track press should be equipped with a sufficient winch that will pull the track onto the conveyor.

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

• The pins and bushings for sealed and lubricated track should be placed in a parts basket, on a cart. These parts can now be transported to and from the cleaning system.

Refer to Undercarriage Reconditioning Guide, SEBF8599 for a complete list of bulletins and wall charts that can be referenced for service procedures.

To achieve a high utilization of equipment and labor the track press service must be efficient. Most time loss can be attributed to parts handling, parts cleaning methods, and track shoe handling.

Roller Reshell

Illustration 4	g02390418
Caterpillar roller press

Roller reshelling is a competitive option that dealers can offer customers. The reshell option depends on efficient cycle times and utilization of reusable parts. Increased costs often cause customers to purchase new roller assemblies instead of the reshelled rollers. This procedure is accomplished at a roller press shown in Illustration 4.

Rebuild area requirements can vary from minimum of 14 m² (144 ft²) to 168 m² (1800 ft²). Often the same space is used to service rollers and idlers.

Track Rollers

The typical work flow for track roller reshell operation includes the following steps:

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

2. Internal components are placed in a parts cart basket.

3. The worn roller rim is placed in the scrap tub.

4. When the basket of internal parts is full, place the basket in the automated washing system.

5. Inspect components for reuse and salvage.

6. After all rollers have been disassembled, a new roller assembly is placed in the press or on the table.

7. The roller is assembled, using the cleaned internal components.

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

9. The roller is dipped in preservative and packaged for transport.

The track roller Disassembly and Assembly information contained in Undercarriage Reconditioning Guide, SEBF8599 should be available at the work station for technician use.

Refer to Illustration 5 for a typical track roller reshell station with the recommended work flow. Utilizing a conveyor/table with the roller press allows for groups of rollers to be serviced at one time. Track roller reshell station and workflow is necessary to control and achieve recommended cycle times. Refer to Undercarriage Reconditioning Bulletin, SEBF8595, "Track, Track Roller, and Track Idler Cycle Times" for recommended cycle times.

Illustration 5	g02390419
Roller and idler service area (A) Length 1524.0 mm (60.00 inch) (B) Height 762.0 mm (30.00 inch)

The floor plan in Illustration 5 includes a “Clean Room” that is used for assembly. The clean room reduces the opportunity for contamination that can cause the seals to leak. A “Clean Room” is simple to construct. Simply enclose the work area and use filtered ventilation to introduce a positive airflow into the enclosure. The filtered airflow should greatly reduce the number of air borne contaminants.

Idler Rebuild

The idler rebuild process is similar to the roller reshelling process. The difference is that the idler shell is typically reconditioned for an extra life. Refer to section "Idler Reconditioning (Weld)" in this document. The internal components of idlers are similar to the internal components of rollers allowing the rebuild process to be identical. The primary difference in the process is due to how the idler is handled and held in position.

Rebuild area requirements can vary from minimum of 14 m² (144 ft²) to 168 m² (1800 ft²). The same space can be used to service idlers and rollers.

Illustration 6	g02390476
Idler service bench

Illustration 7	g02390477
Idler press

Refer to Table 4 for approximate idler weights. Tooling capable to service and support the idler safely is required. Refer to Illustration 6 for a typical idler service bench and Illustration 7 for a typical idler press.

Idler Reconditioning (Weld)

A weld process is used to recondition the wear surface of idlers. This process is a rebuild process that can be performed at a fraction of the cost of a new idler. Wear characteristics of the rebuilt idler are similar to the original idler. The repair process must be managed to ensure quality and efficiency.

Refer to Undercarriage Reconditioning Bulletin, SEBF8552, "Idler Weld Rebuild Procedure" for information about the idler reconditioning process.

Idler Welding

The typical work flow for idler welding operation includes the following steps:

1. Inspect the idler for reusability

2. Clean the idler

3. Disassemble the idler in the idler rebuild area

4. Prepare the idler shell for welding - clean and remove all debris from idler surface

5. Use idler welding machine to build up the wear surfaces to the original dimensions

6. Place idler in a well-insulated cool down box to allow idler to cool slowly. Idler should not be removed until all heat has slowly dissipated

7. Inspect idler for dimensional changes once idler cools to room temperature

Illustration 8	g02390478
Idler welding machine

Illustration 9	g02390479
Isolated idler weld area

The idler reconditioning information contained in Undercarriage Reconditioning Guide, SEBF8599 should be available at the work station for technician use. Refer to Illustration 8 for a typical idler welder and Illustration 9 for a typical idler reconditioning station with the recommended work flow .

The weight of the idlers is a factor that must be considered. Efforts should be taken to secure the idler from falling or shifting. Refer to Table 4 for approximate idler weight.

The floor plan in Illustration 9 is an isolated room that can be ventilated as necessary. The ventilation reduces the weld dust and contaminants that enter the assembly areas.

Track Shoe Regrouser

Worn track shoes can be reconditioned by replacing the worn grouser bar with a new grouser bar. Replaceable grouser bars are available from multiple vendors.

There is variation in processes that are used to regrouse a track shoe. However, the following process was selected to allow the process to meet the following requirements:

• Contamination control of weld process

• Prevent heat damage to related components

• Shoes removed from tractor to eliminate need to have the tractor in the shop

• Process efficiency

Floor space requirements are 14 m² (144 ft²).

Refer to Undercarriage Reconditioning Guide, SEBF8599 for a complete list of bulletins that discuss the grouser reconditioning process.

Regrouser Process

The typical work flow for the regrouser operation includes the following steps:

1. Remove the track shoe from the link assembly.

2. Buff surface area of track shoe to remove contaminants.

3. Position track shoe in grouser trim station - if necessary.

4. Grind or buff trimmed track shoe, if necessary.

5. Position track shoe and new grouser in weld station.

6. Weld first side of grouser bar to track shoe.

7. Reposition track shoe in second weld station.

8. Weld second side of grouser bar to track shoe.

The regrouser reconditioning information contained in Undercarriage Reconditioning Guide, SEBF8599 should be available at the work station for technician use.

Illustration 10	g02390480
Work flow of a grouser bar welding machine

Refer to Illustration 10 for the work flow on a grouser welding machine.

Roller Shell Rebuild (Welding)

Roller shell welding is a process that can be used to rebuild the roller shell to the original dimensions. The typical floor space requirement is 30 m² (324 ft²). Successful welding of the roller shell depends on process control and the integrity of the worn roller shell. Roller shell rebuilding (welding) is done by few dealers because of poor cost effectiveness. Roller reshelling tends to be more cost effective.

Refer to Undercarriage Reconditioning Guide, SEBF8599 for a complete list of bulletins that discuss the roller reconditioning process.

Illustration 11	g02390481
Water-cooled welding station

Refer to Illustration 11 for a typical roller shell reconditioning station with the recommended work flow and Illustration 8 for a typical roller and idler welder.

The typical work flow for roller welding operation includes the following steps:

1. Roller assembly is disassembled in the roller disassembly area.

2. Evaluate roller shell for rebuild.

3. Move to roller welding staging area.

4. Clean the roller.

5. Buff the roller.

6. Assemble water cooling equipment on the roller.

7. Preheat the roller.

8. Rebuild the roller (weld).

9. Post heat control of roller (cool down).

10. Evaluate roller dimensions following weld procedure.

11. Move completed roller to assembly area.

The roller shell reconditioning information contained in Undercarriage Reconditioning Guide, SEBF8599 should be available at the work station for technician use.