Idler/Roller Assembly Machine{0374, 0599, 0729, 4159, 4180} Caterpillar


Idler/Roller Assembly Machine{0374, 0599, 0729, 4159, 4180}

Usage:

769C 01X


Caterpillar Products: All

Introduction

Important Safety Information




Illustration 1g02139237

Think Safety

European Union Compliant, CE marked

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.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information




Illustration 2g02166423

Personal Protection/Important Information

Prohibited Action


No smoking

Hazard Avoidance


Crushing hazard (foot)


Crushing hazard (hand)


Pinch point


Fire hazard


Electrical Shock - Hazard


Fire hazard

Safety Section

------ WARNING! ------

Personal injury or death can result from escaping fluid under pressure.

Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

----------------------


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.



NOTICE

To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected.

This action also lessens the chance of oil spills.


General Information

Introduction




Illustration 3g02722608



Illustration 4g02722609

The Caterpillar Idler/Roller Assembly Machine can be used on all Caterpillar roller models, including snap ring, oval track, and duo-cone seal track rollers. This machine is designed for easy assembly and disassembly of idler/rollers.

The idler/roller assembly machine is custom built at DST to include a specific, customer-selected hydraulic power supply unit (Table 1).

Ordering Information

The idler/roller assembly machine and power supply unit must be ordered separately. Table 1 lists available power supply units.

Table 1
Power Supplies    
Part No.     Description     Phase    
149-7359     115V, 60 Hz     1 Phase    
146-2460     220V, 50/60 Hz     1 Phase    
146-2461     230/460V, 60 Hz     3 Phase    
140-6241     220/380/440V, 50 Hz     3 Phase    

Note: The power supply is shipped without any hydraulic oil. Fill with 10W hydraulic oil (HYDO).




Illustration 5g02722612

Each hydraulic power supply has an identification and serial number plate, providing the basic hydraulic and electrical hookup information.

Features

Quick Set-Up

The machine comes completely assembled, requiring only electrical hookup.

The tooling for the idler/roller assembly machine is easy to install. Simply select the proper contact tooling plunger and screw it into the rod end of the hydraulic cylinder. Select the proper cradle assembly, set it in place, and adjust the roller wheels (depending on model/size of part).

Work Table

The work table base sits on the interior slide rails of the machine frame. The work table moves on four rollers to allow the idler/roller to be easily positioned in the idler/roller assembly machine.

The work table is used to support the three cradle assemblies. A center bearing allows the cradle to be rotated 180 degrees in order to press bearings into both sides of the idler/rollers without removing the part from the cradle.

A hydraulic power supply and control valve is used to raise and lower the work table.

Cradle

Three cradles are available with the idler/roller assembly machine.

The smallest carrier is used for all rollers (models D3 through D11).

The mid-sized carrier is used for idlers (models D3 through D10). This carrier uses the top cradle hold-down assembly to secure the idler in the carrier.

The large carrier is used for the D11 idler. This carrier also uses the top cradle holddown assembly to secure the idler in the carrier.

Adjuster Arms

A pair of adjuster arms hold the idler/roller in place while pressure is applied to the idler/roller assembly shaft by the hydraulic cylinder.

The adjuster arms mate with a gear rack and require no special tooling to change their position. The gear rack and gear teeth provide a variable combination of adjustments.

Collar Adjustment Arms

A set of collar adjustment arms are included for use with oval track rollers. These arms can be attached to an end collar of an oval track roller with customer-supplied bolts.

Work Table Height Adjustment

The operator controls the machine using a variable pressure control valve. Pushing or pulling the control valve handle slightly results in slower operation of the work table or the hydraulic cylinder. Pushing or pulling the control valve handle completely results in faster operation.

Carrier Slide

Slide rails inside the idler/roller machine frame allow the work table to slide back and forth along the interior length of the machine frame.

Hydraulic Cylinder

The hydraulic cylinder has a 152 mm (6.0 in) bore, a 914 mm (36.0 in) stroke, and a 64 mm (2.5 in) rod. The cylinder provides 42 tons of force for assembling/disassembling the idler/rollers.

References

Disassembly and Assembly, RENR2059, "Disassembly and Assembly Procedures for Rollers with Inverted Duo-Cone Seals"

Disassembly and Assembly, RENR3961, "Disassembly and Assembly Procedures for Rollers with Conventional Duo-Cone Seals"

Disassembly and Assembly, RENR3962, "Disassembly and Assembly Procedures for Snap Ring and Oval Track Rollers"

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

USA: 1-800-542-8665, Option 1International:: 1-309-578-7372

Assembly Instructions

The Idler/Roller Assembly Machine may be shipped as two separate units. Idler/roller assembly machine frame (1) will be shipped with power supply (3) pre-installed. Hydraulic cylinder (2) may be shipped as a separate unit, requiring customer installation.

Unpacking the Parts

  1. Remove the smallest cradle from the shipping container. This cradle is used for all rollers.



    Illustration 6g02722618

  1. Remove the mid-sized idler cradle from the shipping container. This cradle is used for D3-D10 idlers.

  1. Remove the largest cradle from the shipping container. This cradle is used for D11 idlers only.



    Illustration 7g02722621

  1. Remove the top cradle hold-down assembly from the shipping container. Remove the four threaded rods used to attach the top hold-down assembly to the mid-sized idler cradles.



    Illustration 8g02722626

  1. Remove the two small roller shafts and the four cradle rollers from the shipping container. Remove the two large roller shafts and the four cradle rollers.



    Illustration 9g02722627

    (1) Shaft and rollers for small roller cradle. (2) Shaft and rollers for both idler cradles.




    Illustration 10g02722628

  1. Remove the four collar adjustment arms, two adjustment arm pins, and four retaining rings from the shipping container.



    Illustration 11g02722641

  1. Remove the threaded pusher pin from the shipping container.



    Illustration 12g02722643

  1. Remove both adjuster arms from the shipping container.



Illustration 13g02722652

Cradle Installation

  1. Make sure the three-pieced thrust washer is installed in the idler/roller frame.



    Illustration 14g02722654

  1. If necessary, use an overhead lifting device to attach a sling to either end of the cradle assembly.

  1. Place the locating pin of the cradle assembly into the thrust washer bearing.



    Illustration 15g02722658

  1. Place the assembled cradle rollers into the cradle, as shown.

    Note: The smaller diameter rollers are used for the smaller cradle. The larger diameter rollers are used for the larger cradle.




    Illustration 16g02722660



    Illustration 17g02722661

    Note: The groove in the roller shaft must be completely seated in the notch of the cradle assembly.




    Illustration 18g02722666

  1. When the mid-sized and large cradles are used, always install the top cradle holddown assembly using the four threaded rods and the dealer-supplied hex nuts.



Illustration 19g02722669

Collar Adjustment Arm Installation

  1. Align two adjuster arms (1) and install adjuster arm pin (2), as shown.



    Illustration 20g02722670

    (1) Adjuster arms. (2) Arm pin. (3) Retaining clips.

  1. Install two retaining clips (3), one on each end of the pin.

  1. Repeat the process for the other adjuster arms.



    Illustration 21g02722678

  1. When not in use, the assembly arms should be in a retracted position, as shown.



Illustration 22g02722680

Adjuster Arm Installation

  1. Loosen the two screws holding the top retaining plate to the adjuster arm.



    Illustration 23g02722681

  1. Insert the bottom retaining clip of the adjuster arm over the lower frame rail, as shown.



    Illustration 24g02722682

    Note: The bottom retaining clip is bent to allow installation of the adjuster arm. Do not straighten the clip.




    Illustration 25g02722685

  1. Place the top retaining clip over the upper frame rail and tighten the screws.



    Illustration 26g02722687

  1. Repeat the process for the other adjuster arms.



Illustration 27g02722689

Initial Set-Up

  1. Anchor the idler/roller assembly machine frame to the floor.

  1. If necessary, install the hydraulic cylinder.

  1. Connect the electrical cable from the Start/Stop switch to a suitable power source.



    Illustration 28g02722692

    Note: When turning the unit ON, make sure the motor is rotating in the proper direction. An arrow on the side of the motor indicates the proper direction of rotation.




    Illustration 29g02722696

  1. Fill the hydraulic tank of the power supply with 10W hydraulic oil (HYDO).



    Illustration 30g02722698


    NOTICE

    DO NOT overfill the hydraulic tank of the hydraulic power supply unit. Overfilling the tank can cause the hydraulic power supply unit to fail.


  1. Check the oil level. It should be visible in the center of the oil sight tube on the side of the hydraulic power supply.



    Illustration 31g02722699

  1. If necessary, install the two control handles, as shown.



    Illustration 32g02722700



    Illustration 33g02722701

  1. Install the threaded pusher pin into the cylinder. Make sure the pin is threaded into the cylinder rod completely.



    Illustration 34g02722709

  1. Start the idler/roller assembly machine and extend and retract the hydraulic cylinder to test the hydraulic system for leaks.

  1. Make sure the hydraulic system pressure is 30684 kPa (3000 psi). To check the pressure, fully retract the cylinder and read the pressure gauge. If adjustments are necessary, see the ""Maintenance" " Section.

Operation Section

This section describes the basic operation of the idler/Roller Assembly Machine. Refer to the ""References" " Section to obtain detailed assembly/disassembly instruction.

  1. Do not place hands or fingers between the cradle and the assembly arms when rotating the cradle.



    Illustration 35g02722715

  1. When raising the idler/roller frame, make sure the cradle is not under the assembly arms or the collar adjustment arms. Raising the idler/roller frame when the cradle is under either of these parts will cause damage to the machine.



Illustration 36g02722724



Illustration 37g02722736

Operation

The operator can control the work table height and cylinder rod movement using a variable pressure control valve. Pushing or pulling the control valve slightly results in slower operation of the idler/roller frame assembly or the hydraulic cylinder. Pushing or pulling the control valve handle completely results in faster operation.

  1. Thread the required tooling for the specific idler/roller into the cylinder rod.



    Illustration 38g02722746


    NOTICE

    Make sure the tooling is fully threaded into the cylinder rod to avoid damaging the threads on the tooling and the hydraulic cylinder.


  1. Install the appropriate cradle (size depends on the part being repaired).

  1. Insert the cradle roller assemblies in the proper notch, depending on the size of the component.



    Illustration 39g02722748

  1. Adjust the roller wheels on the cradle to contact the flats of the idler/roller.

  1. Place the idler/roller on the work table.

  1. Align the adjuster arms. Make sure the adjuster arms are properly aligned (side-to-side) and properly seated.


    NOTICE

    Make sure the teeth of the adjuster group are firmly mated against the teeth of the gear rack before applying pressure against the idler/roller, to prevent damage to the adjuster groups or the gear rack.


  1. Slide the work table forward until the idler/roller is firmly seated against both the adjuster arms.


    NOTICE

    Make sure only the solid, flat surfaces of the idler/rollers are placed against the adjuster arms. Pressing against the interior hub or bolts could result in damage to the idler/roller or the adjuster groups.


  1. Start the idler/roller assembly machine. To turn the machine ON, press START (I) button. To turn the machine OFF, press STOP (O) button.



    Illustration 40g02722751

  1. Raise or lower the work table to align the idler/roller with the hydraulic cylinder rod. To raise the idler/roller frame table, lift the control lever. To lower it, press down on the control lever.



    Illustration 41g02722753



    Illustration 42g02722757

  1. Extend the hydraulic cylinder rod against the idler/roller shaft. To extend the hydraulic cylinder, press the control lever down, and to retract the cylinder, pull the lever up.



    Illustration 43g02722758



    Illustration 44g02722759

  1. Follow the instructions in the appropriate idler/roller disassembly and assembly manual.

Collar Removal

An oval idler/roller may have an end collar which must be removed before removing the idler/roller shaft.

  1. Attach the collar adjustment arms to the end collar.

  1. Start the idler/roller assembly machine.

  1. Advance the hydraulic cylinder rod against the idler/roller shaft until the idler/roller is clear of the end collar.

  1. Retract the hydraulic cylinder.

  1. Stop the idler/roller assembly machine before removing the end collar from the hydraulic cylinder rod.

Maintenance Section

Hydraulic Tank

To drain the hydraulic tank, remove the plug in the bottom of the tank.




Illustration 45g02722760

Note: Properly dispose of any used oil following federal, state, and local guidelines.

Change the hydraulic oil filter (9U-6981) whenever the differential pressure gauge is in the red area.




Illustration 46g02722761

Work Table Height Adjusting Chain

  1. Periodically check the tension of the roller frame drive chain.



    Illustration 47g02722762

  1. If the chain is loose, loosen the two hydraulic motor mounting bolts, and adjust the hydraulic motor to increase the tension on the chain.



    Illustration 48g02722764

  1. Periodically lubricate (grease) the chain and sprocket.



    Illustration 49g02722766

  1. Periodically lubricate (grease) the drive screw.



Illustration 50g02722769

Clean and Inspect

  1. Periodically clean the rollers on the idler/roller frame assembly.



    Illustration 51g02722773

  1. Periodically check the tightness of the eight hydraulic cylinder mounting bolts.



Illustration 52g02722775

Work Table Roller Wheels

To remove or reposition the idler/roller frame assembly roller wheels, the idler/roller frame must be supported so the roller wheels are not engaged on the frame.




Illustration 53g02722776

(1) Screws. (2) Roller wheel shaft.

  1. Loosen two screws (1) in the roller wheel collar.

  1. Remove roller wheel shaft (2) and remove the wheel.

Hydraulic Hoses

Power Supply

  1. If removed, replace the six hydraulic power supply hoses in their proper order.



    Illustration 54g02722779

    (1) Outlet hose (pressure). (2) Inlet hose (filter). (3) Cylinder rod end hose. (4) Cylinder head end hose.




    Illustration 55g02722782

    (5) Inlet (hydraulic motor). (6) Outlet (hydraulic motor).

  1. Attach hose (3) to the cylinder rod end of the cylinder. Attach hose (4) to the head end of the cylinder rod.



    Illustration 56g02722789

    (3) Hose. (4) Hose.

  1. Attach hose (5) and hose (6) to the hydraulic motor.



    Illustration 57g02722792

    (5) Hose. (6) Hose.

  1. Attach hose (1) and hose (2) to the hydraulic power supply, as shown.



Illustration 58g02722795

(1) Hose. (2) Hose.

Hydraulic Control Valve

If removed, replace the six hydraulic power supply hoses on the valve assembly in the proper order, as shown.




Illustration 59g02722800

(1) Outlet hose (pressure). (2) Inlet hose (filter). (3) Cylinder rod end hose. (4) Cylinder head end hose. (5) Inlet (hydraulic motor). (6) Outlet (hydraulic motor).

Adjusting Hydraulic Pressure

Change the hydraulic pressure by adjusting the relief control valve located on the front of the directional valve.

Note: The maximum hydraulic pressure is 20684 kPa (3,000 psi).




Illustration 60g02722804

  1. Remove the cap from the relief control valve.

  1. Start the machine.

  1. Fully retract the hydraulic cylinder and continue to hold the hydraulic control lever in the retract position.

  1. Turn the valve adjusting screw until the reading on the gauge reads 20684 kPa (3000 psi).

  1. Release the hydraulic control lever.

  1. Partially extend and then fully retract the hydraulic cylinder while checking the gauge to verify the pressure setting.

  1. Release the hydraulic control handle, and replace the cap on the relief control valve.

  1. Repeat Step 6 to verify the pressure setting again.

Parts Section

Idler/Roller Assembly Machine




Illustration 61g02722806

Table 2
Idler/Roller Assembly Parts List    
Item     Qty.     Part No.     Description    
(1)     4     8C-8844     Bolt    
(2)     1     190-1607     Roller Assembly Group    
(3)     1     1U-7544     Hydraulic Pump (Hand)    
(4)     1     199-5449     Directional Valve    
(5)     4     192-1611     Collar Adjustment Arm    
(6)     1     -     Hydraulic Cylinder    
(7)     1     192-1606     Frame Assembly    
(8)     2     192-1609     Adjuster Group    
(9)     1     192-1612     Stand Assembly    
(10)     1     192-1617     Carrier Assembly Group    
(11)     4     -     Stop Angle    
(12)     14     0S-1614     Bolt    
(13)     4     1J-5257     Bolt    
(14)     4     2J-3507     Nut    
(15)     1     -     Angle Mount    
(16)     2     -     Carrier Guard    
(17)     3     9S-8750     Nut    
(18)     3     1S-2713     Bolt    
(19)     6     0S-1618     Bolt    
(20)     4     9M-1974     Washer    
(21)     2     192-1602     Gear Rack    
(22)     4     2J-3503     Nut    
(23)     4     3B-4516     Lock Washer    
(24)     4     2K-6073     Socket Head Cap Screw    
(25)     2     192-1604     Pin    
(26)     4     134-2263     Retaining Pin    
(27)     1     1U-7530     Hydraulic Ram (10 ton)    
(28)     4     5P-8250     Washer    
(29)     1     -     Roller Cradle    
(30)     2     -     Roller Shaft for Item #29    
(31)     4     -     Rollers for Item #29    
(32)     1     -     Mid-Sized Idler Cradle    
(33)     2     -     Roller Shaft for Items 32 & 35    
(34)     4     -     Rollers for Items 32 & 35    
(35)     1     -     Large Idler Cradle    
(36)     1     -     Top Cradle Hold-Down Assembly    
(37)     4     -     Threaded Rods    
(A)     8     -     Anchor Bolts (customer supplied)    

Power Supply Unit




Illustration 62g02722809

Table 3
Power Supply Group    
Item     Qty     Part No.     Description    
(1)     1     146-2457     Motor, Electric, 220 VAC, 50/60 Hz, 1 phase (146-2460)    
146-2458 Motor, Electric, 230/460 VAC, 60 Hz, 3 phase (146-2461)    
140-6240 Motor, Electric, 220/380/440 VAC, 50 Hz, 3 phase (140-6241)    
149-7363 Motor, Electric, 115 VAC, 60 Hz, 1 phase (149-7359)    
149-7359 Motor, Electric, 115 VAC, 60 Hz, 1 phase    
(2)     1     9U-6988     Filter Head    
(3)     1     9U-6981     Filter Element    
(4)     1     6V-7483     Adapter, Straight    
(5)     1     1F-6660     Nipple, Pipe    
(6)     1     147-1263     Coupling Assembly    
(7)     4     0S-1617     Bolt    
(8)     -     122-6915     Hose,
152 mm (6.0 in)    
(9)     2     9M-0164     Clamp    
(10)     1     033-0820     Elbow, 90°    
(11)     1     3B-7257     Bushing, Reducing    
(12)     1     147-1264     Element    
(13)     1     149-7364     Pump (149-7363 Motor only)    
(14)     1     -     Adapter    
(15)     1     147-1265     Gasket    
(16)     4     0S-1595     Bolt    
(17)     1     139-5448     Tank    
(18)     1     -     Cover Kit    
(19)     1     147-1545     Gasket    
(20)     1     9U-6986     Gauge    
(21)     -     -     Wire, Electric
549 cm (18 ft)    
(22)     3     -     Cord Grip    
(23)     1     149-5477     Starter, Motor    

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