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Producto:  TRACK-TYPE TRACTOR

Modelo:  D10R TRACK-TYPE TRACTOR 3KR01844
Configuración: D10R Custom Parts Manual Track-Type Tractor 3KR00001-UP (MACHINE)

Boletín de Reacondicionamiento del Tren de Rodaje

Facility and Equipment Layouts{4150}
Número de medio -SEBF8519-05 Fecha de publicación -05/04/2011 Fecha de actualización -05/04/2011

   
i04346410

Facility and Equipment Layouts{4150}

SMCS - 4150

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
Table 1
Revision   
Summary of Changes in SEBF8519    
 
Added Revisions Table
Updated Contact Information
Updated Effectivity
05     Added Website Address for "Contamination Control Self-Review "
Updated Idler Cooling Information
Added Reference to Track, Track Roller, and Track Idler Cycle Times SEBF8595
   

© 2011 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.

This Undercarriage Reconditioning Bulletin contains the necessary information in order 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 in order 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 questions or additional information concerning this guideline, submit a form for feedback in
the Service Information System. In order to address an urgent issue, use the following resources in
order to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

• Dealer Solution Network

• Caterpillar Technical Representative

• Knowledge Network

Facility Planning
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.

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.

Table 2
Floor Space requirements for Undercarriage Service    
Service Function     Square Feet     Square Meter    
Track press and conveyor 1600 150  
 Idler and roller reconditioning (weld)   144 to 324 14 to 30
Idler and roller Disassembly and Assembly 144 to 1800     14 to 168  
Track shoe regrouser 144 14  

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.

Table 3
Weight and Length of Track Assemblies    
Model     Track Assembly     Link Assembly     Length    

D3  
360.9 kg (795.6 lb) 192.8 kg (425 lb) 5.6 m (18.4 ft)  

D6
1600.3 kg (3528 lb)     793.8 kg (1750 lb)   9.14 m (30 ft)

D8  
2984.6 kg (6580 lb) 1188.4 kg (2620 lb) 9.5 m (31.2 ft)  

D10
5220.8 kg (11510 lb)     2299.71 kg (5070 lb)   11.5 m (37.6 ft)
 D11    
7257.4 kg (16000 lb)   3129.8 kg (6900 lb) 13.02 m (42.7 ft)

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".

Website: https://dealer.cat.com/cda/files/12248/7/ccdsr.pdf

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 as well as 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 Chemical dumpster breath is one example of products that are
available.

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 7257.5 kg (16000 lb).
The amount of staging area needed is dependent on 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 essential for process to clean undercarriage components to be an efficient process.
Technician efficiency is negatively impacted if manual washing is utilized in the process. There
are many companies that offer automated washing systems.Proceco,Hotsy Equiptment
Company,InstaClean Cleaning Equipment, and many others.

Recommendation: Install automated washing equipment in each area to allow efficient

uninterrupted cleaning for each area. Specialize parts baskets for the wash cabinet to ensure a
complete wash process.

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 1 g02390416

Caterpillar 375T track press

Most track work is performed on the track press. A typical track press station is shown in
Illustration 1.

Refer to Illustration 2 to view a track service area floor plan.

Illustration 2
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 and DVD Undercarriage Service Guide,
SERF8890 for a complete list of bulletins and wall charts that can be referenced for service
procedures.

In order 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 3 g02390418

Caterpillar roller press

Roller reshelling is a competitive option that dealers can offer customers. The reshell option is
dependent 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 3.

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 on a table and disassembled.

2. Internal components are placed in 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 and DVD Undercarriage Service Guide, SERF8890 should be
available at the work station for technician use.

Refer to Illustration 4 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 Track, Track Roller and Track Idler Cycle Times, SEBF8595 for
recommended cycle times.
Illustration 4
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 4 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 amount 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 additional 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 5 g02390476

Idler service bench

Illustration 6 g02390477

Idler press

Refer to Table 4 for approximate idler weights. Tooling capable to service and support the idler
safety is required. Refer to Illustration 5 for a typical idler service bench and Illustration 6 for a
typical idler press.

Table 4
Approximate Idler Weights    
Model     Idler Assembly Weight     Idler Shell Weight    

D3
96 kg (212 lb) 68 kg (150 lb)  

D6
240 kg (529 lb) 134 kg (295 lb)  

D8
345 kg (761 lb) 307 kg (677 lb)  

D11
910 kg (2006 lb) 805 kg (1775 lb)  

5230
2500 kg (5512 lb) 1762 kg (3885 lb)    

Idler Reconditioning (Weld)

A weld process is used to recondition the wear surface of idlers. This process is an exceptional
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 Guide, SEBF8599 and DVD Undercarriage Service Guide,
SERF8890 for a complete list of bulletins that discuss 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 an 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 7 g02390478

Idler welding machine

Illustration 8 g02390479

Isolated idler weld area

The idler reconditioning information contained in Undercarriage Reconditioning Guide,

SEBF8599 and DVD Undercarriage Service Guide, SERF8890 should be available at the work
station for technician use. Refer to Illustration 7 for a typical idler welder and Illustration 8 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 8 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 and DVD Undercarriage Service Guide,
SERF8890 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 and DVD Undercarriage Service Guide, SERF8890should be available at the work
station for technician use.

Illustration 9 g02390480

Work flow of a grouser bar welding machine

Refer to Illustration 9 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 is dependent on process control and the integrity of the worn roller shell. Roller shell
rebuilding (welding) is done by few dealers. Roller reshelling tends to be more cost effective.

Refer to Undercarriage Reconditioning Guide, SEBF8599 and DVD Undercarriage Service Guide,
SERF8890 for a complete list of bulletins that discuss the roller reconditioning process.
Illustration 10

Water-cooled welding station

Refer to Illustration 10 for a typical roller shell reconditioning station with the recommended work
flow and Illustration 7 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 and DVD Undercarriage Service Guide, SERF8890 should be available at the work
station for technician use.

Copyright 1993 - 2011 Caterpillar Inc.   Thu Aug 4 20:33:19 UTC-0400 2011
Todos los derechos reservados.
Red privada para licenciados del SIS.