Transcript
Cerrar SIS Pantalla anterior
Producto: Modelo:
TRACK-TYPE TRACTOR
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 -05/04/20 11
Fecha de actualización -05/04/201 1
i04346410
Facility and Equipment Layouts{4150} SMCS - 4150 - 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
05
Summary of Changes in SEBF8519 Added Revisions Table Updated Contact Information Updated Effectivity Added Website Address for "Contamination Control Self-Review " Updated Idler Cooling Information Added Reference to Track, Track Roller, Rolle r, and Track Idler Cycle Times SEBF8595
© 2011 Caterpillar All Rights Reserved. Reserve d. This guideline is for the use of Cate rpillar dealers only. Unauthorized use of this document or the proprietary proces ses therein without permission may be violation of intellectual property law. This Undercarriage Reconditioning Bulletin contains the neces sary information in order to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit bene fit 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 t he latest technical information that is available from Caterpillar.
For questions or additional information concerning this guideline, submit a form for f eedback in the Service Information System. In order to address an urgent issue, use the following f ollowing resources in order to communicate your request to Caterpilla r 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 Trac k Type Tractor (TTT) 35% to 50% of the parts dollars spent ar e for undercarriage components. Undercarriage service also provides pr ovides the opportunity for the dealer to perform service on other systems of the machine. For these reasons the facility faci lity must be planned, properly equipped, and efficient. This bulletin is intended i ntended to provide information that will assist the plans to build new or remodel existing undercarriage service areas. Caterpillar offers ser vices 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 greatl y affect space requirements for a particular parti cular 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 Track press and conveyor
Square Feet
Square Meter
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
144
14
Track shoe regrouser
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 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 faci litates 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 suffici ent to handle the assembled weight of the tracks. A crane with wit h 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 Recommendation: Review all lifting requirements to ensure that lifting devices are suitable for the application. Table 3 Weight and Length of Track Assemblies Model D3 D6 D8 D10
Track Assembly
Link Assembly
Length
360.9 kg (795.6 lb)
192.8 kg (425 lb)
5.6 m (18.4 ft)
1600.3 kg (3528 lb)
793.8 kg (1750 lb)
9.14 m (30 ft)
2984.6 kg (6580 lb)
1188.4 kg (2620 lb)
9.5 m (31.2 ft)
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 Contact: District Caterpilar Service Operations Representative (SOR) to evaluate or plan for contamination control. Recommendation: Evaluate 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 trac k 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 exa mple of products that are available. Recommendation: Utilize 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 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 we lding flux are all examples of consumables c onsumables that are used to service undercarriage. wil l maintain the quality of the product while in Recommendation: Provide Recommendation: Provide suitable storage that will storage.
Information Resource Center Service information should be readily accessible in the undercarriage service area. Recommendation: The Recommendation: The following items should be available within the s ervice 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 undercar riage being serviced. Congestion in the staging area can create problems that reduce service efficiency. Recommendation: Provide 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 a utomated washing systems.Proceco,Hotsy Equiptment Company,InstaClean Cleaning Equipment, and many others. Recommendation: Install 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. ha ndling. 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 achie ved 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
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Caterpillar 375T track press
Most track work is performed on the track tr ack press. A typical track trac k 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 tr ack press conveyor. • A hydraulic torque turn wrench should be used to remove and install tra ck shoe bolts. • Track conveyor should be equipped with a track shoe lifter . The track shoe lifter eliminates the need for the technician to t o lift the track shoes off the t he link assembly. • The length of the track conveyor should accommodate the length of the lar gest model in the dealer territory. • The track press should be equipped with a suffici ent winch that will pull the track trac k 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, basket , on a cart. These parts ca n now be transported to and from the cleaning system. Refer to Undercarriage Reconditioning Re conditioning 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 utiliza tion of equipment and labor the track press service must be efficient. Most time loss l oss can be attributed to parts handling, parts cleaning methods, and track shoe handling.
Roller Reshell
Illustration 3 Caterpillar roller press
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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 i n 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 c leaned internal components. 8. The roller is lubricated and placed on the outgoing roller rack. 9. The roller is dipped in preservative a nd packaged for transport. The track roller Disass Disassembly embly 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. ass embly. 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 are a and use filtered ventilation ventilat ion 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 sec tion ""Idler Reconditioning (Weld)" " in this document. The internal components of idlers are similar to the internal inter nal 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. 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 Idler service bench
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Illustration 6
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Idler press
Refer to Table 4 for approximate a pproximate 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 D3 D6 D8 D11 5230
Idler Assembly Weight
Idler Shell Weight
96 kg (212 lb)
68 kg (150 lb)
240 kg (529 lb)
134 kg (295 lb)
345 kg (761 lb)
307 kg (677 lb)
910 kg (2006 lb)
805 kg (1775 lb)
2500 kg (5512 lb)
1762 kg (3885 lb)
Idler Reconditioning (Weld) A weld process is used to t o recondition the wear surface of idlers. idler s. 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 discus s the idler reconditioning process. Idler Welding The typical work flow for idler welding operation includes t he 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 s urfaces 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 Idler welding machine
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Illustration 8
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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 fl ow . The weight of the idlers is a factor that must be considered. c onsidered. Efforts should be taken to secure the idler from falling or shifting. shifti ng. Refer to Table 4 for approximate idler weight. The floor plan in Illustration 8 is an a n isolated room that can be ventilated ventila ted as necessary. The ventilation reduces the weld dust and a nd contaminants that enter the assembly asse mbly areas.
Track Shoe Regrouser Worn track shoes can be reconditioned by replaci ng the worn grouser bar with a new grouser bar. Replaceable grouser bars are available from multiple vendors. There is variation in processes processe s that are used to regrouse r egrouse 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 t he shop • Process efficiency Floor space requirements are 14 m² (144 ( 144 ft²). Refer to Undercarriage Reconditioning Re conditioning 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. asse mbly. 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. nece ssary. 5. Position track shoe and new grouser in weld station. 6. Weld first side of grouser bar ba r 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
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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 proces s 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 de pendent on process control and the integrity of the worn roller s hell. Roller shell rebuilding (welding) is done by few dealers. Roller r eshelling tends to be more cost effective. ef fective. Refer to Undercarriage Reconditioning Guide, SEBF8599 and DVD Undercarriage Service Guide, SERF8890 for a complete list of bulletins that discus s the roller reconditioning process.
Illustration 10 Water-cooled welding station
Refer to Illustration 10 for a typical roller shell reconditioning station with the t he 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. Todos los derechos reservados. Red privada para licenciados del SIS.
Thu Aug 4 20:33:19 UTC-0400 2011
