Optimizing Component Removal & Installation Quality through Customer Certification

1.0 Introduction
Proper Major Component Removal and Installation (R&I) practices are vitally important for component reliability and life. Mistakes made during component removal and installations are a leading cause of early hour failures or shortened life. To ensure that component removal and installation is performed following a well-defined process, many Caterpillar dealers have provided training, and in some cases, even “Certified” customers as qualified to perform component R & I.

2.0 Best Practice Description
Caterpillar Dealers have invested considerable financial and manpower resources into creating major component rebuild capabilities that deliver cost efficient, high quality for their customers. A poorly performed removal and / or installation process can negate the efforts put into component rebuild.
Some dealers have taken steps to control the R&I process in order to protect their investment in the rebuild and also to ensure that the component delivers expected reliability and life.
Typical actions have included:
• Dealer must do the component installation.
• Dealer must supervise the installation
• Dealer trains and certifies the customer to perform component removals and installations.

3.0 Implementation Steps
Start with a process audit by the dealer to the customer. Then provide subsequent training on proper major component removal and installation. The most important success factor is a common, shared objective by customer and dealer. A shared objective will ensure component reliability and life through proper R & I practices.
Implementation Steps:
1. Customer Shop Audit / Inspection
a. Tooling
b. Contamination control practices
c. Cleaning equipment
d. R & I area
e. Component storage / staging

2. Training:
a. Failure Analysis – Determine cause for removal
b. Document removal – hours, history, oil analysis, particle count
c. System inspection and clean up process– debris removal
d. Rebuild related system: radiator, coolers, pumps, hoses, and air intake, etc.
e. Installation procedures / checklists
f. Test and brake-in procedures
g. Fluid cleanliness - ISO particle count specifications
h. Standardized installation parts kits (see example to the right)
i. Record keeping –installation checklists, parts Bill of Materials, particle count, test results.
j. Dealer feedback – completed installation checklists, initial SOS

During replacement of any major component, attention should be given to the related systems & sub-components, which may impact performance and life of the newly replaced component.

4.0 Benefits
• Improved reliability
o Improper installation is a leading cause of early hour component failures and shortened life.
o Proper installation positively impacts:
�� Machine availability, which impacts production rates at the site.
�� Maintenance costs by avoiding unnecessary costly repairs.
• Improved durability.
o Proper installation helps to maximize component life and reduce cost per ton.

5.0 Resources Required
• Dealer must have a qualified inspector and training instructor. In addition, training materials may need to be developed.
• Customer may require improved tooling or shop facility improvements.

6.0 Supporting Attachments / References
References:
See also, Improving Component Durability – Component Removal and Installation - SEBF1017

This booklet explains how problems in the component removal and installation process often cause components to fail.
The booklet contains 24 pages of high -quality, full color graphics and text, which provide an easy -to -understand explanation of:
• Common failures caused by poor R&I practices
• Importance of the R&I process
• Best practices
• Risk management in cleaning contaminated systems
 

The booklet also explains the how the component replacement process has evolved from the days of the early track-type tractors to today’s modern machines with electronically controlled engines and transmissions. A common sense approach to risk management is also discussed regarding how much time to invest in system disassembly and cleaning after a catastrophic component failure.

The booklet is intended for all levels of dealer and customer personnel involved with the operation and maintenance of earthmoving equipment. It is particularly useful to those who manage equipment operation and maintenance