Master Idler

Master Idler
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Master Idler

Product catalog summary
Introduction
The Master Idler Catalog by Caterpillar provides reference part numbers and technical specifications for CAT belt system components. It emphasizes the importance of adhering to safety standards and precautions. Caterpillar disclaims liability for errors and reserves the right to make changes.
Idler PAL™
The Idler PAL™ features a steel roll with Positive Automatic Lubrication, designed for increased strength and a close fit to the deflector cap. It includes a unique bearing cavity design for extra lubricant capacity, ensuring grease remains in the bearing. Grease movement and expansion are managed by a compensator disc and wave spring.
EXALON®
The EXALON® Idler roll, made from high molecular weight polyethylene, offers three times the abrasion resistance of steel rolls and reduces noise by 20%. It is available in various diameters and CEMA class ratings, featuring extended shell life, decreased belt damage, and cost efficiency.
RETRO-LOC™
RETRO-LOC™ provides replacement rolls for Caterpillar's product range and allows retrofitting for non-Cat Idlers using adaptor nuts.
Catalog Map
The catalog is organized by idler style, diameter, technical data, and ordering information.
Customer Support
Caterpillar maintains 13 facilities for customer support, with key contacts listed for inside sales, financial, and technical support.
Sections Overview
  • Section 1: In-line Idlers - Details specifications for various in-line idler assemblies, including dimensions and weights for different belt widths and roll diameters.
  • Section 2: Offset Idlers - Begins on page 231.
  • Section 3: Engineered Class Pulleys - Begins on page 371.
  • Section 4: Technical Guides - Begins on page 373.
Appendix
  • Conversion Factors
  • Purchase Agreement
  • Terms & Conditions of Sale
  • Notes
Overview
This document provides detailed specifications and dimensions for various CEMA E and CEMA C steel and EXALON rolls used in conveyor systems. It includes information on carrying idler assemblies, replacement carrying rolls, and return rolls, focusing on different diameters and materials.
Specifications
  • All CEMA E steel rolls are manufactured with a 1/4” shell, with an optional 7 gauge shell available upon request.
  • Dimensions are subject to change without notice, and certified prints are available upon request.
Carrying Idler Assemblies
  • Available in various belt widths ranging from 36” to 72”.
  • Includes both steel and EXALON materials, with diameters of 6” and 7”.
  • Specific part numbers and dimensions are provided for each configuration.
Replacement Carrying Rolls
  • Detailed dimensions and weights are listed for rolls with diameters of 6” and 7”.
  • Materials include steel and EXALON, with specific part numbers for each size and type.
Replacement Return Rolls
  • Available in steel, EXALON, and rubber disc materials.
  • Dimensions and weights are provided for each type, with belt widths from 36” to 72”.
Important Notes
  • All dimensions are subject to change without notice.
  • Certified prints are available upon request.
  • Replacement roll pricing and dimensional data are located on specific pages as noted in the document.
Structure and Components
The document outlines specifications for various Caterpillar components, including roof plates and chains. Roof plates are available for 1/4” and 5/16” chains, with part numbers and dimensions provided. Chains are specified for both 1/4” and 5/16” sizes, with details on dimensions and part numbers.
Pulleys
Caterpillar offers Engineered Class Pulleys designed for higher reliability and longer life. These pulleys use A53 grade pipe, eliminating the need for stiffeners or center discs, and include features like keyless locking elements and machined rims. The document encourages submitting pulley application data for optimal selection.
Technical Guides
The technical section provides troubleshooting guides for belt conveyors, referencing the CEMA Belt Conveyors for Bulk Materials 6th Edition. It includes a list of common issues, causes, and solutions, such as belt misalignment, excessive tension, and material build-up.
Alignment and Installation
Guidelines for conveyor stringer alignment are provided, emphasizing the importance of parallel, straight, square, and level installation. Tolerances for alignment are specified, and the importance of proper pulley and shaft alignment is highlighted to prevent unnecessary wear and operational issues.
Conclusion
The document serves as a comprehensive guide for the specifications, installation, and maintenance of Caterpillar conveyor components, ensuring optimal performance and longevity.
Specifications and Procedures
Pulleys should not deviate more than +/- 1/32 inch at the bearing. When mounted by the supplier, pulleys must be secured according to the locking element manufacturer's recommendations. If assembled in the field, follow the pulley manufacturer's guidelines to prevent issues like dishing of end discs. Clamping bolts may need multiple checks for security.
Installation Tolerances
Proper alignment and installation tolerances are crucial for the longevity of mechanical apparatus. Reducer/motor bases should be rigid to minimize vibration. Structural bases require flat surfaces, and concrete supports must be correctly installed to minimize shimming. Alignment checks are mandatory post-installation.
Idler and Belt Alignment
Idlers should be aligned square to the conveyor centerline using laser alignment or a tight wire. Belt training involves adjusting idlers to correct any misalignment. Training should be supervised by one person to ensure consistency. Initial alignment should be done without load, followed by adjustments under full load.
Appendix
Includes conversion factors between English and SI units relevant to belt conveyor calculations, and a purchase agreement template.
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Catalog excerpts

Master Idler-1

Master Idler Catalog ©2012 Caterpillar, Inc.

 Open the catalog to page 1
Master Idler-2

Notice THIS CATALOG PROVIDES REFERENCE PART NUMBERS AND TECHNICAL SPECIFICATIONS FOR CAT BELT SYSTEM COMPONENTS. THE INFORMATION CONTAINED HEREIN IS GENERAL IN NATURE AND PRESENTED UNDER THE ASSUMPTION THAT ALL PERSONNEL ARE FAMILIER WITH BOTH COMPANY AND REGULATORY SAFETY STANDARDS APPLICABLE TO THE WORK AREA WHERE THESE COMPONENTS ARE INSTALLED. ALL SAFETY PRECAUTIONS ESSENTIAL TO THE PROTECTION OF PERSONNEL WORKING AROUND THESE COMPONENTS MUST BE FOLLOWED. SHOULD YOU ENCOUNTER A CONDITION OR SITUATION NOT COVERED IN THIS CATALOG OR HAVE ADDITIONAL REQUIREMENTS, CONTACT CATERPILLAR FOR ASSISTANCE....

 Open the catalog to page 2
Master Idler-4

Introduction Idler PAL™ The Cat Steel Roll with Positive Automatic Lubrication (Idler PAL™) is a result of over two years of design and engineering effort and represents new technology in Idler designs. In our steel roll, the end cap (bearing housing) has been redesigned for increased strength and a close fit to the deflector cap. Our automated assembly process includes three separate, metered grease inputs to ensure every roll has plenty of grease for a lifetime of trouble-free operation. The Idler PAL bearing cavity design allows for extra lubricant capacity, which is unmatched in the industry...

 Open the catalog to page 4
Master Idler-5

Introduction EXALON® Designed with a high molecular weight polyethylene, the Cat® EXALON® Idler roll is the 2nd-generation roll. A perfect complement to our full range of robust steel Idler rolls, EXALON is available in 4", 5", 6" and 7" diameters and CEMA C, D and E class ratings. Providing three times the abrasion resistance of a steel Idler roll, real-life test results show a shell life over three times that of a steel Idler roll. EXALON minimizes belt damage by eliminating any threat of exposed steel edges, reduction of material buildup on the Idler roll, and has a low coefficient of friction....

 Open the catalog to page 5
Master Idler-6

Introduction RETRO-LOC™ Replacement Steel and EXALON rolls are available to support Caterpillar’s expansive product range of In-line, Off Set, and Trainer carrying and return Idler assemblies, as well as replacement impact and rubber disc rolls. Each replacement roll is manufactured with Caterpillar’s standard ISO closed-slotted shaft ends. RETRO-LOC uses adaptor nuts that are mounted to Caterpillar’s standard ISO closed-slotted ends and pinned in place at our factory for complete retrofitting and replacement capability. In the event your current bulk material conveyance system employs Non-Cat...

 Open the catalog to page 6
Master Idler-7

Idler Style Idler Image Technical Data In-hns Carrying Idler Assemhly i" Diamelei Sleel Hull

 Open the catalog to page 7
Master Idler-8

Introduction Customer Support We maintain 13 modern facilities, strategically located to provide the highest standard of customer support and service Manufacturing Plant Locations Customer Service Centers Houston, PA Washington, PA Hillsville, VA Pearisburg, VA Pulaski, VA Duffield, VA Tazewell, VA Oak Hill, WV Mt. Sterling, KY Carrier Mills, IL Kilgore, TX Gillette, WY Huntington, UT Key Customer Advocates Inside Sales Kim Gardner Tessa Allison Jennifer Reece Email [email protected] [email protected] [email protected] Direct Line 276.730.1202 276.730.1214 276.730.1221 Financial /...

 Open the catalog to page 8
Master Idler-52

Return Idler Assembly 4" Diameter Steel Roll Drop Bracket List Price: Sold separately from return roll All Cat CEMA C Steel Rolls are manufactured with a 7gauge shell, optional 1/4" shell available upon request. All dimensions are subject to change without notice. Certified prints are available upon request. *Note: CEMA C replacement roll pricing and dimensional data begins on page 79.

 Open the catalog to page 52
Master Idler-53

Return Idler Assembly 5" Diameter Steel Roll Drop Bracket List Price: Sold separately from return roll. All Cat CEMA C Steel Rolls are manufactured with a 7gauge shell, optional 1/4" shell available upon request. All dimensions are subject to change without notice. Certified prints are available upon request. *Note: CEMA C replacement roll pricing and dimensional data begins on page 79.

 Open the catalog to page 53
Master Idler-54

Return Idler Assembly 6" Diameter Steel Roll Drop Bracket List Price: Sold separately from return roll. All Cat CEMA C Steel Rolls are manufactured with a 7gauge shell, optional 1/4" shell available upon request. All dimensions are subject to change without notice. Certified prints are available upon request. *Note: CEMA C replacement roll pricing and dimensional data begins on page 79.

 Open the catalog to page 54
Master Idler-55

Return Idler Assembly 4" Diameter EXALON Roll Drop Bracket List Price: Sold separately from return roll All dimensions are subject to change without notice. Certified prints are available upon request. *Note: CEMA C replacement roll pricing and dimensional data begins on page 79.

 Open the catalog to page 55
Master Idler-56

Return Idler Assembly 5" Diameter EXALON Roll Drop Bracket List Price: Sold separately from return roll. All dimensions are subject to change without notice. Certified prints are available upon request. *Note: CEMA C replacement roll pricing and dimensional data begins on page 79.

 Open the catalog to page 56
Master Idler-57

Return Idler Assembly 6" Diameter EXALON Roll Drop Bracket List Price: Sold separately from return roll. All dimensions are subject to change without notice. Certified prints are available upon request. *Note: CEMA C replacement roll pricing and dimensional data begins on page 79.

 Open the catalog to page 57
Master Idler-58

Return Idler Assembly 5" Diameter Rubber Disc Roll Drop Bracket List Price: Sold separately from return roll. All dimensions are subject to change without notice. Certified prints are available upon request. *Note: CEMA C replacement roll pricing and dimensional data begins on page 79.

 Open the catalog to page 58
Master Idler-59

Return Idler Assembly 6" Diameter Rubber Disc Roll Drop Bracket List Price: Sold separately from return roll. Number of discs m picture ere (or representation purposes oafy. Alt inner discs, are events spaced and quantities vary between belt widths. All dimensions are subject to change without notice. Certified prints are available upon request. *Note: CEMA C replacement roll pricing and dimensional data begins on page 79.

 Open the catalog to page 59

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