- Pipelayer
- 561H (S/N: 6NL1-UP)
- 572R (S/N: AAC1-UP; 2HZ1-UP)
- 572R Series II (S/N: DSC1-UP)
- 578 (S/N: 8HB1-UP)
- 583R (S/N: 2XS1-UP)
- 589 (S/N: 31Z1-UP)
- 572R (S/N: AAC1-UP; 2HZ1-UP)
- Track-Type Loader
- 939 (S/N: 9GL1-UP)
- 943 (S/N: 03Y1-UP; 31Y1-UP; 04Z1-UP; 19Z1-UP)
- 953 (S/N: 76Y1-UP; 77Y1-UP; 78Y1-UP; 05Z1-UP; 20Z1-UP; 44Z1-UP)
- 963 (S/N: 29S1-UP; 06Z1-UP; 11Z1-UP; 18Z1-UP; 21Z1-UP; 48Z1-UP)
- 973 (S/N: 66G1-UP; 86G1-UP; 90L1-UP; 91L1-UP; 26Z1-UP; 32Z1-UP)
- 943 (S/N: 03Y1-UP; 31Y1-UP; 04Z1-UP; 19Z1-UP)
- Track-Type Skidder
- 527 (S/N: 2RS1-UP; 3DS1-UP; 4NS1-UP; BDW1-UP)
- Track-Type Tractor
- D10 (S/N: 84W1-UP; 76X1-UP)
- D10N (S/N: 2YD1-UP)
- D10R (S/N: 3KR1-UP; AKT1-UP)
- D10T (S/N: RJG1-UP)
- D11N (S/N: 4HK1-UP; 74Z1-UP)
- D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)
- D11T (S/N: RAL1-UP)
- D4H (S/N: 8PB1-UP; 9DB1-UP; 2AC1-UP; 3AC1-UP)
- D5H (S/N: 7NC1-UP; 8RC1-UP; 9HC1-UP; 1DD1-UP; 1YD1-UP; 2SD1-UP; 3MD1-UP; 4KD1-UP)
- D6H (S/N: 8KB1-UP; 4RC1-UP; 6FC1-UP; 7PC1-UP; 8FC1-UP; 8YC1-UP; 3ZF1-UP; 3YG1-UP; 1FJ1-UP)
- D6H Series II (S/N: 1KD1-UP; 2KD1-UP; 3ED1-UP; 4YF1-UP; 2TG1-UP; 4GG1-UP; 4LG1-UP)
- D6M (S/N: 9ZM1-UP; 2RN1-UP; 3WN1-UP; 4JN1-UP; 5NR1-UP; 5WR1-UP; 6LR1-UP; 2YS1-UP; 4GS1-UP; 4HS1-UP)
- D6N (S/N: CBF1-UP; CCG1-UP; ALH1-UP; CBJ1-UP; CCK1-UP; AKM1-UP; ALR1-UP; CCS1-UP; ALY1-UP)
- D6R (S/N: 2HM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; 2YN1-UP; 3ZN1-UP; 4HN1-UP; 4MN1-UP; 5LN1-UP; 6JN1-UP; 7KN1-UP; 8LN1-UP; 8XN1-UP; 9MN1-UP; 9PN1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP)
- D6R Series II (S/N: BNC1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-UP)
- D7H (S/N: 2SB1-UP; 4AB1-UP; 5WB1-UP; 5BF1-UP; 2RG1-UP; 3XG1-UP; 4FG1-UP; 77Z1-UP; 79Z1-UP; 80Z1-UP; 82Z1-UP)
- D7R (S/N: BPK1-UP; BNM1-UP; BRM1-UP; 9HM1-UP; 2EN1-UP; 3DN1-UP; BRP1-UP; 2HR1-UP; 3ZR1-UP; 4SR1-UP; 5MR1-UP; 6ER1-UP; BPT1-UP; BNX1-UP)
- D7R Series II (S/N: AEC1-UP; AFG1-UP; ABJ1-UP; AGN1-UP; ACS1-UP; ADW1-UP)
- D8L (S/N: 4FB1-UP; 7YB1-UP; 7JC1-UP; 53Y1-UP)
- D8N (S/N: 9TC1-UP)
- D8R (S/N: 7XM1-UP; 9EM1-UP; 6YZ1-UP)
- D8R Series II (S/N: AKA1-UP)
- D8T (S/N: KPZ1-UP)
- D9L (S/N: 14Y1-UP)
- D9N (S/N: 1JD1-UP)
- D9R (S/N: ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)
- D9T (S/N: RJS1-UP)
- D10N (S/N: 2YD1-UP)
Introduction
Revision | Summary of Changes in SEHS8515 |
04–07 | Added serial number prefixes for New Product Introduction. |
© 2018 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. Information contained in this document is considered Caterpillar: Confidential Yellow.
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:
Summary
This bulletin provides the steps, required tooling, and parts necessary to repair retainer assemblies on track idlers and rollers. The repair is performed by attaching a new thrust washer on a former retainer with dowels.
Do not perform repairs until becoming familiar with the information in this bulletin.
Safety
Illustration 1 | g02139237 |
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 in order to perform these functions properly.
This bulletin may contain hazardous steps. Hazardous steps will be identified by warning symbols like the one below.
Warning messages identify a specific, imminent, latent, hazard that has a reasonable probability of resulting in personal injury or death if the warning is ignored.
Illustration 2 | g03186216 |
Example warning |
Do not attempt to disassemble or assemble this machine until you read and understand the disassembly and assembly instructions. Improper disassembly and assembly procedures could result in injury or death. |
Inspect all threaded components before use. Damaged threads may fail under hydraulic pressure. Broken threads may release flying objects that are propelled with great force. Personal injury or death can occur if struck by flying objects. |
Canceled Part Numbers and Replaced Part Numbers
This document may not include all canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.
Required Tooling and Parts
Illustration 3 | g01194886 |
(1) (2) (3) (4) (5) Drill Fixture |
Required Tooling and Parts For Idlers | |||
Model | Retainer Assembly | Replacement Thrust Washer | Fabricated Tooling(1) |
D11T
D11R Conventional |
|||
D11T
D11N Inverted |
|||
D10T
D10R Conventional |
|||
D10N
Inverted |
|||
D10
Inverted |
|||
D9L
589 Inverted |
|||
D9T
D9R/N Inverted |
|||
D8T
D8L Inverted |
|||
D8R/N
583R 578 Inverted |
|||
D7R/H
572R Inverted |
|||
D6R/H
Inverted |
|||
D6M/N
D5H Inverted |
|||
D6M/N
D5H Inverted |
|||
D4H
Inverted |
(1) | |
(2) | Four |
(3) | Four |
(4) | Four |
(5) | Four |
Required Tooling and Parts For Rollers | |||
Model | Retainer Assembly | Replacement Thrust Washer | Fabricated Tooling(1) |
D11T
D11R |
|||
D11N
Inverted |
|||
D10T
D10R |
|||
D10T
D10N Inverted |
|||
D10
Inverted |
|||
D9L
589 Inverted |
|||
D9T
D9R/N Inverted |
|||
D8L
Inverted |
|||
D8T
D8R/N 583R 578 Inverted |
|||
D7H
Inverted |
|||
D6H
Inverted |
|||
D5H
Inverted |
|||
D4H
561H Inverted |
|||
973
Inverted |
|||
963B
963 Inverted |
|||
953B
953 Inverted |
|||
943
Inverted |
|||
939
Inverted |
(1) | |
(2) | Four |
(3) | Four |
(4) | Four |
Repair Procedure
Illustration 4 | g01177053 |
(A) Holes for the dowels |
- Remove the idlers and/or rollers and remove the retainer assembly. See the Service Manual for the correct procedure.
Show/hide table
Illustration 5 g01195863 - Remove the damaged thrust washer from the retainer assembly.
Show/hide table
Illustration 6 g01176093 - Remove the protrusions from the former retainer with a die grinder and grinding wheel.
Note: Use a small grinding wheel to prevent the removal of excessive plate material.
Show/hide tableIllustration 7 g01194882 - Remove any remaining roughness from the retainer with a flat file.
Show/hide table
Illustration 8 g01195871 - Use a straightedge on the retainer and the thrust washer to make sure that all the protrusions have been removed.
- Wipe the thrust washer and mating surfaces of the retainer with a clean cloth.
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Illustration 9 g01194900 Show/hide tableIllustration 10 g01194902 - Assemble the thrust washer and the retainer in the drill fixture.
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Illustration 11 g01195902 (B) Channels for lubrication
(C) Holes of drill fixture - Align the holes of drill fixture (C) between channels for lubrication (B) in the thrust washer.
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Illustration 12 g01196031 - Use the drill fixture as a guide. Mark the holes for drilling with a transfer punch in the four holes on the drill fixture.
- Use a
4.8 mm (0.19 inch) transfer punch on retainers with 8H-4952 Dowels, 190-6055 Dowels, or 2H-1190 Dowels. - Use a
3.2 mm (0.13 inch) transfer punch on retainers with 1L-5072 Dowels.
Show/hide tableIllustration 13 g01196034 (D) Marks from the transfer punch - Use a
- Loosen the drill fixture. Rotate the drill fixture in order to allow the marked holes to be drilled.
Note: Only turn the drill fixture. Rotating the thrust washer may result in drilling into the former holes on the retainer.
- Tighten the drill fixture in order to hold the thrust washer in place.
Show/hide table
Illustration 14 g01196038 Show/hide tableIllustration 15 g01196040 - Drill and ream the four holes. Refer to Table 4 for the correct size of drill bit.
Note: The depth of the hole should be equal to the length of the dowel. The depth includes the thrust washer and the retainer.
Note: An interference fit of
0.05 mm (0.002 inch) is required. Refer to the final hole sizes in Table 5 in order to select the correct drill and the correct reamer.Show/hide tableTable 4 Drill Size Dowel Letter Designation Dimension 8H-4952 D 6.248 mm (0.246 inch) 190-6055 2H-1190 C 6.147 mm (0.242 inch) 1L-5072 -- 4.60 mm (0.181 inch) Show/hide tableTable 5 Dimensions of the Dowel Holes Dowel Final Hole Size 8H-4952 6.327 mm (0.2491 inch) diameter190-6055 2H-1190 6.165 mm (0.2427 inch) diameter1L-5072 4.577 mm (0.1802 inch) diameterShow/hide tableIllustration 16 g01196160 Show/hide tableIllustration 17 g01196163 - Drill a chamfer on the thrust washer in order to create a countersunk hole in the thrust washer.
- Use a hammer with a soft tip to drive the dowels through the thrust washer and into the retainer holes. Remove the retainer assembly from the drill fixture.
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Illustration 18 g01196472 - Drive the dowels into the retainer assembly until the dowels hit the bottom of the hole.
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Illustration 19 g01196478 - Use a punch in order to create a mushroomed end on the dowel.
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Illustration 20 g01196516 - Remove any remaining protrusions on the thrust washer with a flat file.
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Illustration 21 g01196519 - Use a straightedge to make sure that all protrusions have been removed.
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Illustration 22 g01196522 Acceptable Show/hide tableIllustration 23 g01196526 Unacceptable - With a feeler gauge, check for a gap between the thrust washer and the retainer. No gap is preferred, but a maximum gap of
0.08 mm (0.003 inch) is acceptable.Note: This step ensures the correct internal clearance after a roller or an idler has been assembled.
- Clean the retainer in a wash tank.
- Assemble the retainer assembly on the roller or the idler.
Show/hide table
Illustration 24 g01196671 - Measure the end play after assembly. Refer to the following tables below for the correct end play.
End Play Values for Inverted Idlers | |
Model | Tolerance |
D11T, D11N, D10N, D9T, D9R, D9N, D8L, D8N, 589, 578 | |
D7H, D6H, D5H, D4H | |
End Play Values for Conventional Idlers | |
Model | Tolerance |
D11T, D11R, D11N | |
D10R, D10N, D9R | |
D10T, D10R, D10N, D9L | |
D8R | |
D7R | |
D6R | |