- Excavator
- LL231 (S/N: 8PD1-UP)
- Pipelayer
- 578 (S/N: 8HB1-UP)
- 583R (S/N: 2XS1-UP)
- 589 (S/N: 31Z1-UP)
- 583R (S/N: 2XS1-UP)
- Track-Type Loader
- 939 (S/N: 9GL1-UP)
- 943 (S/N: 31Y1-UP; 63Y1-UP; 73Y1-UP; 04Z1-UP; 19Z1-UP)
- 953 (S/N: 63Y1-UP; 73Y1-UP; 76Y1-UP; 77Y1-UP; 78Y1-UP; 05Z1-UP; 20Z1-UP; 44Z1-UP)
- 953B (S/N: 5MK1-UP)
- 963 (S/N: 29S1-UP; 43Y1-UP; 06Z1-UP; 11Z1-UP; 18Z1-UP; 21Z1-UP; 48Z1-UP)
- 963B (S/N: 9BL1-UP)
- 973 (S/N: 11B1-UP; 66G1-UP; 86G1-UP; 91L1-UP; 26Z1-UP; 32Z1-UP)
- 943 (S/N: 31Y1-UP; 63Y1-UP; 73Y1-UP; 04Z1-UP; 19Z1-UP)
- Track-Type Tractor
- D10 (S/N: 84W1-UP; 76X1-UP)
- D10N (S/N: 3SK1-UP)
- D10R (S/N: 3KR1-UP; AKT1-UP)
- D11N (S/N: 4HK1-UP; 74Z1-UP)
- D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)
- D4H (S/N: 9DB1-UP; 2AC1-UP; 3AC1-UP)
- D4H Series III (S/N: 4NK1-UP)
- D5H (S/N: 7NC1-UP; 8RC1-UP; 8SC1-UP; 9HC1-UP; 1DD1-UP; 1YD1-UP; 2SD1-UP; 3MD1-UP; 4KD1-UP)
- D5H Series II (S/N: 8RJ1-UP)
- D6H (S/N: 8KB1-UP; 4RC1-UP; 6FC1-UP; 7PC1-UP; 8FC1-UP; 8YC1-UP; 3ZF1-UP; 5HF1-UP; 6CF1-UP; 3YG1-UP; 1FJ1-UP; 3YJ1-UP)
- D6H Series II (S/N: 1KD1-UP; 2KD1-UP; 3ED1-UP; 4YF1-UP; 2TG1-UP; 4GG1-UP; 4LG1-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; DMP1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6GR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP; S6T1-UP; S6X1-UP; S6Y1-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)
- D8L (S/N: 4FB1-UP; 7YB1-UP; 7JC1-UP; 53Y1-UP)
- D8N (S/N: 9TC1-UP; 1XJ1-UP; 5TJ1-UP; 7TK1-UP)
- D8R (S/N: 7XM1-UP; 9EM1-UP)
- D9L (S/N: 14Y1-UP)
- D9N (S/N: 1JD1-UP; 6XJ1-UP)
- D9R (S/N: JJB1-UP; HWH1-UP; ABK1-UP; ACL1-UP; 8BL1-UP; WDM1-UP)
- D10N (S/N: 3SK1-UP)
Introduction
Revision | Summary of Changes in SEBF8582 |
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 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
The following information is given to provide Disassembly and Assembly procedures for idlers with inverted Duo-Cone seals.
The information in this bulletin should serve as an aid in determining whether an idler with inverted Duo-Cone seals can be reconditioned. During rebuild procedures, always correct any conditions which may have caused the original failure or wear and never install a component that falls within the “Do not use again” criteria.
References
Reference: Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals"
Reference: Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers"
Reference: Special Instruction, SEHS8483, "Assembly and Installation of Inverted Duo-Cone Seals"
Reference: Special Instruction, SEHS8974, "Tool and Specification Chart for Inverted Duo-Cone Seals"
Reference: Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume"
Reference: Undercarriage Reconditioning Bulletin, SEBF8594, "Nitrogen Pressure Test Unit FT2724"
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. A safety alert symbol like the one below is used to call attention to a hazard.
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.
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. |
Do not stand near the hydraulic press while the press is in operation. A component that slips or breaks under pressure may fly into the air 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.
Tooling and Equipment
Required Tools | |
Seal Installer | |
Model Number | Part Number |
D11N, D11R | |
D9L D10N, D10R, 589 | |
D10 | |
D9N, D9R | |
D8L, D8N, D8R, 578 | |
D6H, D6R, D7H | |
D5H | |
D4H | |
Seal Height Tooling | |
D11N, D11R, D10, D10N,
D10R, D9L, D9N, D9R, D8L, D5H, D4H |
( 8T-0447 Dial Caliper As) |
Miscellaneous Tooling | |
Part Description | Part Number |
Installer Tool | |
Stopper Installation Tool Group | |
O-Ring Assembly Compound |
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. |
Disassembly
- Drill out the stopper from the end of the pin shaft with a 0.5 inch drill bit to drain the oil.
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Illustration 3 g02409477 Remove bolts and retainers. - Remove the 6 to 12 bolts and the retainer assembly.
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Illustration 4 g02409479 Remove thrust washers. - Remove the thrust washers from each end of the idler.
Note: Some thrust washers are pinned.
Note: Refer to Undercarriage Reconditioning Bulletin, SEHS8515, "Repair Procedure for Retainer Assemblies on Track Idlers and Rollers" for the salvage procedures on retainers with damaged thrust washers.
Show/hide tableIllustration 5 g02409480 Remove retainer seal ring and o-ring from retainers. - Remove the retainer seal ring and o-ring from each retainer assembly.
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Illustration 6 g02409481 Remove the Duo-Cone seals from the idler shaft. Show/hide tableIllustration 7 g02409482 Remove Duo-Cone seals from retainer assemblies. - Remove the Duo-Cone seals from the idler shaft and retainer assemblies. Inspect each set of seals side by side for reusability.
Note: If the seals are reusable, the seals must be kept in matching pairs. Refer to Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals" for proper reuse information.
Show/hide tableIllustration 8 g02409483 Remove stabilizers. - Remove the toric stabilizers from both sides of the idler.
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Table 3 Shaft/Bearing Clearance Model Number Clearance (min/max) D11R, D11N, D10L,
D10R, D10N, D9L,
D9R, D9N, 589,
D8L, D8R, D8N,
578, D7R, D7H, 9730.44/0.56 mm (0.0173/0.022iinch) D6H, 963, D5H, 953 0.33/0.52 mm (0.013/0.021 inch) D4H, 943 0.26/0.44 mm (0.010/0.017 inch) - Measure the shaft-to-bearing clearance using a feeler gauge. The clearance must fall within the specifications given in Table 3.
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Table 4 Idler Rebuild Dimensions Model Idler Assembly Idler Bore
DiameterIdler Hub
WidthBearing
Part NumberBearing and Idler
Assembly DiameterD11N/ D11R 9W-9650 148-3730 168.89 ± 0.04 mm (6.650 ± 0.002 inch) 402.00 ± 0.13 mm (15.827 ± 0.005 inch) 9W-4195 148-3540 162.77 ± 0.03 mm (6.408 ± 0.001 inch) D10N/ D10R 7T-0961 142.85 ± 0.04 mm (5.624 ± 0.002 inch) 326.00 ± 0.13 mm (12.8345 ± 0.005 inch) 9W-4194 136.78 ± 0.03 mm (5.385 ± 0.001 inch) D10L 6Y-0216 7T-2175 9W-4340 168.89 ± 0.04 mm (6.650 ± 0.002 inch) 375.00 ± 0.13 mm (14.764 ± 0.005 inch) 9W-4195 P4-7838 162.77 ± 0.03 mm (6.408 ± 0.001 inch)
162.62 ± 0.02 mm (6.402 ± 0.001 inch) D9N/ D9R 7T-2770 133.32 ± 0.04 mm (5.250 ± 0.002 inch) 290.00 ± 0.13 mm (11.417 ± 0.005 inch) 9W-9499 127.25 ± 0.03 mm (5.010 ± 0.001 inch) D9L 9W-6037 142.85 ± 0.04 mm (5.624 ± 0.002 inch) 290.00 ± 0.13 mm (11.417 ± 0.005 inch) 9W-4194 136.78 ± 0.03 mm (5.385 ± 0.001 inch) D8N/ D8R 6Y-0553 (Rear)133.32 ± 0.04 mm (5.250 ± 0.002 inch) 250.00 ± 0.13 mm (9.843 ± 0.005 inch) 9W-9499 127.25 ± 0.03 mm (5.010 ± 0.001 inch) 6Y-0556 (Front)133.32 ± 0.04 mm (5.250 ± 0.002 inch) 250.00 ± 0.13 mm (9.843 ± 0.005 inch) 9W-9499 154-3298 127.25 ± 0.03 mm (5.010 ± 0.001 inch) D8L 6Y-0556 133.32 ± 0.04 mm (5.250 ± 0.002 inch) 250.00 ± 0.13 mm (9.843 ± 0.005 inch) 9W-9499 154-3298 127.25 ± 0.03 mm (5.010 ± 0.001 inch) D7N/ D7R 6Y-2030 133.32 ± 0.04 mm (5.250 ± 0.002 inch) 216.00 ± 0.13 mm (8.504 ± 0.005 inch) 6Y-1757 127.25 ± 0.03 mm (5.010 ± 0.001 inch) 9W-7646 133.32 ± 0.04 mm (5.250 ± 0.002 inch) 216.00 ± 0.13 mm (8.504 ± 0.005 inch) 6Y-1757 127.25 ± 0.03 mm (5.010 ± 0.001 inch) 6Y-2033 133.32 ± 0.04 mm (5.250 ± 0.002 inch) 216.00 ± 0.13 mm (8.504 ± 0.005 inch) 6Y-1757 127.25 ± 0.03 mm (5.010 ± 0.001 inch) D7H 3Q-3873 133.32 ± 0.04 mm (5.250 ± 0.002 inch) 216.00 ± 0.13 mm (8.504 ± 0.005 inch) 6Y-1757 127.25 ± 0.03 mm (5.010 ± 0.001 inch) D6N/ D6R/ D6H 7T-8940 114.28 ± 0.04 mm (4.500 ± 0.002 inch) 199.00 ± 0.13 mm (7.835 ± 0.005 inch) 9P-2245 108.06 ± 0.02 mm (4.254 ± 0.001 inch) 6T-3217 114.28 ± 0.04 mm (4.500 ± 0.002 inch) 199.00 ± 0.13 mm (7.835 ± 0.005 inch) 9P-2245 108.06 ± 0.02 mm (4.254 ± 0.001 inch) D5H 6T-1763 102.00 ± 0.04 mm (4.016 ± 0.002 inch) 189.00 ± 0.13 mm (7.441 ± 0.005 inch) 9P-1360 95.84 ± 0.08 mm (3.773 ± 0.003 inch) 517 8E-4008 114.28 ± 0.04 mm (4.500 ± 0.002 inch) 199.00 ± 0.13 mm (7.835 ± 0.005 inch) 9P-2245 108.06 ± 0.02 mm (4.254 ± 0.001 inch) D4H/D5M 6T-2615 96.00 ± 0.04 mm (3.780 ± 0.002 inch) 168.00 ± 0.13 mm (6.614 ± 0.005 inch) 8P-7002 89.67 ± 0.08 mm (3.530 ± 0.003 inch) 7T-4399 96.00 ± 0.04 mm (3.780 ± 0.002 inch) 168.00 ± 0.13 mm (6.614 ± 0.005 inch) 8P-7002 89.67 ± 0.08 mm (3.530 ± 0.003 inch) 589 9W-6037 142.85 ± 0.04 mm (5.624 ± 0.002 inch) 290.00 ± 0.13 mm (11.417 ± 0.005 inch) 9W-4194 136.78 ± 0.03 mm (5.385 ± 0.001 inch) 578 6Y-0556 133.32 ± 0.04 mm (5.250 ± 0.002 inch) 250.00 ± 0.13 mm (9.843 ± 0.005 inch) 9W-9499 154-3298 127.25 ± 0.03 mm (5.010 ± 0.001 inch) Show/hide tableTable 5 Shaft Specifications CAT Model Idler Assembly Shaft Part Number Outer Shaft Diameter Bearing Surface Length D11N/ D11R 9W-9650 148-3730 6T-8660 162.27 ± 0.03 mm (6.389 ± 0.001 inch) 377.00 ± 0.05 mm (14.842 ± 0.002 inch) 153-9461 162.27 ± 0.03 mm (6.389 ± 0.001 inch) 377.00 ± 0.05 mm (14.842 ± 0.002 inch) 138-4331 162.27 ± 0.03 mm (6.389 ± 0.001 inch) 377.00 ± 0.10 mm (14.843 ± 0.004 inch) D10N/ D10R 7T-0961 7T-0955 136.28 ± 0.03 mm (5.365 ± 0.001 inch) 301.00 ± 0.05 mm (11.850 ± 0.002 inch) 128-9693 136.28 ± 0.03 mm (5.365 ± 0.001 inch) 301.00 ± 0.10 mm (11.850 ± 0.004 inch) D10L 6Y-0216 7T-2175 9W-4340 7G-2622 162.27 ± 0.03 mm (6.389 ± 0.001 inch) 350.00 ± 0.05 mm (13.800 ± 0.002 inch) 138-4330 162.27 ± 0.03 mm (6.389 ± 0.001 inch) 350.00 ± 0.10 mm (13.800 ± 0.004 inch) D9N/ D9R 7T-2770 7T-2778 126.75 ± 0.03 mm (4.990 ± 0.001 inch) 265.00 ± 0.05 mm (10.433 ± 0.002 inch) 138-9378 126.75 ± 0.03 mm (4.990 ± 0.001 inch) 265.00 ± 0.10 mm (10.433 ± 0.004 inch) D9L 9W-6037 3T-3617 136.28 ± 0.03 mm (5.365 ± 0.001 inch) 265.00 ± 0.05 mm (10.433 ± 0.002 inch) 140-0291 136.28 ± 0.03 mm (5.365 ± 0.001 inch) 265.00 ± 0.10 mm (10.433 ± 0.004 inch) D8N/ D8R 6Y-0556 6Y-0553 8P-6938 126.75 ± 0.03 mm (4.990 ± 0.001 inch) 225.00 ± 0.05 mm (8.858 ± 0.002 inch) 138-9712 126.75 ± 0.03 mm (4.990 ± 0.001 inch) 225.00 ± 0.10 mm (8.858 ± 0.004 inch) D8L 6Y-0556 8P-6938 126.75 ± 0.03 mm (4.990 ± 0.001 inch) 225.00 ± 0.05 mm (8.858 ± 0.002 inch) 138-9712 126.75 ± 0.03 mm (4.990 ± 0.001 inch) 225.00 ± 0.10 mm (8.858 ± 0.004 inch) D7N/ D7R/ D7H 6Y-2030 9W-7646 6Y-2033 3Q-3873 6Y-1756 126.75 ± 0.03 mm (4.990 ± 0.001 inch) 191.00 ± 0.10 mm (7.520 ± 0.004 inch) D6N/ D6R/D6H 7T-8940 6T-3220 107.71 ± 0.03 mm (4.241 ± 0.001 inch) 160.00 ± 0.05 mm (6.300 ± 0.002 inch) 6T-3217 D6H 7T-8940 116-1422 107.71 ± 0.03 mm (4.241 ± 0.001 inch) 160.00 ± 0.05 mm (6.300 ± 0.002 inch) 6T-3217 D5H 6T-1763 6T-3285 95.43 ± 0.03 mm (3.757 ± 0.001 inch) 150.00 ± 0.05 mm (5.906 ± 0.002 inch) 517/D5H 8E-4008 8E-4017 107.71 ± 0.03 mm (4.241 ± 0.001 inch) 160.00 ± 0.05 mm (6.300 ± 0.002 inch) D4H
D5M7T-4399 6T-2620 89.30 ± 0.03 mm (3.516 ± 0.001 inch) 129.00 ± 0.05 mm (5.079 ± 0.002 inch) 6T-2615 589 9W-6037 9W-0621 3T-3617 140-0291 136.28 ± 0.03 mm (5.365 ± 0.001 inch) 265.00 ± 0.05 mm (10.433 ± 0.002 inch) 578 6Y-0556 8P-6938 138-9712 126.75 ± 0.03 mm (4.990 ± 0.001 inch) 225.00 ± 0.05 mm (8.858 ± 0.002 inch) Note: Table 4 and Table 5 include the dimensions to determine the shaft-to-bearing clearance. The clearance can be checked dimensionally or with feeler gauges.
Show/hide tableIllustration 9 g02409484 Remove the shaft. Show/hide tableIllustration 10 g02409485 Shaft with hoist attached. - Partially slide the shaft out of the idler. If necessary, attach a hoist to help remove the shaft the rest of the way.
Illustration 2 | g02409476 |
Remove plug and stopper. |
Assembly
NOTICE |
---|
Be sure that the correct assembly and installation procedures are followed when using inverted Duo-Cone seals. Many failures are the direct result of mistakes made during assembly and installation of seals. |
- Wash and remove all debris from the idler and all of the components.
- Use alcohol to clean components with a lint free cloth.
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Illustration 12 g02409487 Install o-ring. - Use 369-9450 O-Ring Assembly Compound to install the new o-rings into the retaining grooves.
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Illustration 13 g02409488 Install seals into retainer. Show/hide tableIllustration 14 g02409489 (1) Retainer - Lubricate the retainer seal ring o-rings with alcohol. Use the installation tool and an arbor press to insert the seal ring and o-ring into the retainer. Press the retainer seal in until the rubber o-ring is seated against the base of the retainer.
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Illustration 15 g02409490 Check retainer seal ring height. Show/hide tableIllustration 16 g02409491 (A) Retainer seal ring height
(1) Retainer
(2) Retainer seal ring - Check the assembled seal ring height in the retainer at four locations 90 degrees apart. (Refer to Table 2 for proper seal height tooling.) The difference in height must not exceed
0.3 mm (0.01 inch) . Also, turn the retainer over to ensure that the rubber o-ring is in contact all around the bottom of the base in the retainer. - Lightly lubricate the idler bearings with the same oil type used to fill the idler.
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Illustration 17 g02409492 Install shaft. - Install the shaft into the idler.
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NOTICE Use care when installing the shaft in the idler. The shaft may scrape bronze particles from the bearing, the bronze particles will cause a failure in the idler.
Show/hide tableIllustration 18 g02409493 Install the toric stabilizers. Show/hide tableIllustration 19 g02409494 (3) Shaft
(4) Toric stabilizer - Install a toric stabilizer on each end of the shaft. Make sure that the toric stabilizers are installed on the shaft with the contoured edge facing the interior of the idler.
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Illustration 20 g02409495 Install thrust washers. - Install the thrust washers on both ends of the idler shaft.
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Illustration 21 g02409497 Assemble shaft seal.
(5) Seal ring
(6) Rubber Toric ring
(7) Retaining lip
(8) Seal ring ramp - When the Duo-Cone seals are being reused, install a new toric ring in the seal ring at the bottom of the seal ring ramp. Against the retaining lip.
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NOTICE Be sure that the toric ring is properly positioned against the retaining lip around the entire circumference of the seal ring. Verify the toric position for new Duo-Cone seals. Failure to do so may result in a failure of the idler.
Show/hide tableIllustration 22 g02409499 Install Duo-Cone seals onto shaft. - Use the correct installation tool to install the Duo-Cone seals onto the idler shaft. (Refer to Table 2 for proper seal installer.) Use even pressure and a slight twisting motion to slide the toric and seal ring down the shaft until the tooling touches the shaft end.
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Illustration 23 g02409501 Check seal height on the shaft. Show/hide tableIllustration 24 g02409502 (B) Seal height
(9) Duo-Coneseal
(10) Shaft thrust face - Check the assembled Duo-Cone seal height from the shaft thrust face at four locations 90 degrees apart. (Refer to Table 2 for proper seal height tooling.) The difference in height around the seal must not exceed
0.8 mm (0.032 inch) .Note: If the seal height specification is not met, the Duo-Cone seals must be removed and reinstalled.
Show/hide tableIllustration 25 g02409504 Clean shaft seal ring. - Wipe the shaft seal ring face with a lint free cloth.
Note: To reduce the risk of introducing airborne contaminants to the face of the Duo-Cone seal ring, minimize the time between seal ring oil application and assembly of the retainer to the idler assembly.
Show/hide tableNOTICE Do not apply oil with contaminated fingers, gloves, or brushes.
Show/hide tableIllustration 26 g03009037 - Use a pneumatic dispenser, squeeze bottles or tubes, or syringes to apply oil to the entire face of the seal rings.
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Illustration 27 g02409506 Clean retainer seal face. - Wipe the entire retainer seal face with a lint free cloth.
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Table 6 Alignment Sleeve Tooling Model Tooling Part Number D11N, D11R 8T-0825 D10, D10N, D10R, 589, D9L 8T-0824 D9N, D9R, D8L, D8N, D8R, 578 8T-0823 D7H, 973, 973 Steel Mill, D6H, D6R,
963, 963B8T-0822 D5H, 953, D4H, 943 8T-0945 Show/hide tableIllustration 28 g02409507 Slide on retainer. - Slip the retainer assembly over the shaft and carefully move the alignment sleeve and the retainer onto the idler. (Refer to Table 6 for correct alignment sleeve.)
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Illustration 29 g02409508 Install two retainer bolts ( threaded guide-rods optional). - Apply an even pressure to the alignment sleeve, at the same time, starting two bolts 180 degrees apart. Tighten the bolts in an alternating fashion until the retainer seats against the idler.
Note: Keep the retainer face parallel to the idler face during the tightening process.
Show/hide tableIllustration 30 g02409509 Torque retainer bolts. - Remove the alignment sleeve and install the remaining six bolts and tighten (Refer to Table 7 for proper retaining bolt torque specifications.)
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Table 7 Torque for Retaining Bolts Model Dynamic Assembly Torque Static Inspection Torque D11 (5/8 inch bolts) 270 ± 40 N·m (199 ± 30 lb ft) 230 N·m (170 lb ft) D11 (1/2 inch bolts)
D10N, D9L, 589135 ± 20 N·m (100 ± 15 lb ft) 115 N·m (85 lb ft) D9R, D9N, D8N, D8L,
578, D7H85 ± 15 N·m (63 ± 11 lb ft) 70 N·m (52 lb ft) D6H, D5H, D4H 55 ± 10 N·m (41 ± 7 lb ft) 45 N·m (33 lb ft) Note: The static torque values listed in Table 7 are minimum requirements. Maximum static torque values, however, must not exceed maximum dynamic torque limits. Check the static torque specifications using a torque wrench. The retaining bolts must not move in the tightening direction when the static torque value specified in Table 7 is applied.
Show/hide tableTable 8 Spin Socket Tooling Model Tooling Part Number D11N, D10 1U-9399 D10N FT-1909 D9L 1U-9398 D9N, D8N, D8L FT-1910 D7H, D6H, 973, 963 FT-1911 D5H, D4H, 953, 943 FT-1994 Show/hide tableIllustration 31 g02409510 Spin the shaft. - Select the correct spin socket from Table 8 and spin the shaft 20 revolutions in both directions.
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Table 9 End play Tolerances Model Tolerance
(min/max)D11N, D10N, D9L, D9R, D9N,
589, D8L, D8N, 5780.38/1.14 mm (0.015/0.045 inch) D7H 0.38/1.24 mm (0.015/0.050 inch) D7H, D6H, D5H, D4H 0.25/1.25 mm (0.010/0.049 inch) - Check the end play.
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NOTICE If the end play does not fall within the tolerances given in Table 9, the idler must be disassembled to determine why the tolerance specification was not achieved.
Show/hide tableIllustration 32 g02409513 Install stopper. - Lubricate the circumference of the stopper and install stopper in the end of the shaft. The stopper must be installed
7.0 ± 15.0 mm (0.28 ± 0.59 inch) below the surface of the shaft.Note: For testing and filling of idlers and rollers in the track shops the preferred Caterpillar tool is the 170-5664 Test and Fill Machine
Show/hide tableIllustration 33 g02722068 (1) 8T-0831 Lubricator Tip
(2) 4C-7099 Reducer Fitting
(3) 170-5665 Pressure Tester
(4) 5P-8998 Pipe Fitting
(5) 006-0210 Pipe Tee
(6) 8T-0848 Pressure Gauge
(7) 4C-7090 Ball Valve - Pressure test the idler using FT-2724 Nitrogen Pressure Testing Tool.
Introduce nitrogen into the lubricant cavity to a pressure of
138 kPa (20.0 psi) . The cavity is to be sealed and pressure observed for 10 seconds. A pressure drop of 2.5 percent,3.5 kPa (0.5 psi) or less is acceptable.Show/hide tableNOTICE Do not allow nitrogen to enter in a surge and do not use pressure in excess of
138 kPa (20.0 psi) . This action may damage the seals.Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume" for proper fill volumes and oil types.
Show/hide tableIllustration 34 g02409515 Determine shaft type. Show/hide tableIllustration 35 g02409516 Add oil to idler. - Add the correct quantity of oil into the idler.
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Table 10 Idler Oil Fill Volumes Model Shaft Part Number Shaft Type Oil Volume D11R/ D11N 6T-8660 Extruded 3000 ± 25 ml 153-9461 138-4331 Double upset 1800 ± 25 ml D10R/ D10N 7T-0955 Extruded 1300 ± 25 ml 128-9693 Double upset 950 ± 25 ml D10L 7G-2622 Extruded 2750 ± 25 ml 138-4330 Double upset 1650 ± 25 ml D9R/ D9N 7T-2778 Extruded 1300 ± 25 ml 138-9378 Double upset 800 ± 25 ml D9L 3T-3617 Extruded 1500 ± 30 ml 140-0291 Double upset 775 ± 25 ml D8R/ D8N/ D8L 8P-6938 Extruded 1050 ± 25 ml 138-9712 Double upset 700 ± 25 ml Note: Refer to Table 10 for inverted idler oil fill volumes.
Note: Oil fill volumes depend on the shaft configuration. Refer to Illustration 34 to determine shaft type and refer to Undercarriage Reconditioning Bulletin, SEBF8576, "Idler Oil Fill Volume" for proper oil type and fill volume.
Show/hide tableTable 11 Plug Depth Specifications Model Usage Plug Height above Stopper Surface D11N, D11R, D10, D10N, D10R,
D9L, D9N, D9R, D8L, D8N,
D8R, D7H, 973, 973 Steel Mill, D6H,
D6R, D5H, D4H, 963, 963B,
953, 943, 9390.0 ± 5.0 mm (0.00 ± 0.20 inch) Show/hide tableIllustration 36 g02409517 Insert plug into stopper. - Use the 5P-7419 Installer Tool to insert the plug into the stopper to the proper depth. (Refer to Table 11 for proper plug depth specifications.)
Note: The plug must not be recessed below the stopper surface after assembly.
Show/hide tableIllustration 37 g02409520 Tap end of idler shaft to determine if oil is present. - Tap the end of the idler shaft to determine if oil is present in the idler. If there is a dull thud, the idler contains oil. If there is a ringing noise, the idler is empty and needs filled.
NOTICE |
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Be sure to maintain the correct surface roughness of the shaft ramp area when removing debris from the idler shaft. Failure to maintain the integrity of this surface could lead to a failure in the idler. |
Illustration 11 | g02409486 |
Factory finish for shaft ramp area. |