- Caterpillar Products
- Machines with Sealed Positive Pin Retention (PPR) Track
Introduction
| Revision | Summary of Changes for SEBF8587 |
| 07 | Added serial number prefixes for New Product Introduction. |
| 06 | Added serial number prefixes for New Product Introduction. |
| 05 | 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 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 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 technical questions when using this document, work with your Dealer technical Communicator (TC).
To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.
Summary
The following information is given to provide Disassembly and Assembly procedures for large mining product rollers. The information in this bulletin should serve as an aid in determining whether a large mining product roller 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, SEBF8574, "Track Roller Oil Fill Volume"
Reference: Special Instruction, SEHS8364, "Assembly and Installation of Conventional Duo-Cone Seals"
Reference: Special Instruction, SEHS8484, "Tool and Specification Chart for Conventional Duo-Cone Seal Groups"
Reference: Undercarriage Reconditioning Bulletin, SEBF8594, "Nitrogen Pressure Test Unit (FT-2724)"
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To avoid personal injury, follow the established Disassembly and Assembly procedures contained in this bulletin. Be sure to use all recommended tooling, and always wear all necessary personal protective equipment. |
Safety
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| 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 to perform these functions properly.
This bulletin may contain hazardous steps. A safety alert symbol like the one below is used to indicate 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.
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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. |
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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. |
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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.
Disassembly
- Use an allen wrench to remove the plug from the shaft.
Note: Some 5110 may have rim fill plug.
Show/hide table
Illustration 3 g02415657 Drive out the dowel-pins. - Using a press or similar tooling, compress the end collars to maintain the pin/hole alignment and drive out the dowel-pins.
Show/hide table
Illustration 4 g02415658 Remove the collars. - Using a press or similar tooling, remove the collars from the shaft.
- Use a feeler gauge to check the clearance between the shaft and bearing. If the clearance does not fall within the appropriate dimensions given in Table 2, measure the shaft and the bearing in the rim assembly to determine why the clearance specification is not met. Also, refer to Table 3 and Table 4 to check the shaft and bearing diameters.
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Table 2 Shaft/Bearing Clearance Model Number Clearance (max/min) 5130, 5130B 0.51/0.29 mm (0.020/0.011 inch) 5110, 5110B 0.48/0.25 mm (0.019/0.010 inch) Show/hide tableTable 3 Shaft Outside Diameter Dimensions Model Number Diameter 5130, 5130B 158.76 ± 0.03 mm (6.250 ± 0.001 inch) 5110, 5110B 122.00 ± 0.03 mm (4.803 ± 0.001 inch) Show/hide tableTable 4 Pressed Inner Bearing Diameter Model Number Diameter 5130, 5130B 159.16 ± 0.09 mm (6.266 ± 0.004 inch) 5110, 5110B 122.37 ± 0.09 mm (4.818 ± 0.004 inch) Show/hide table
Illustration 5 g02415659 Remove the shaft. - Using a hoist, slide the shaft out of the roller shell.
Show/hide table
Illustration 6 g02415660 Remove the Duo-Cone seals. - After inspecting the Duo-Cone seals for reuse criteria, remove the seals from the end collars and the roller assembly.
Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals" for the proper assembly procedures for Duo-Cone seals. If the seals are reusable, keep seals in matching pars.
Show/hide table
Illustration 7 g02415661 Remove the o-rings. - Remove the o-ring from the collars.
Show/hide table
Table 5 Tooling Model Number Bearing Puller (5) Sleeve (1) Plate (2) 5110, 5110B 9U-6227 124-4641 9U-6501 5130, 5130B 9U-6261 5P-5211 5P-5212 Show/hide table
Illustration 8 g02415662 Remove the bearings.
(1) Sleeve
(2) Plate
(3) Nut
(4) Threaded shaft
(5) Bearing puller
(6) Thrust washer
(7) Bearing
(8) Roller shell - If the bearing (7) has too much clearance, use the proper tooling from Table 5 to pull out each bearing (7). Using the device shown in Illustration 8, remove the bearing (7) by tightening the nut (3).
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| Illustration 2 | g02415656 |
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Remove the plug. | |
Assembly
- If the bearing was removed, use a properly sized bearing puller from Table 5 and a press to install the new bearings. Rotate the roller 180 degrees and install the other new bearing.
Show/hide table
NOTICE When lubricating the toric rings, alcohol with a purity of 99% or greater must be used. Using alcohol will allow for proper drying of the Duo-Cone seals and will prevent slipping of the toric rings.
Show/hide table
Illustration 9 g02415663 Clean the Duo-Cone seals. - Clean the Duo-Cone seals with alcohol if the Duo-Cone seals are being reused. Always use new toric rings for reassembly.
Show/hide table
Illustration 10 g02415664 Clean the end collars. - Clean the contact surface area of the toric rings in the end collars with alcohol.
Show/hide table
Illustration 11 g02415665 Lubricate the toric rings. - Lubricate the rubber toric rings with alcohol. Lubrication will ease the installation of the Duo-Cone seals.
Show/hide table
Illustration 12 g02415666 Install the Duo-Cone seals into the end collars. - Use the proper Duo-Cone seal installer from Table 6 to install the seals into the end collars. Press down evenly with a perpendicular force on the seal installer.
Show/hide table
Table 6 Seal Installers Model Number Installer Part Number 5110, 5110B 1U-6439 5130, 5130B 1U-6436 Show/hide table
Illustration 13 g02415667 Clean the roller assembly. - Clean the roller assembly with alcohol or other approved cleaner.
- Use the proper Duo-Cone seal installer to install the seals into the roller assembly. Press down evenly with a perpendicular force on the seal installer.
- Dry the toric rings using pressurized air at
207 kPa (30 psi) for 1 minute.Show/hide table
Illustration 14 g02415669 Check seal height. - Check the assembledDuo-Coneseal height in at least four places, 90 degrees apart, for each seal. The difference in height around the ring must not exceed
1.0 mm (0.04 inch) . - Apply 369-9451 Grease - Petro Gel to the new o-rings and install them into the collars.
Show/hide table
Illustration 15 g02415670 Apply oil to the Duo-Cone seals in the end collars. - Make sure that the seal faces are free of all debris. Apply a thin film of clean oil to the entire seal ring face in the end collars or in the roller assembly. Use a horse hair brush to distribute the oil evenly.
Show/hide table
NOTICE Do not get oil on the rubber toric rings. Oil on the toric rings can lead to oil leakage due to slippage between the toric and the seal ramp.
Show/hide table
Illustration 16 g02415671 Slide the shaft into the roller assembly. - Slide the shaft into the roller assembly.
Show/hide table
Illustration 17 g02415672 Drive in the dowel-pins. - Using a press or similar tooling, compress the collars until the holes are aligned and then drive in the dowel-pins.
Show/hide table
Table 7 Axial End Play Model Number End Play (max/min) 5110, 5110B 1.36/0.16 mm (0.054/0.006 inch) 5130, 5130B 1.55/0.30 mm (0.061/0.012 inch) - Check the end play.
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NOTICE If the end play does not fall within tolerances given in Table 7, the roller must be disassembled to determine why the end play specification is not met.
Show/hide table
Illustration 18 g02020655 Test and Fill Machine 170-5664 - Use the test and fill machine 170-5664 to evaluate and fill the joint. If this equipment is not available, perform the following test using the FT-2724 tooling. Introduce nitrogen into the lubricant cavity to a pressure of
138 kPa (20.02 psi) . Close the pressure differential gauge. The pressure is to be observed for 10 seconds. A pressure drop of 2.5 percent (3.5 kPa (0.52 psi) or less is acceptable.Show/hide table
Illustration 19 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 ValveShow/hide tableNOTICE Do not allow air to enter in a surge and do not use pressure in excess of
138 kPa (20 psi) , as pressure in excess of138 kPa (20 psi) may damage the seals.Show/hide table
Illustration 20 g02415674 Add the correct oil to the roller. - Add the correct quantity of SAE oil into the roller.
Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8574, "Track Roller Oil Fill Volume" for correct oil type and quantity.
Show/hide table
Illustration 21 g02415675 Install the plug. - Using an allen wrench, install the plug into the collar.
Note: Some 5110 may have rim fill plug.
- Tap the end of the roller shaft with a hammer to determine if the roller is full or empty. If there is a ringing noise, the roller is empty. If there is a dull thud, the roller contains oil.
Disassembly
- Use an allen wrench to remove the plug from the shaft.
Show/hide table
Illustration 22 g02415676 Remove retaining ring. - Using a press or tooling, compress the end collars and remove the retaining rings.
Show/hide table
Illustration 23 g02415677 Remove end collar. - Remove the end collar.
- Use a feeler gauge to check the clearance between the shaft and bearing. If the clearance does not fall within the appropriate dimensions given in Table 8, measure the shaft and the bearing in the rim assembly to determine why the clearance specification is not met. Also, refer to Table 9, and Table 10 to check the shaft and bearing diameters.
Show/hide table
Table 8 Shaft/Bearing Clearance Model Number Clearance (max/min) 5230, 5230B 0.51/0.29 mm (0.020/0.011 inch) Show/hide tableTable 9 Shaft Outside Diameter Dimensions Model Number Diameter 5230, 5230B 192.76 ± 0.03 mm (7.590 ± 0.001 inch) Show/hide tableTable 10 Pressed Bearing Inner Diameter Model Number Diameter 5230, 5230B 193.16 ± 0.09 mm (7.605 ± 0.004 inch) Show/hide table
Illustration 24 g02415678 Remove the o-ring. - Remove the shaft o-ring seal from the end where the collar was removed in Step 3.
Show/hide table
Illustration 25 g02415679 Drive out the dowel-pin. - Using a hammer and a punch, drive the dowel-pin out of the other collar and remove dowel-pin.
Show/hide table
NOTICE Safety glasses should be worn at all times when performing Disassembly and Assembly procedures.
- Remove the other shaft o-ring seal.
Show/hide table
Illustration 26 g02415680 Remove the shaft. - Using an overhead crane, slide the shaft out of the roller assembly.
Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals" for the proper reusability and assembly procedures for Duo-Cone seals. If the seals are reusable, the Duo-Cone seals must be kept in matching pairs.
Show/hide table
Illustration 27 g02415681 Remove the Duo-Cone seals. - After inspecting the Duo-Cone seals for reuse criteria, remove the Duo-Cone seals from the end collars and the roller assembly.
Show/hide table
Table 11 Tooling Model Number Bearing Puller (5) Sleeve (1) 5230, 5230B 123-8527 4C-8149 Show/hide table
Illustration 28 g02415682 Remove the bearings.
(1) Sleeve
(2) Plate
(3) Nut
(4) Threaded shaft
(5) Bearing puller
(6) Thrust washer
(7) Bearing
(8) Roller shell - If the bearing (7) has too much clearance, use the proper tooling from Table 11 to pull out each bearing (7). Using the device shown in Illustration 28, remove the bearing (7) by tightening the bolt.
Assembly
- If the bearing was removed, use the proper size bearing puller from Table 11 and a press to install the new bearings. Rotate the roller end and install the other new bearing.
Show/hide table
NOTICE When lubricating the toric rings, alcohol with a purity of 99% or greater must be used. Alcohol will allow for proper drying of the Duo-Cone seals and will prevent slipping of the toric rings.
- Clean the Duo-Cone seals with alcohol if the Duo-Cone seals are being reused. Always use new toric rings for reassembly.
- Clean the toric rings and the contacting surface of the toric rings in the end collars with alcohol.
Show/hide table
Illustration 29 g02415683 Lubricate the rubber toric. - Lubricate the rubber toric rings with alcohol. Alcohol will ease the installation of the Duo-Cone seals.
Show/hide table
Illustration 30 g02415684 Install the Duo-Cone seals into the end collars. - Use the proper Duo-Cone seal installer from Table 12 to install the seals into the end collars. Press down evenly with a perpendicular force on the seal installer.
Show/hide table
Table 12 Seal Installers Model Number Installer Part Number 5230, 5230B 1U-6434 Show/hide table
Illustration 31 g02415696 Install the Duo-Cone seals into the roller assembly. - Use the proper Duo-Cone seal installer to install the seals into the roller assembly. Press down evenly with a perpendicular force on the seal installer.
- Dry the Duo-Cone seals using pressurized air at
207 kPa (30 psi) for 1 minute. - Check the assembledDuo-Coneseal height in at least four places, 90 degrees apart, for each seal. The difference in height around the ring must not exceed
1.0 mm (0.04 inch) .Show/hide table
Illustration 32 g02415697 Clean the bearings. - Clean the bearings with alcohol.
Show/hide table
Illustration 33 g02415698 Apply oil to the Duo-Cone seals in the end collars. - Make sure that the seal faces are free of all debris. Apply a thin film of clean oil to the entire seal ring face in the end collars or in the roller assembly. Use a horse hair brush to distribute the oil evenly.
Show/hide table
NOTICE Do not get oil on the rubber toric rings. Oil on the toric rings can lead to oil leakage due to slippage between the toric and seal ramp.
Show/hide table
Illustration 34 g02415699 Slide the shaft into the roller assembly. - Slide the shaft into the roller assembly.
Show/hide table
Illustration 35 g02415700 Install the o-ring. - Apply 369-9451 Grease - Petro Gel to the o-ring and install onto the shaft end with the pin hole.
Show/hide table
Illustration 36 g02415719 Drive the dowel-pin in. - Slide the collar on and drive in the dowel-pin with a hammer.
- Install the other shaft o-ring seal.
Show/hide table
Illustration 37 g02415720 Install the other end collar. - Install the other end collar and compress end collar with tooling or a press.
Show/hide table
Illustration 38 g02415721 Insert the retaining ring. - Insert the retaining ring into the end collar.
- Make sure that the retaining ring is installed before decompressing the roller.
- Check the end play.
Show/hide table
Table 13 Axial End Play Model Number End Play (max/min) 5230, 5230B 1.50/0.50 mm (0.060/0.020 inch) Show/hide tableNOTICE If the end play does not fall within tolerances given in Table 13, the roller must be disassembled to determine why the end play specification is not met.
Show/hide table
Illustration 39 g02020655 Test and Fill Machine 170-5664 - Use the test and fill machine 170-5664 to evaluate and fill the joint. If this equipment is not available, perform the following test using the FT-2724 tooling. Introduce nitrogen into the lubricant cavity to a pressure of
138 kPa (20.02 psi) . Close the pressure differential gauge. The pressure is to be observed for 10 seconds. A pressure drop of 2.5 percent (3.5 kPa (0.52 psi) or less is acceptable.Show/hide table
Illustration 40 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 ValveShow/hide tableNOTICE Do not allow air to enter in a surge and do not use pressure in excess of
138 kPa (20 psi) , as pressure in excess of138 kPa (20 psi) may damage the seals.Show/hide table
Illustration 41 g02415723 Add the correct oil to the roller. - Add the correct quantity of SAE oil into the roller.
Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8574, "Track Roller Oil Fill Volume" for correct oil type and quantity.
- Using an allen wrench, install the plug into the collar.
- Tap the end of the roller shaft with a hammer to determine if the roller is full or empty. if there is a ringing noise, the roller is empty. If there is a dull thud, the roller contains oil.
