Disassembly and Assembly Procedures for Track Rollers with Conventional Duo-Cone Seals {4180, 7561} Caterpillar

Caterpillar Products

Machines with Positive Pin Retention (PPR) Track

Machines with Sleeve Bearing Track

Pipelayer

PL72 (S/N: P721-UP; P731-UP)

PL83 (S/N: CB21-UP; DLW1-UP)

PL87 (S/N: TEC1-UP; ZAC1-UP)

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 questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding this 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 track rollers with conventional Duo-Cone seals. The information in this bulletin should serve as an aid in determining whether a track roller with conventional 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: 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 Gps"

Reference: Undercarriage Reconditioning Bulletin, SEBF8594, "Nitrogen Pressure Test Unit"

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 to perform these functions properly.

This bulletin may contain hazardous steps. Hazardous steps will be identified by warning symbols like the ones 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.

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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.

Tooling and Equipment

Disassembly

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Illustration 2	g02403416
Remove plug and stopper.

1. Remove the plug and stopper to drain the oil.
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   Illustration 3	g02403417
   Loosen retaining bolts.

2. Remove the six retaining bolts on each retainer assembly.
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   Illustration 4	g02403418
   Place roller in press.

3. Use a hoist to place the track roller in the roller press.
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   Illustration 5	g02403419
   Remove collar assemblies.

4. Press the shaft in one direction to remove the first end collar assembly. Rotate the roller 180 degrees, and press the shaft from the other direction to remove the other end collar assembly.
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   Illustration 6	g02403420
   Remove retainer assemblies.

5. Remove retainer assemblies, including the thrust washers, from each end of the track roller.

   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.

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   Table 3

   Specifications for the End Collar
   Sales Model	Part Number of the End Collar	Inner Diameter (A)
   D11N D11R D11T	184-2607	74.4 ± 0.02 mm (2.92 ± 0.001 inch)
   D10N D10R D10T	107-3947	68.4 ± 0.02 mm (2.69 ± 0.001 inch)
   D9N D9R D9T D8L D8N D8R D8T PL83 PL87 578 583R 583T 587R 587T	107-3945	58.4 ± 0.02 mm (2.29 ± 0.001 inch)
   PL72	471-8713	63.3 ± 0.02 mm (2.49 ± 0.001 inch)

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   Table 4

   Specifications for the Shaft
   Sales Model	Part Number of the Shaft	Diameter (B)
   D11N D11R D11T	155-2048	74.5 ± 0.02 mm (2.93 ± 0.001 inch)
   D10N D10R D10T	154-3306	68.5 ± 0.02 mm (2.69 ± 0.001 inch)
   D9N D9R D9T	104-3494	58.5 ± 0.02 mm (2.30 ± 0.001 inch)
   PL72	471-8713	63.3 ± 0.02 mm (2.49 ± 0.001 inch)
   D8L D8N D8R D8T PL83 PL87 578 583R 583T 587R 587T	107-8084	58.5 ± 0.02 mm (2.30 ± 0.001 inch)
   PL72	471-8577	63.5 ± 0.05 mm (2.50 ± 0.002 inch)

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   Illustration 7	g02403421
   Measure collar inside diameter. (A) Collar diameter

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   Illustration 8	g02403422
   Measure shaft mounting diameter. (B) Shaft mounting diameter.

6. Measure the inside collar diameter (A) and shaft mounting diameter (B) using a micrometer. Compare the measurements to the specifications in Table 3 and Table 4. Do not use the component again, if the measurements are not within specifications. Replace the component.
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   Illustration 9	g02403423
   Remove o-ring from each retainer assembly.

7. Remove the large diameter o-ring seals from each retainer assembly.
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   Illustration 10	g02403424
   Remove o-ring from collar assembly.

8. Remove the rubber o-rings from the end collar assembly.
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   Illustration 11	g02403425
   Remove retainer seals.

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   Illustration 12	g02403426
   Remove collar seals.

9. Remove the Duo-Cone seals from the retainer and end collar assemblies. Inspect each set of seals side by side for reusability.

   Note: If the seals are reusable, keep seals in matching pairs. Refer to Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals" for proper reusability information.

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   Table 5

   Shaft / Bearing Clearance
   Sales Model	Track Roller Group	Clearance (min/max)
   D11N D11R D11T	184-6306 (DF) 184-6305 (SF) 200-5701 (SF High Abrasion)	0.43 mm (0.017 inch) to 0.57 mm (0.022 inch)
   D10N D10R D10T	309-7678 (DF) 309-7679 (SF)	0.43 mm (0.017 inch) to 0.57 mm (0.022 inch)
   D9N D9R D9T	196-9954 (DF) 196-9955 (SF)	0.43 mm (0.017 inch) to 0.57 mm (0.022 inch)
   D8L D8N D8R D8T PL83 PL87 578 583R 583T 587R 587T	246-0779 (DF) 246-0775 (SF) 278-9539 (SF Arctic) 278-9538 (SF High Heat)	0.43 mm (0.017 inch) to 0.57 mm (0.022 inch)
   PL72	471-8572 (DF)	0.68 mm (0.027 inch) to 0.84 mm (0.033 inch)

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   Illustration 13	g02403427
   Measure shaft-to-bearing clearance.

10. Measure the shaft-to-bearing clearance using a feeler gauge. The clearance must fall within the specifications given in Table 5.
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    Table 6

    Shaft Outside Diameter Specifications
    Sales Model	Part Number of the Shaft	Diameter
    D11N D11R D11T	155-2048	136.28 ± 0.03 mm (5.365 ± 0.001 inch)
    D10N D10R D10T	154-3306	126.75 ± 0.03 mm (4.990 ± 0.001inch)
    D9N D9R D9T	104-3494	114.05 ± 0.03 mm (4.490 ± 0.001 inch)
    D8L D8N D8R D8T PL83 PL87 578 583R 583T 587R 587T	107-8084	114.05 ± 0.03 mm (4.490 ± 0.001 inch)
    PL72	471-8577	107.17 +1.50/-0.25 mm (4.21928 +0.06/-0.01 inch)

    Note: Table 6 includes the shaft outside diameter specifications.

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    Illustration 14	g02403428
    Remove the shaft.

11. Partially slide the shaft out of the track roller. If necessary, attach a hoist to help remove the shaft the rest of the way.

Assembly

1. Wash and remove all debris from the track roller and all the components.
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   Illustration 15	g02403429
   Clean components.

2. Use alcohol or other approved cleaning agents to clean the roller components. Dry with a lint free cloth.
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   Illustration 16	g02403430
   Install o-rings into retainers.

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   Illustration 17	g02403431
   Install o-rings into end collars.

3. Use Loctite^® C5-A^® Copper-based Anti-Seize Lubricant to install new o-rings into the retainer and collar grooves.

   Note: Always use new rubber components.

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   Illustration 18	g02403432
   Inspect seals for reusability.

4. Inspect seals for reusability.

   Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8511, "Reusability Recommendations for Duo-Cone Seals" for reusability guidelines for Duo-Cone seals.

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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. Also verify the toric position for new Duo-Cone seals. Failure to do so may result in a failure of the roller.

5. If the Duo-Cone seals are being reused, replace the toric rings.

   Note: The toric ring must not be twisted on the seal ring.

   Note: Refer to Special Instruction, SEHS8364, "Assembly and Installation of Conventional Duo-Cone Seals" for proper assembly procedures for conventional Duo-Cone seals. Refer to Table 2 for proper seal installation tooling.

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   Illustration 19	g02403433
   Lubricate lower half of toric ring with isopropyl alcohol.

6. Lightly dampen the lower half of the rubber toric with isopropyl alcohol.
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   Illustration 20	g02403434
   Install seals into end collars.

7. Once the toric is lubricated, use a sudden, even, perpendicular force on the installation tool to install the Duo-Cone seals into the end collars.
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   Illustration 21	g02403435
   Install seals into retainers.

8. Once the toric is lubricated, use a sudden, even, perpendicular force on the installation tool to install the Duo-Cone seals into the retainers.
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   Illustration 22	g02403436
   Check retainer seal height.

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   Illustration 23	g02403437
   Check collar seal height.

9. Check the assembled seal height in the collar and retainer at four locations 90 degrees apart. The difference in height must not exceed 1.0 mm (0.04 inch). Refer to Table 2 for proper seal height tooling.

   Note: If the seal height specification is not met, the Duo-Cone seals must be removed and reinstalled.

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   Illustration 24	g02403438
   Install shaft.

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   NOTICE
   The shaft may scrape bronze particles from the bearing, the bronze particles will cause a failure in the rollers.

10. Carefully install the shaft into the track roller.
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    Illustration 25	g02403439
    Install thrust washers.

11. Install the thrust washers on both ends of the shaft.
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    Illustration 26	g02403440
    Slide on the retainer.

12. Slide the retainer assembly over the shaft and carefully move the retainer to the final position.
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    Illustration 27	g02403441
    Tighten retainer bolts.

13. Tighten the retainer bolts.
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    Table 7

    Torque for Retaining Bolts
    Model	Dynamic Assembly Torque	Static Inspection Torque
    D11N D11R D11T	270 ± 40 N·m (199 ± 30 lb ft)	230 N·m (170 lb ft)
    D10N D10R D10T D9N D9R D9T D8L D8N D8R D8T PL83 PL87 578 583R 583T 587R 587T	135 ± 20 N·m (100 ± 15 lb ft)	115 N·m (85 lb ft)

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    Illustration 28	g02403442
    Torque bolts to proper specifications.

14. Torque bolts to the proper specifications. Refer to Table 7 for proper retaining bolt torque specifications.

    Note: The static inspection torque valves listed in Table 7 are minimum requirements. Static torque values, however, must not exceed maximum dynamic assembly torque limits. Check the static torque specification using a torque wrench. The retaining bolt must not move in the tightening direction when the static torque value specified in Table 7 is applied.

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    Illustration 29	g02403443
    Wipe entire retainer seal face.

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    NOTICE
    Failure to remove debris from seal faces will cause a failure.

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    Illustration 30	g02403444
    Wipe entire collar seal face.

15. Wipe the entire Duo-Cone seal ring faces in the retainers and end collars with a clean, dry lint free cloth.
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    Illustration 31	g02403445
    Apply oil to the entire seal face.

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    NOTICE
    Do not get oil on the rubber toric rings. Possible failure could result.

16. Apply a thin film of oil to the entire Duo-Cone seal face using a horse hair brush.

    Note: To reduce 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 collar to the retainer assembly.

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    Illustration 32	g02403446
    Place end collar against retainer.

17. Position the end collar on the shaft.
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    Table 8

    End Collar Drivers
    Model Number	Driver Part Number
    D11N D11R D11T	170-5404
    D10N D10R D10T	170-5408
    D9N D9R D9T	170-5410
    D8L D8N D8R D8T PL83 PL87 PL72 578 583R 583T 587R 587T	170-5407

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    Illustration 33	g02403447
    Press end collar into place.

18. Slowly move the collar assembly against the retainer assembly refer to Illustration 33. Use a hydraulic press to press the collar into it's final position. Refer to Table 8 for proper end collar tooling.

19. Repeat Step 18 for the other collar.
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    Table 9

    Spin Socket Tooling
    Tooling Part Number	Model Usage
    D11N D11R D11T D10N D10R D10T	1U-9398
    D9N D9R D9T D8L D8N D8R D8T PL83 PL87 PL72 578 583R 583T 587R 587T	FT-1910

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    Illustration 34	g02403448
    Spin the shaft.

20. Select the correct spin socket from Table 9 and spin the shaft 20 revolutions in each direction at a maximum of 100 rpm.
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    Table 10

    End play Tolerances
    Model	Tolerance (min/max)
    D11N D11R D11T D10N D10R D10T D9N D9R D9T D8L D8N D8R D8T PL83 PL87 578 583R 583T 587R 587T	0.26 to 1.26 mm (0.010 to 0.050 inch)
    PL72	0.19 to 1.27 mm (0.007 to 0.050 inch) 1.27 mm (0.05000 inch)

21. Check the end play.

    Note: If the end play does not fall within the tolerance given in Table 10, the roller must be disassembled to determine why the tolerance specification is not met.

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    Illustration 35	g02403449
    Lubricate and install stopper.

22. Lubricate the stopper with a lightweight oil and install in the end of the shaft. The stopper must be installed 7.0 to 15.0 mm (0.28 to 0.59 inch) below the surface of the shaft.
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    NOTICE
    Do not allow air to enter in a surge, and do not use pressure in excess of 138 kPa (20 psi), excess pressure may damage the seals.

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    Illustration 36	g02902616
    170-5664 Test and Fill Cart Gp

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    Illustration 37	g02902598
    FT-2724 Pressure Gauge Tool Gp

23. Use 170-5664 Test and Fill Cart Gp to evaluate and fill the idler. If 170-5664 Test and Fill Cart Gp is not available. Use FT-2724 Pressure Gauge Tool Gp to perform a pressure test on the idler.

    Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8594, "Nitrogen Pressure Test Unit" for proper pressure test procedures.

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    Table 11

    Oil Fill Volumes
    Model	Assembly Oil Volume (ml)	Shaft Part Number
    D11N D11R D11T	1850 ± 50	155-2048
    D10N D10R D10T	1300 ± 30	154-3306
    D9N D9R D9T	850 ± 20	104-3494
    D8L D8N D8R D8T PL83 PL87 578 583R 583T 587R 587T	500 ± 15	107-8084
    PL72	290 ± 15	471-8577

24. Add the correct quantity of oil into the roller.

    Note: Refer to Undercarriage Reconditioning Bulletin, SEBF8574, "Track Roller Oil Fill Volume" for proper fill volumes and oil types. Also refer to Table 11 for oil fill volumes.

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    Table 12

    Plug Depth Specifications
    Model Usage	Plug Height Above Stopper Surface
    D11N D11R D11T D10N D10R D10T D9N D9R D9T D8L D8N D8R D8T PL83 PL87 PL72 578 583R 583T 587R 587T	0.0 to 5.0 mm (0.00 to 0.20 inch)

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    Illustration 38	g02403451
    Insert plug into stopper.

25. Use the 5P-7419 Installer Tool to insert the plug into the stopper to proper depth. Refer to Table 12 for proper plug depth specifications.

    Note: The plug must not be recessed below the stopper surface after assembly.

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    Illustration 39	g02403452
    Tap end of roller shaft to determine if roller contains oil.

26. Tap the end of the roller shaft to determine if the roller has oil inside. If there is a dull thud, the roller contains oil. If there is a ringing noise, the roller is empty.